Au5 Online Operating Manual

PRODUCTION DEPARTMENT
Gujarat Refinery Units (GRU)
ATMOSPHERIC UNIT-V (AU -V)

O PE R AT I N G
M AN U AL
SEQ/PN/(GR-I)/SI/7.5.1/4 (Rev No: 03)
Revised By
: G.SRINIVASAN (SPNE)
CHECKED BY
: K.M. TAMBOLI (PNM)
Approved By
: P.V.SOLANKI (CPNM)
GUJARAT REFINERY
INDIAN OIL CORPORATION LTD.

VADODARA
PREFACE
The unit has been revamped during August/Sept 02 to modify the flexibility of operation
by installing new preheat train and increase in the number of pumps for different products
& circulating refluxes.
This operating manual contains necessary guidelines for normal operation and emergency
procedures such as startup, shutdown and different emergencies and is supplemented with
write-ups, drawings etc. wherever necessary. The various operating parameters are
indicative only. It may call for any modification or change in operating parameters based
on the actual operating experience in near future. The operating manual was updated in
May-05 and various changes were incorporated such as shut down & start up checklists,
PSVs list, unit equipments list etc., for fusing the plant related information.
In revision March09, special attention was given for startup, shutdown and emergency
handling procedures. It was thoroughly revised & step-by-step procedure was given for
easy understanding. New chapters on Safety System, Control Valve Data and Advanced
Process Control have been added. Control valves fail safe position and Operation and
Maintenance of HSD Coalescer has been incorporated in this manual for better operation
guidance. In this revision Dechocking procedure of equipment drain line is incorporated.
LPG Vapouriser to MSQ and Light Naphtha from AU-V to AU-I rerun section lines were
commissioned and that has been incorporated in the revised manual.
Inter connections and routings under RUP PROJECT has been incorporated in this
revision ( May , 2011)
Following modifications were done during APRIL-2013 M&I and the same has been
incorporated in this revision .(SEPT-2013)
a) Relocating of EE-06A/B from downstream of desalter to upstream of desalterThe above change was done to increase the desalter inlet temp.for better
separation.
b) A new hook-up has been made in the main F.G header line of AU-5 at B/L to
MSQ UNIT .in addition to the existing line.
The above mentioned modification was done to ensure the un interrupted
supply of F.G to MSQ unit.
c) Back washing system is provided for all the overhead condensers of both columns
C-01& C-05.
The main aim of the modification was to increase the performance of the
condensers especially during summers & and to avoid fouling.
d) A new hook-up has been provided in the following exchangers
EE-20, EE-12A/B/C& EE-13D/E/F .
The purpose of the above modification is to increase the preheat of wash water
To desalter, utilizing the HEAVY NAPTHA Rundown temp
e) MOVs were installed in the following under mentioned locations.The objective is to
ensure the safe isolation during emergencies.
i)
V-2 naptha ex(in the common suction line of 05-PA-5A/B/C&

05-PA-6A/B/C)
ii) V-3 LPG ex(in the suction line of 05-PA-14A/B)

iii) C-04 diesel ex(in the suction of 05-PA-11A/B)
f) DCS system was upgraded from CENTUM CS to CENTUM VP.

g) 2-nos of stubs with isolation valves provided in the main flare header system
for future hook-up jobs
All the above modifications are explained in detail in Anneture-1
P.V.SOLANKI
CHIEF PRODUCTION MANAGER
GR-1 UNITS,
AU-5.
CONTENTS
Sl. No
DESCRIPTION
Page. No
Chapter 1
BASIC PRINCIPLES OF DISTILLATION
9-15
Chapter 2
INTRODUCTION OF THE UNIT
16-25
2.1
ONSTREAM FACTOR
17
2.2
DESIGN FEED RATE
17
2.3
FEED & PRODUCT SPECIFICATIONS
18
2.4
FEED & PRODUCT BATTERY LIMIT CONDITIONS
22
2.5
UTILITY SPECIFICATIONS
23
Chapter 3
EQUIPMENT DATA
26-37
3.1
COLUMNS
27
3.2
HEAT EXCHANGERS/COOLERS/CONDENSERS
27
3.3
PUMPS
1
28
3.4
FURNACE/AIR PRE-HEATER
29
3.5
TURBO BLOWERS (ID & FD FANS)
29
3.6
VESSELS
30
3.7
TANKS
31
3.8
FILTERS
31
3.9
PSVS
31
3.10
TSVS
33
3.11
LIST OF CONTROLLERS
35
Chapter 4
PROCESS DESCRIPTION
38-100
4.1
BASIC OPERATIONS INVOLVED
39
4.2
CRUDE CHARGING INTO UNIT
40
4.3
CRUDE PREHEAT TRAIN-I
41
4.4
CRUDE DESALTING
42
4.4.1
DESALTERS OPERATION
43
4.4.2
DESALTER WATER SYSTEM
48
4.5
CRUDE PREHEAT TRAIN-II
49
4.6
FURNACE
50
4.6.1
PROCESS SYSTEM
50
4.6.2
FUEL SYSTEM
52
4.6.2.A
FUEL GAS SYSTEM
53
4.6.2.B
FUEL OIL SYSTEM
54
4.6.3
AIR PRE-HEATER (APH)
55
4.6.4
COMBUSTION AIR SYSTEM
55
4.6.5
ID/FD FAN STARTING & STOPPING PROCEDURE
56
4.6.5.1
ID FAN STARTING PROCEDURE
56
4.6.5.2
ID FAN STOPPING PROCEDURE
56
4.6.5.3
FD FAN STARTING PROCEDURE
57
4.6.5.4
FD FAN STOPPING PROCEDURE
58
4.6.5.5
FURNACE LIGHT UP & CUTOFF PROCEDURE
59
Sl. No
DESCRIPTION
Page. No
4.6.5.6
FURNACE CUTOFF PROCEDURE
60
4.6.5.7
FURNACE INTERLOCKS
61
4.6.6
DECOKING SYSTEM
63
4.7
MAIN ATMOSPHERIC COLUMN
64
4.7.1
FLASH ZONE
64
4.7.2
OVERHEAD SECTION
65
4.7.3
MIDDLE SECTION
66
4.7.4
BOTTOM SECTION (RCO CIRCUIT)
67
4.7.5
CIRCULATING REFLUXES/PUMP AROUND CIRCUITS
6
68
4.7.6
PRODUCT DRAW OFF TRAYS
68
4.8
PRODUCT STRIPPERS
69
4.8.1
HEAVY NAPHTHA STRIPPER
69
4.8.2
KEROSENE/ATF STRIPPER
70
4.8.3
GASOIL STRIPPER
71
4.9
NAPHTHA STABILISER
73
4.10
LPG-AMINE ABSORPTION SECTION
76
4.11
PRODUCT COOLING & RUNDOWN FACILITY
7
77
4.12
CAUSTIC/WATER WASH FACILITY FOR PRODUCTS
79
4.12.1.A
LPG CAUSTIC WASH SYSTEM
80
4.12.1.B
LPG WATER WASH SYSTEM
81
4.12.2.A
LIGHT NAPHTHA CAUSTIC WASH SYSTEM
82
4.12.2.B
LIGHT NAPHTHA WATER WASH SYSTEM
84
4.12.3.A
KERO/ATF CAUSTIC WASH SYSTEM
84
4.12.3.B
KERO/ATF WATER WASH SYSTEM
86
4.13
CHEMICAL INJECTION FACILITIES
8
87
4.13.1
CAUSTIC INJECTION
88
4.13.2
AMMONIA SOLUTION INJECTION
89
4.13.3
DEMULSIFIER INJECTION
89
4.13.4
CORROSION INHIBITOR/AHURALAN SOLN. INJECTION
89
4.13.5
WASH WATER SYSTEM
90
4.14
EFFECT OF OPERATING VARIABLES
90
4.14.1
DESALTER PARAMETERS
91
4.14.1.A
WATER INJECTION & PRESSURE DROP
9
91
4.14.1.B
OIL/WATER INTERPHASE LEVEL
91
4.14.1.C
DESALTER PRESSURE
92
4.14.1.D
DESALTER TEMPERATURE
92
4.14.1.E
92
4.14.1.F
VOLTAGE & AMPERAGE
92
4.14.2
FURNACE COIL OUTLET TEMPERATURE & OVERFLASH FLOW
93
4.14.3
MAIN FRACTIONATING COLUMN PRESSURE
93
4.14.4
MAIN FRACTIONATING COLUMN TEMPERATURE
10
94
Sl. No
DESCRIPTION
Page. No
4.14.5
CIRCULATING REFLUXES FLOW
94
4.14.6
PRODUCT WITHDRAWL TEMPERATURE
95
4.14.7
STRIPPING STEAM
95
4.14.7.A
STRIPPING STEAM IN FRACTIONATING COLUMN
96
4.14.7.B
STRIPPING STEAM IN STRIPPERS
96
4.15
NORMAL OPERATING CONDITIONS
97
4.16
CRITICAL OPERATING PARAMETERS & INSTRUMENTS
98
11
Chapter 5
UTILITIES SYSTEM
101-116
5.1
INTRODUCTION
102
5.2
INSTRUMENT AIR
102
5.3
PLANT AIR
103
5.4
COOLING WATER
103
5.5
SERVICE WATER
104
5.6
DM WATER
104
5.7
BOILER FEED WATER
105
12
5.8
LP STEAM
105
5.9
MP STEAM
106
5.10
HP STEAM
107
5.11
FUEL GAS
107
5.12
FUEL OIL
108
5.13
FLUSHING OIL
108
5.14
ELECTRIC SYSTEM
110
5.14.1
ELECTICAL POWER FOR PUMPS
110
13
5.14.2
PLANT ILLUMINATION
110
5.14.3
INSTRUMENTATION POWER SYSTEM
111
5.15
EFFLUENT SYSTEM
111
5.15.1
SLOP SYSTEM
112
5.15.2
CLOSED BLOWDOWN (CBD) SYSTEM
112
5.15.3
OILY WATER SEWER (OWS) SYSTEM
113
5.15.4
SEWER WATER SYSTEM
114
5.15.5
AMINE DRAIN SYSTEM
114
14
5.15.6
FLARE SYSTEM
114
Chapter 6
NORMAL START-UP PROCEDURE
117-155
6.1
INTRODUCTION
118
6.2
BRIEF START-UP PROCEDURE
118
6.3
DETAILED START-UP PROCEDURE
(AFTER M&I SHUT DOWN)
120
6.3.1
PRELIMINARY PREPARATION
120
6.3.2
AIR REMOVAL FROM THE PROCESS SYSTEM
124
Sl. No
DESCRIPTION
Page. No
6.3.3
TIGHTNESS/PRESSURE TEST
132
15
6.3.4
FUEL GAS BACKUP
132
6.3.5
COLD CIRCULATION
135
6.3.6
HOT CIRCULATION
139
6.3.7
COMMISSIONING OF DESALTERS
145
6.3.8
NORMALIZATION OF OPERATING CONDITIONS
146
6.3.9
BRINGING UP NAPHTHA STABILISER SYSTEM
148
6.4
STEPS INVOLVED IN START UP FROM BOTTLED UP CONDITION
150
6.5
CHECK LIST FOR UNIT NORMAL STARTUP FROM BOTTLED UP CONDITION
153
Chapter 7
NORMAL SHUT DOWN PROCEDURE
156-166
7.1
16
INTRODUCTION
157
7.2
BRIEF SHUT DOWN PROCEDURE
157
7.3
DETAILED SHUT DOWN PROCEDURE
(FOR M&I SHUT DOWN)
158
7.3.1
THROUGHPUT REDUCTION
158
7.3.2
DISCONTINUATION OF CHEMICAL INJECTION
159
7.3.3
SHUT DOWN OF NAPHTHA STABILISER
159
7.3.4
DECOMMISSIONING OF DESALTERS
160
7.3.5
NORMAL SHUT DOWN
161
7.3.6
SHUT DOWN OF ATMOSPHERIC SECTION FOR M&I
162
7.3.7
EMPTYING OUT OF THE UNITS AND PURGING/ISOLATION
17
163
7.3.8
CHECK LIST FOR UNIT NORMAL SHUTDOWN FOR BOTTLED UP CONDITION
164
Chapter 8
EMERGENCY PROCEDURES
167-209
8.1
GENERAL GUIDELINES
168
8.2
POWER FAILURE
170
8.3
STEAM FAILURE
181
8.4
COOLING WATER FAILURE
185
8.5
INSTRUMENT AIR FAILURE
189
8.6
FEED FAILURE
193
8.7
ALL UTILITIES FAILURE
193
Sl. No
18
DESCRIPTION
Page. No
8.8
FAILURE OF HEATER TUBES
194
8.9
110V DC SUPPLY FAILURE
195
8.10
198
8.11
UPS FAILURE
201
8.12
DCS CONSOLE FAILURE
205
8.13
FIRE IN THE PLANT
208
Chapter 9
PROCEDURES
FOR
EQUIPMENT
MAINTENANCE/INSPECTION
210-224
9.1
PUMPS
211
9.1.1
COLD PUMP
19
HAND
OVER
TO
211
9.1.2
HOT PUMP
212
9.2
VESSELS
213
9.3
COLUMNS
217
9.4
EXCHANGERS/COOLERS/CONDENSERS/REBOILERS
222
9.5
TANKS
222
9.6
FURNACE
223
9.7
FLARE HEADER
223
9.8
CONTROL VALVES
224
9.9
SAFETY VALVES
224
Chapter 10
20
PROCEDURES FOR EQUIPMENT TAKING OVER FROM MAINTENANCE

225-229
10.1
PUMPS/MOTORS
226
10.2
EXCHANGERS/CONDENSERS/COOLERS/REBOILERS/
FIN COOLERS
226
10.3
FURNACE
227
10.4
VESSELS
227
10.5
COLUMNS
228
Chapter 11
SAFETY
230-245
11.1
FIRE PREVENTION REGULATIONS
231
11.2
FIRE PREVENTION ACTIVITIES
231
11.2.1
SOUND ENGINEERING
231
21
11.2.2
GOOD HOUSE KEEPING
231
Sl. No
DESCRIPTION
Page. No
11.2.3
INSTRUCTION TO PERSONNEL
231
11.2.4
REGULAR TRAINING OF EMPLOYEES
231
11.2.5
SAFETY AUDITS/SAFETY STUDIES
232
11.2.6
FIRE EMERGENCY MOCK DRILLS
232
11.3
FIRE PROTECTION SYSTEM IN REFINERY
232
11.4
FIRE PROTECTION SYSTEM IN THE UNIT
234
11.5
WORK PERMIT SYSTEM
234
11.5.1
TYPES OF WORK PERMITS
235
11.5.1.A
22
HOT WORK PERMIT

235
11.5.1.B
COLD WORK PERMIT
235
11.5.1.C
EXCAVATION PERMIT
235
11.5.1.D
WORK AT HEIGHT PERMIT
236
11.5.1.E
WORK AT DEPTHS
236
11.5.1.F
ELECTRICAL WORK PERMIT
236
11.5.1.G
VESSEL ENTRY PERMIT
236
11.5.2
RESPONSIBILITIES OF THE PERMITTEE
237
11.5.3
RENEWAL OF THE PERMIT
237
11.5.4
SURENDERING OF THE PERMIT
237
11.5.5
23
SIGNATORIES FOR FIRE PERMITS

237
11.5.6
COPIES OF PERMIT
238
11.5.7
POINTS TO BE ENSURED WHILE GIVING CLEARANCE
238
11.5.8
ACCIDENT REPORTING PROCEDURE
239
11.5.9
CONTROL VALVE FAIL SAFE CONDITION
241
11.5.10
CORRECTIVE ACTION FOR PREVENTING HAZARDOUS SITUATION FROM
ESCALATING
243
11.5.11
SAFETY SYSTEM AND THEIR FUNCTIONS IN THE UNIT
244
Chapter 12
MATERIAL SAFETY DATA SHEET
246-264
12.1
AHURALAN
247
12.2
AMMONIA
251
24
12.3
CAUSTIC SODA
254
Sl. No
DESCRIPTION
Page. No
12.4
DIETHANOL AMINE
258
12.5
DEMULSIFIER
261
Chapter 13
PROCESS UPSET & CORRECTIVE ACTIONS
265-272
13.1
RANGE OF CRITICAL OPERATING PROCESS PARAMETERS
269
13.2
CRITICAL INSTRUMENTS/CRITICAL OPERATING PARAMETERS AND ITS
IMPLICATIONS
270
Chapter 14
HANDING & TAKING OVER OF INFORMATION DURING SHIFT CHANGE
273-275
Chapter 15
CONTROL OF HAZARDOUS CHEMICAL INVENTORY LEVEL
276-277
Chapter 16
PLANT EQUIPMENT IDLING METHOD
278-279
25
16.1
FOR SHORT SHUTDOWN
279
16.2
FOR LONG SHUTDOWN
279
Chapter 17
TASK PERFORMED BY OPERATORS
280-297
17.1
PANEL OPERATOR
281
17.2
FURNACE OPERATOR
288
17.3
FIELD OPERATOR
292
17.4
PUMP OPERATOR
298
Chapter 18
DCS INFORMATION
298-300
Chapter 19
ADVANCED PROCESS CONTROL SYSTEM
301-312
Chapter 20
LABORATORY TEST SCHEDULE
313-314
26
Chapter 21
MASTER BLIND LIST
315-318
Chapter 22
CONTROL VALVES DATA
319-321
Chapter 23
LIST OF INTERLOCKS
322-327
Chapter 24
SKO/ATF SALT DRYER
328-330
Chapter 25
HSD COALESCER
331-335
Chapter 26
CHECLKISTS FOR TASK OBSERVATION
336-358
26.1
HANDING OVER PUMP FOR MAINTENANCE
341
26.2
TAKING OVER PUMP FOR MAINTENANCE
341
26.3
HANDING OVER VESSEL FOR MAINTENANCE
342
26.4
COMMISSIONING OF VESSEL
342
26.5
HEAT EXCHANGER COMMISSIONING
343
26.6
HEAT EXCHANGER DECOMMISSIONING
344
26.7
HANDING OVER OF TANK TO MAINTENANCE
345
27
26.8
TAKING OVER OF TANK FROM MAINTENANCE
346
26.9
CONTROL VALVE HANDOVER TO MAINTENANCE
347
26.10
CONTROL VALVE TAKING OVER FROM MAINTENANCE
347
26.11
HANDING OVER OIL GUN TO MAINTENANCE
348
26.12
TAKING OVER OIL GUN FROM MAINTENANCE
348
26.13
HANDING OVER OF APH FOR CLEANING
348
26.14
LPG VESSEL WATER DRAINING
349
26.15
FURNACE LIGHT UP DURING START UP
350
26.16
OIL BURNER LIGHT UP DURING NORMAL OPERATION
351
26.17
WARMING UP OF PUMP
351
26.18
HOT PUMP CHANGE OVER
352
26.19
COLD PUMP CHANGE OVER
353
26.20
EMERGENCY HANDLING DUE TO POWER FAILURE
354
26.21
TANK WATER DRAINING
354
26.22
CHANGE OVER OF PRODUCT ROUTING
355
26.23
AHURALAN SOLUTION PREPARATION
355
26.24
AMMONIA SOLUTION PREPARATION
356
28
26.25
CAUSTIC SOLUTION PREPARATION
356
26.26
AMMONICAL CAUSTIC SOLUTION PREPARATION
357
26.27
CAUSTIC REPLENISHMENT IN LPG/NAPHTHA CAUSTIC WASH SYSTEM
357
26.28
WATER REPLENISHMENT IN LPG/NAPHTHA CAUSTIC WASH SYSTEM
357
26.29
FLARE KOD DRAINING
358
Chapter 27
LIST OF GAS/SMOKE DETECTORS
359-360
Chapter 28
PROCESS FLOW DIAGRAMS (FROM P&ID)
361-363
Chapter 29
FURNACE DECOKING PROCEDURE
364-367
Chapter-30
EQUIPMENT DRAIN LINE DECHOCKING PROCEDURE
368-369
Chapter-31
INTER CONNECTIONS AND ROUTINGS UNDER RUP PROJECT.
370-371
Chapter-32
ANNEXTURE-1
i)
MODIFICATIONS OF M&I-2013
372-381
29
ii) GENERAL SAFETY INSTRUCTIONS

382-383
iii) HVLR MONITOR

384
iv) LIST OF SEQMS DOCUMENTS

385-386
CHAPTER-1
BASIC PRINCIPLES OF DISTILLATION
30
PRINCIPLES OF DISTILLATION
Distillation is a technique by which two or more substances with different boiling points
can be separated from each 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.
31
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. Bubblepoint is the temperature at which the liquid starts to boil.
32
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.
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
33
(point A) is heated, its concentration remains constant until it reaches the bubblepoint (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
Example
Imagine a mixture of three liquids, A, B, and C. A has a boiling point of 86F (30C); B
has a boiling point of 104F (40C); and C has a boiling point of 122F (50C). Ordinary
gasoline is such a mixture, except that it consists of many more than three components.
34
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 86F. Liquid A begins to boil when the
temperature in the flask reaches 86F. It turns into a vapor at that temperature, rises in the
distilling flask, and passes 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 passing through the outer jacket of the condenser cools the vapor passing
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 containera 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.
Once liquid A has boiled away, the temperature in the distilling flask begins to rise again.
When it reaches 104F, 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
35
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.
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.
36
37
CHAPTER-2
INTRODUCTION
2.1
INTRODUCTION
38
The atmospheric Unit AU-V of Gujarat Refinery is designed to process 3.0

MMTPA of Arab Mix Crude (50:50 by weight of Light and Heavy Arab
Crude).
This unit was commissioned in the year 1997.
The unit was revamped during August/Sept 02 to increase the on stream

factor and flexibility of operation by providing additional heat exchanger
train and increase in the number of pumps for different products &
circulating refluxes.
The unit comprises of Crude Preheat Train, Crude Desalting, Atmospheric Distillation,
Naphtha Stabilization, LPG Amine wash and Caustic wash, Light Naphtha Caustic wash,
and Kerosene/ATF caustic wash. The main products from the unit are LPG, Light
Naphtha, Heavy Naphtha, Kerosene, Gas Oil and Long residue. Provision is also there for
with drawl of ATF (boiling range 140-240) during alternate mode of operation. During
ATF mode of operation Kerosene will not be withdrawn and the material boiling in the
range of 240-370 C will be withdrawn as Gas Oil stream.
2.2
ONSTREAM FACTOR
No of onstream hours in a year considered for design is 8000 hrs.

2.3
DESIGN FEED RATE
The following table provides hourly rates of feed and various products based on Arab
Mix Crude feed.
Sl no
1
Material
Quantity
375,000
Crude
39
Wt%
100
2
3.
4.
5.
6.
7.
LPG (Ex Stabilizer)

Light Naphtha
Heavy Naphtha
Kerosene
Gas Oil
Long residue
4750
34350
9280
73,571
57,551
195,573
1.3
9.1
2.5
19.6
15.1
52.3
2.4 FEED & PRODUCT SPECIFICATION

A. CRUDE:
a) 100% Arab mix Crude consisting of Light and Heavy Arab Crude in 50:50
proportion by weight.
b) Main Column along with overhead condensers and furnace have flexibility to
process 3.0 MMTPA Arab mix crude in 50:50 weight proportion with respect
to flow and hydraulics alone.
The properties of Arab Crude mix are as follows:
Sr.
No.
1.
2.
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Specification
Unit
Specific gravity @15 oC

o
TBP
Distillation
(%
C
volume)
o
IBP
C
o
5
C
o
10
C
o
30
C
o
50
C
o
70
C
o
90
C
o
95
C
o
EP
C
o
API Gravity
C
o
Viscosity @37.8 C
Cst
o
Pour Point
C
o
RVP@38 C
Kg/cm2
Salt content(max)
Ppm
BS&W
%Vol
B. PRODUCTS
40
Value
0.8728
27.3
52.9
97.2
223.0
344.4
476.8
658.3
709.3
732.2
30.6
10.5
-124
0.6
165
2.0
Sr.No
.
1.
2.
Product
Specification
Value
TBP cut oC
TBP cut oC
IBP-170 oC
120-170 oC
3.
O/H Naphtha
Heavy
Naphtha
ATF
TBP cut oC
Flash Point oC
Freezing point oC
ASTM D-86 EP
140-240
38 (min)
-50 (max)
288 oC
4.
SKO
5.
Gas Oil
6.
Long residue
TBP cut oC
Flash Point oC
ASTM D-86 EP
TBP cut oC
Flash Point oC
ASTM D-86 95%
TBP cut oC
7.
LPG
140-270
36 (min)
300 (max)
240/270-370
34 (min)
Not to exceed 365oC
Shall not contain
more than 8% vol
(max) of material
boiling below 370 oC
Not more than 16.87
Kg/cm2
Vapor pressure 6.5

Kg/cm2
Weathering oC
95% vol to contain

not more than 2% of
C5+ component.
MOTOR SPIRIT
S. Characteristic
No
1
Density, 15C,
Kg/m3
2
RON, min.
Distillation:
Recovery at
70C, %v
BIS
Spec
710-770
Prec.
Limits
0.5/1.2
91
0.2/0.7
Manf.
Spec.
711768*
91.2
10-45
Slope
11-38*
41
Justification/Remarks
To take care of addition of 5%
ethanol
To take care of test margin
(In case due to sensitivity of
the blend MS is not in a
position to meet AKI, meeting
AKI will be guiding factor in
line with BIS Spec)
Lower limit to take care of
storage and handling impact.
Upper limit to take care of
addition of ethanol.
4
5
6
7
Recovery at
100C, %v
Recovery at
180C, %v, min
FBP,0C max
Benzene
Content, %v,
max
Total Sulphur,
ppm mass, max
RVP at 38C,
kPa
40-70
Slope
41-70
90
Slope
91
215
1
Slope
0.04/0.18
200
0.9
3
500
1000
35-60
0.03/0.84
145/467
153/495
3.2/5.2
2.7
450
900
38-57*
Copper
Corrosion
1 max
NA
1a

storage and handling impact.
To take care of storage and
handling impact.
Based on present quality trend.
To take care of test margins and
environmental parameter.
-doTesting margin and
environmental parameter
testing margin. Upper limit to
facilitate absorption of ethanol.
To improve product quality
further
*
Parameters are applicable for ethanol doping areas only. For other areas BIS specs will
Prevail.
Gasoline containing ethanol should be supplied with addition of metal deactivator.
KEROSENE
S.No.
Characteristic
BIS Spec.
Prec. Limits
Smoke
Point,
mm , min
18
1/2
3
4
Distillation:
Final
Boiling
Point, Deg C,
max
Flash
point,
degree C, min
Total
sulphur,
ppm mass, max
Manf.
Spec
19
20 (Rlys)
20 (Rlys)
22(Def)
300
Slope
22(Def)
290
35
1/1.5
38
2500
175/580
2400
Justification/
Remarks
To take care of
test margin
To take care of
test margin.
Safety parameter.
To take care of
test margin.
Environmental
parameter.
To
take care of test
margin.
HIGH SPEED DIESEL

S.No
.
1
Characteristi
c
Cetane Index,
BIS
Spec.
46
Prec.
Limits
Function
42
Manf
Justification/ Remarks
. Spec
47
min
Rec at 370C,
%v, min
Flash
Point,
Deg C, min
Total sulphur,
ppm
mass,
max
Lubricity,
microns, max
Copper
Corrosion,
max
Particulate
Matter,
mg/Kg,
max
of density
and
distillation
43
(Assam
crude)
95
44
Slop
96
35
1/1.5
37
To take care of test margin.

Recovery higher than 95% to
be ensured.
500
145/467
450
2500
460
175/580
60/120
2400
420
NA
1a
Not
specified
2.4/7.2
24
Customer problem of filter

chokage.
BIS
Spec.
-47
Prec.
Limits
0.7/2.6
Manf.
Spec
-49
300
Slope
290
38
1/1.5
40
3000
(Genl)
2500
(Defense)
50-450
50/175
2500
3-20/1063
250440
-do-

To take care of test margin and
also
due
to
customer
complaints.
To improve product quality
further
AVIATION TURBINE FUEL

S.No
.
1
2
3
4
Characteristi
c
Freezing
Point, degree
C, max
Distillation,
final boiling
point, degree
C, max
Flash
Point,
Deg C, min
Sulphur total,
ppm
mass,
max
Electrical
Conductivity,
43
Defense requirement. Product

can not be segregated to
defense and non defense
categories
transit losses.
ps/m,
Aromatics, %
vol, max
25
(Genl.)
20
(Defense)
Sulphur
30 (Genl)
Mercaptan,
20
ppm
mass, (Defence
max
)
Lubricity,
0.85
WSD mm max (General)
0.65
(Defense)
2.5
1.4/3.0
20
Defense requirement. Product

can not be segregated.
NA
20
Defence requirement
0.65
To meet Defense requirement.

Product cannot be segregated.
Not applicable to Haldia
Refinery as it produces entire
ATF thru hydro treatment .
FEED & PRODUCT BATTERY LIMIT CONDITIONS
Sl.No.
FEED
1.
2.
3.
4.
Feed/Product
Crude
Sour LPG
Lean Amine
Wild Naphtha/
Drag Stream
PRODUCTS
1.
LPG
2.
Light Naphtha
PressureKg/cm2 /
Temp o C
9.5/30
12.0/40
26.5/35
15/38
OM&S
AU2/AU3/AU4
Amine Regeneration Unit
DHDS/LAB
CRU/MSQ
12.0/40
7.0/40
LPG Horton Sphere

a) Storage/H2 feed storage
b) AU-1 rerun section
a) Light Naphtha r/d within the
unit
b) SKO r/d within the unit
c) Gas Oil r/d within the unit
OM&S
Routed to 6GHP r/d line
outside AU-V b/l
3.
Heavy Naphtha
-/40
4.
5.
SKO
ATF
7.0/40
7.0/40
6.
Gas Oil
Kero Case
6.0/40
ATF case
7.0/40
Long residue
6.5/120
6.5/120
6.5/80 (min)
7.
Source/Destination
44
Storage for DHDS unit

feed/DHDS unit
Sweet Diesel Storage (During
Gujarat Crude processing)
Old FPU
New FPU
VDU
2.6
8.
9.
Sour Water
FLO
-/40
(2.5/5.0)/40
10.
11.
12.
Slop
Spent Caustic
Rich Amine
6.0/40
5.0/40
7.0/55
Storage
SRU
Routed to line from AU-3 to
GHP
GRE-ETP
Amine Regeneration Unit
UTILITY SPECIFICATIONS
Sr.No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Utilities
HP Steam
MP Steam
LP Steam
BFW
Instrument Air
Plant Air
DM Water
Fuel Oil(VR +
VBLSHS)
Fuel Gas
PressureKg/cm2
33
11.5
4.5
17(max)
6.5
6.5
5
5
Temp oC
430
230
165
120(max)
Ambient
Ambient
40
90
40
Specification
-15oC dew point

-15oC dew point
Calorific Value 9600
Kcal/Kg
Calorific Value 13000
Kcal/Kg
FUELOIL
S.No
.
1
Characteristi BIS Spec.

c
Kinematic
125 (winter)
Viscosity
at
50C, cSt, max
180(summer
)
150
Water content, 1 max
%v, max
Prec.
Limits
0.8/2.5
Manf Justification/ Remarks

. Spec
120
1.0/3.6
175
0.8/3.0
148
0.025/0.1
0.8
HPS
45
Test margin and cushion
S.No.
1
Characteristi
c
Kinematic
Viscosity
at
100C,
cSt,
max
BIS:Spec./Customer
rqmt.
40
Prec.
Limits
0.24/0.8
0
50
Flash point, C,
max
Water content,
%v, max
Test margin
48
0.3/1.0
100
2
Manf
. Spec
38
98
0.6/2
2/3.5
72
1.0
0.025/0.
1
93
0.8
In line with LSHS flash

spec
Test margin and cushion
LSHS
S.No.
1
Characteristic
Kinematic
Viscosity
at
100C, cSt, max
Water
content,
%v, max
BIS
Spec./Cust
omer rqmt.
50
Prec. Limits
0.3/1.0
Man
f
Spec
49
100
0.6/2
98
---do---
1.0
0.025/0.1
0.8
Test
margin
cushion
46
Justification/
Remarks
To take care of test
margin
and
PAVING BITUMEN (S-65/S-90 grades)
S.No
.
1
Characteristi
c
Penetration,
1/10mm
BIS
Spec.
80100
Prec. Limits
(Repeatability/
Reproducibility
)
2.4-3/6.4-8
Manf
. Spec
84-96

1.8-2.1/4.8-5.6
60-70
47
62-68
CHAPTER-3
EQUIPMENT DATA
48
EQUIPMENT DATA
3.1 COLUMNS
Sl.
No
1
2
3
4
5
6
Col.
No
Service
CC-01
CC-02
CC-03
CC-04
CC-05
CC-06
Atmospheric Distillation column

Heavy. Naphtha Stripper
Kero Stripper
Gas Oil Stripper
Naphtha stabilizer
LPG Amine Absorber
Tray
No
Type
51
10
6
6
43
10
Valve
Valve
Valve
Valve
Valve
Valve
Safety Valves
Set Pr
Kg/Cm2
4.5
15
29.5
3.2 HEAT EXCHAGERS/COOLERS & CONDENSERS

S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
S.No
22
23
Exchanger No
EE-01
EE-02
E03
EE-04
EE-05
EE-06A/B
EE-07A/B/C
EE-08A/B
EE-09A/B
EE-10A/B/C/D
EE-12A/B/C
EE-13
EE-14
EE-15
EE-16A/B/C/D/E/F
EE-17A/B/C/D
EE-18A/B/C/D
EE-19A/B
EE-20
EE-21
EE-22A/B/C/D
Exchanger No
EE-23A/B/C
EE-24
Shell
Crude
Crude
Crude
LR
Kero/ATF
Kero/ATF
LR
Crude
GO CR
LR
Desalter water
Brine
GO CR
GO CR
C-01 O/H
C-05 O/H
C-05 FEED
LN
HN
LR
LR
GO
ATF / KERO
Service
Tube
Kero/ATF
Top CR
Gas Oil
Crude
Crude
Crude
Crude
Gas Oil
Crude
Crude
Brine
CW
C-05 Bottom.
Hy. Naphtha.
CW
CW
LN
CW
CW
CW
CW
Service
CW
CW
No
3
2
2
24
25
26
27
28
29
30
31
32
33
34
35
36
37
3.3
EE-28A/C
EE-28B/D
EE-29
EA-01A to H
EE-102A/B
EE-103A/B/C
EE-104A/B
EE-105A/B/C/D/E
EE-106 A/B/C/D
EE-107 A/B/C/D
EE-108 A/B
EE-109
EE-110 A/B
EE-111 A/B
FO
HP Steam
LPG
Fin Cooler
Crude
LR
CRUDE
LR
CRUDE
LR
HGO CR
KERO-I
LGO
LR
HP Steam
FO
LP Steam
C-01 O/H
LGO
CRUDE
KERO-I CR
CRUDE
LGO
CRUDE
CRUDE
CW
CW
CW
PUMPS
Pump
No
PA
1A to E
2A to E
5A/B/C
6A/B/C
7A/B
8A/B
9A/B
10A/B/C
11A/B
12A/B/C
14A/B
15A/B
16A/B
17A/B
18A/B
19A/B
20A/B
23A/B
24A/B
25A/B
26A/B
Pump
No
PA
Service
Crude Feed
Desalted Crude
Top Reflux
CC-05 Feed
Top CR
HN r/d
Kero r/d
Kero CR
GO r/d
GO CR
LPG Reflux
Desalter Water Stage-I
Desalter Water Stage-II
LPG NaOH Circulation
LPG water wash
LN caustic wash
LN water wash
Kero caustic wash
Kero Water wash
LPG Caustic / Water makeup
NH3 Injection
Service
KW
Rated
Amps
240
300
45
75
37
30
75
75
75
160
22
15
55
75
75
5.5
5.5
7.5
7.5
18.5
0.37
KW
25
31
75
126
62
52
126
126
126
260
37
26
93
14
14
10
10
14
14
32
1.1
Rated
Amps
Capacity
M3/hr.
max
287
310
146
79
242
18
124
358
125
361
78
38
38
36
36
25
25
34
34
5
7 Lit/hr
Capacity
M3/hr.
max
DP
Kg/cm
2
16
22
11
20
9
15
17
10
14
15
14
17.5
19
11
12
9
13
18
17
20
8.5
DP
Kg/cm
2
27A/B
29A/B
31A/B
32A/B
33
40A/B
41A/B
42A/B
43A/B
44A/B
45A/B
46
48
50A/B
51A/B/C
52A/B
102A/B
103A/B
104A/B
101A/B
3.4
Demulsifier Injection
Ahuralan Injection
Caustic injection
Caustic Circulation / m- up
47% caustic transfer
Wash water make up
LN rundown
VV-2 sour water
Spent caustic
Kero / ATF caustic M/up
IFO
CBD
ABD
LPG booster
LR
Coolant Water
Kero-I CR
LGO product
HGO CR
Kero-I
FIRED HEATER
05-FF-001-Charge heater
3.5
AIR PREHEATER
05-FD-001-Cast Air pre-heater

05-FD-002-Glass Air pre-heater
3.6
FANS
05-KA-001A/B FD fans
05-KA-02-ID fan.
3.7
DRUMS/VESSELS
0.37
0.37
0.75
11
3.7
11
15
3.7
5.5
15
45
18.5
7.5
45
180
30
90
90
90
110
1.1
1.1
2.7
20
20
26
7.3
10.2
28
75
37
9.6
75
19
50
150
150
150
183
11 Lit/hr
24 Lit/hr
410 Lit/hr
5
5
5
58
9
10
5
30
20
6
37
275
98
371
132
470
106
11
10
15.8
11.5
3.1
10.5
8
6
6.5
19.3
15.5
6.8
5
22
16.8
5.5
11
15.1
9
21.6
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
32
33
3.8
1.
Vessel no
VV-01A
VV-01B
VV-02
VV-03
VV-04
VV-05
VV-06
VV-07
VV-08
VV-09
VV-10
VV-13
VV-14
VV-15
VV-16
VV-17
VV18A/B
VV19A/B
VV-120
VV-25
VV-26
VV-27
VV-28
VV-29
VV-30
Desalter 1st stage

Desalter 2nd stage
CC-01 O/H reflux Drum
CC-05 O/H reflux Drum
Amine settler
Desalting water drum
LPG caustic wash
LPG water wash
LPG coalescer
LN caustic wash
LN water wash
Kero / ATF Caustic wash
Kero / ATF water wash
Kero / ATF Coalescer
Spent caustic degasser
Decoking pot
NH3 solution Vessel
Operating
Pres./ Temp
Kg/cm2 // 0
C
11.5 / 123.5
11.5 / 123.5
2.1 / 40
9/40
18.7 / 40
Atm / 40
18 / 40
16.5 / 40
15 / 40
9.5 /40
8 / 40
15/40
14/40
13/40
1.2/40
Atm / 100
Atm / 40
Ahuralan soln. Vessel
Atm / 40
LPG surge drum

HN coalescer
IFO surge drum
HP steam condensate
FG KOD
LPG drum
CBD
VV-32
VV-33
VV-34
VV-35
VV37A/B
VV-38
Flare KOD
ABD drum
Brine degasser
Flash condensate
Inst. Air vessel
9/40
10/40
1.5 / 90-120
32/237 -430
2/40-80
10 / 40-80
Atm/ 80120
1.5 /144
Atm / 60
Atm / 45
4 / 152
7.5 / amb
Coolant sump
Salt Dryer
HSD Coalescer
amb
4 / amb.
4/amb
VV-301
Service
TANKS
05-TT-001-47% Caustic Solution Tank
Safety valve data

PSV tag
1201A/B
1202A/B
1601 / 1602
1703 / 1704
Set
Press
16
16
4.5
15
1901 / 1902
1903/1904
29.5
29.5
2001 / 2002
2003 / 2004
2201/2202
2203/2204
16
16
23
23
2501 A/B
14.5
3101 / 3102
3105
3203/3204
3201/3202
3.5
43
6.5
14.5
9.0
16.0
2.
3.
4.
3.9
05-TT-002A/B-10% Caustic Dilution Tank

05-TT-005-Wash water make-up Tank
05-TT-06A/B-3.5% Caustic Dilution Tank
FILTERS
1.
2.
05-GN-DO-001A/B IFO Pump suction strainers

05-GN-DO-002A/B IFO Pump discharge strainers
3.10
LIST OF SAFETY VALVES & RELIFE VALVES
Safety valves are normally characterized by fast opening, (popping action). These are
used for compressible fluids like gases. In this category come pressure safety valves
(PSV). Relief valves are used for non-compressible fluids (normally liquids). Relief
valves open in proportion to pressure increase over the set value or opening pressure. In
this category come temperature safety valves (TSV).
These pressure relief devices (safety valves as well as relief valves) are spring-loaded
valves. It is important to note that relief valves provide no protection against high
temperature.
The pressure relief valves are actuated by inlet static pressure and designed to open
during an emergency or abnormal condition, causing pressure build up. This action of
relief valve prevents internal fluid pressure from rising above specified value. Depending
upon type of application, safety valves are selected as closing type (auto reset) or nonclosing type.
Brief description of pressure and temp. Safety valves: a) LIST OF PSVs

TAG NO.
Service
LOCATION
Set
Relieving
Selection
pressure
Temp C
Basis
Hold
Hold
H/C
Desalter-I
Kg/cm2 g
16.00
B
PSV1202A/
H/C
stage
Desalter-II sta
16.00
Hold
Hold
B
PSV-1501
PSV-1502
PSV-1503
PSV-1601
PSV-1602
PSV-1701
PSV-1702
PSV-1703
PSV-1704
PSV-1901
PSV-1902
PSV-1903
PSV-1904
PSV-2001
PSV-2002
PSV-2003
PSV-2004
PSV-2201
PSV-2202
PSV-2203
PSV-2204
PSV-2501A
TAG NO.
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
H/C
LPG
Service
05-CC-001
05-CC-001
05-CC-001
05-VV-002
05-VV-002
05-CC-005
05-CC-005
05-CC-003
05-CC-003
05-VV-006
05-VV-006
05-VV-007
05-VV-007
05-VV-009
05-VV-009
05-VV-0010
05-VV-0010
05-VV-013
05-VV-013
05-VV-014
05-VV-014
05-VV-020
LOCATION
4.5
4.5
4.5
4.5
4.5
15
15
15
15
29.5
29.5
29.5
29.5
16
16
16
16
23
23
23
23
14.5
Set
130
130
130
128
128
87
87
97
97
132
243
132
243
205
212
205
212
316
230
316
230
85
Relieving
Block discharge
Block discharge
Block discharge
Fire
Fire
Block discharge
Block discharge
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
Selection
pressure
Temp C
Basis
Kg/cm2 g
14.5
29.5
29.5
3.5
3.5
43
6.5
6.5
14.5
14.5
14.5
14.5
85
110
110
526
526
266
173.5
173.5
96
96
60
60
Fire
External fire
External fire
External fire
External fire
Fire
Fire
Fire
Fire
Fire
Fire
Fire
PSV1201A/
PSV-2501B
PSV-2601A
PSV-2601B
PSV-3101
PSV-3102
PSV-3105
PSV-3108
PSV-3109
PSV-3201
PSV-3202
PSV-3203
PSV-3204
LPG
LPG
LPG
Fuel oil
Fuel oil
HP steam
LP steam
LP steam
LPG
LPG
FG
FG
05-VV-020
05-CC-006
05-CC-006
05-VV-026
05-VV-026
05-VV-027
05-VV-035
05-VV-035
05-VV-029
05-VV-029
05-VV-020
05-VV-020
PSV43002A/B
PSV-4401
PSV-4402
PSV-0000
PSV-0000
Inst Air
MP
Steam
MP
Steam
HC
HC
05-
9.0
186.6
Fire
VV0037A/B
05-MD-001
15
285
C/V failure
05-MD-001
15
285
C/V failure
Salt dryer
Salt dryer
16
16
Ambient
Ambient
b) LIST OF TSVs
TAG.NO
SERVICE
LOCATION SP kg/cm2
TSV-1101
TSV-1102
TSV-1103
TSV-1104
TSV-1105
TSV-1201
TSV-1202
TSV 1301
TAG.NO
Crude
Crude
Crude
Crude
Crude
CW
CW
Crude
SERVICE
35.5
35.5
35.5
35.5
35.5
6
22
43
LOCATION SP kg/cm2
TSV 1302
TSV 1303
TSV 1304
TSV 1305
TSV 1307
TSV 1308
TSV 1604
TSV 1605
TSV 1606
TSV 1703
TSV 1704
TSV 1705
TSV 1801
TSV 1802
TSV 1803
TSV 1805
TSV 1806
TSV 1807
TSV 1808
TSV 1809
TSV 1810
Crude
Crude
Crude
Crude
Crude
Crude
CW
CW
CW
CW
CW
CW
CW
CW
CW
CW
CW
CW
CW
CW
CW
43
43
43
43
43
43
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
Relievin
g Temp.
150
150
150
150
150
65
65
215
Relievin
g Temp.
175
215
225
255
305
65
65
65
65
65
65
65
65
65
65
65
65
65
65
65
65
Selection Basis
Thermal Expansion
Selection Basis
TSV 1811
TSV 1812
TSV 3101
TSV 3102
TSV 3103
TSV 3104
TSV 3105
TSV 3106
TSV 5002
TSV 5003
TSV 5004
TSV 5005
TSV 5006
TSV 5007
TSV 5008
TSV 5009
TSV 5010
TSV 5011
TSV 5012
TSV 5013
TSV 5014
TSV 5015
TAG.NO
CW
CW
FO
FO
FO
FO
FO
FO
H/C
H/C
H/C
WATER
WATER
WATER
WATER
WATER
H/C
H/C
H/C
H/C
H/C
WATER
SERVICE
TSV 5016
TSV 5017
TSV 5018
TSV 5019
TSV 5020
TSV 5021
TSV 5022
TSV 5023
TSV 5024
TSV 5025
TSV 5026
WATER
WATER
WATER
WATER
WATER
WATER
H/C
H/C
H/C
H/C
H/C
2.12
6.0
6.0
16.5
16.5
3.5
3.5
16.5
16.5
EE-102A/B
35.5
EE-103A/B
35.5
EE-104A/B
35.5
EE-13B
6.9
EE-12 A/B/C
2.2
EE-16D
6.9
EE-16E
6.9
EE-16F
6.9
EE-106A/B
43
EE-105A/B
43
EE-107A/B
43
EE-108A/B
43
EE-18 C/D
2.5
EE-17D
6.9
LOCATION SP kg/cm2
EE-19B
EE-109
EE-110A/B
EE-111A
EE-111B
EE-103C
EE105C/D
EE-105 A/B
EE-107 C/D
6.9
6.9
6.9
6.9
6.9
6.9
35.5
43
43
43
43
65
65
245
245
245
245
245
245
150
150
150
65
130
65
65
65
210
250
310
310
150
65
Relievin
g Temp.
65
65
65
65
65
65
150
210
250
250
310
THER.EXPANSION
Selection Basis
LIST OF CONTROL VALVES
S.No.
1
2
3
4
TAG NO.
5LV2602
5LV3104
5LV3106
SERVICE
BOILER FEED WTR
RICH AMINE TO ARU
STM CONDEN. TO FLASH DRM
LP STM COND. FRM VV-035
SIZE(in.)
1
1
1
1
Action
A/O
A/O
A/O
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
5FV1807
5FV2502
5LV3202
5PV1701
5FV2501
5PV3111
5FV1508
5FV2011
5FV2503
5PV1415
5PV1504A
5PV1504B
5PV1912
5PV2011
5PV3203
5PV4406
5SDV1406
5SDV1701
5SDV1901
5SDV1902
5SDV1903
5SDV1904
5SDV2001
HY. NAPHTHA FOR GAS OIL

LPG BOOSTER PMP FLW
LPG TO LPG DRM VV-029
VENT FRM VV-003
LPG SURGE DRM
FO TO VV-026(BPC)
STRIPPING STM TO CC-001 BTM.
HY. NAPHTHA TO KERO R/D
LPG FRM PA-014A/B
FO TO HTR
FG TO FLARE FRM CC-001
FG TO VV-002
LPG PRODUCT R/D
HY. NAPHTHA TO STORAGE
LPG TO FG KOD VV-028
HP STM TO DESUPER HTR
FG SUPPLY(PILOT)
DRAIN FRM VV-003
CAUSTIC SOL. EX VV-006
WASH WTR EX VV-007
WTR EX VV-008
CAUST. WASH WTR EX VV-016
CASTIC EX VV-009
1.5
1.5
1.5
1.5
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
A/O
A/O
A/O
A/O
A/C
A/C
A/C
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
S.No.
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
TAG NO.
5SDV2002
5SDV2003
5SDV2201
5SDV2202
5SDV2203
5SDV2601
5SDV2602
5LV1201
5LV3103
5FV1201
5FV1409
5FV2501
5LV1602
5PV3202
5SDV1401
5LV1202
5TV1702
5FV1401
5FV1402
5FV1403
5FV1404
5FV1804
5FV2206
5FV3102
SERVICE
WASH WTR EX VV-010
WTR FRM VV-025
CAUSTIC EX VV-013
WASH WTR EX-VV-014
WASH WTR EX VV-015
AMINE SETTLER BTM
LPG AMINE ABSORBER BTM
BR IN FRM DSTLR TO DGASR
FO TO VV-026
2nd STAGE DESAL. WTR I/L
PLANT AIR FOR DECOCKING
LPG TO AMINE ABSORBER
SOUR WTR TO VV-005
LP STM TO LPG VAPORISER
FO RETURN
1st STAGE DIST. WTR I/L
NAPH. STAB. BTM. SAT. EE-018A/B
CRUDE TO HTR PASS-1
CRUDE I/L PASS-2
CRUDE I/L PASS-3
CRUDE I/L PASS-4
HSD R/D
KERO/ATF COALASCER O/L
HP STM TO EE-028A/B/C/D
SIZE(in.)
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
A/O
LOCK
A/C
A/C
A/C
A/C
A/O
A/O
A/O
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
S.No.
73
74
75
76
77
78
79
80
81
82
83
5HV1701
5PDV1420
5SDV1402
5SDV1601
5SDV2501
5PV1423
5FV1410
5FV1412
5FV1413
5FV1414
5FV1505
5FV1805
5FV1806
5HV2001
5HV2002
5HV2201
5HV2202
5SDV1801
5FV1501
5LV1508
5LV1510
STABISER O/H VAPOUR

ATM STM TO HTR
FO SUPPLY
SOUR WTR TO SRU
LPG TO LPG SURGE DRM
FG TO HTR
DECOCKING STM TO HTR PASS-1
TOP RFLX TO CC-001
LR TO BL(FPU)
LR TO BL STORAGE
LN+CAUSTIC TO VV-009
LN WTR TO VV-010
KERO+ATF+CAUST. TO VV-013
KERO+ATF+WASH WTR TO VV-014
LN TO CAUSTIC WASH
TOP CIR. RETURN TO CC-001
KERO STRIPPER FEED
GAS OIL STRIPPER FEED
4
4
4
4
4
6
6
6
6
6
6
6
6
6
6
6
6
6
8
8
8
TAG NO.
SERVICE
SIZE(in.)
5SDV1403
FG SUPPLY
8
5LV1206
CRUDE BOOSTER PMP D/S
8
5FV1502 ATF/KERO CR RETURNED TO CC-001
10
5TV1116
EXCH-05-EE-006 A/B BYPASS
12
5FV6201
SKO TO DHDT
8
5FV6202
SKO TO ATF MEROX
8
5FV6203
HOT RCO TO DCU
8
5FC6204
HN TO DHDT
2
5FV6205
GO TO DHDT
6
5FV7218
LN TO ISOM
4
5FV7219
LN TO ISOM
4
A/O
A/O
A/O
A/O
A/O
A/O
A/C
A/C
A/C
A/C
A/C
A/O
A/O
A/C
A/C
A/C
A/C
A/O
A/C
A/O
A/O
A/O
A/C
A/C
A/C
A/O
A/O
A/O
A/O
A/O
A/O
A/O
CHAPTER-4
PROCESS DESCRIPTION
PROCESS
DESCRIPTION
59
PROCESS DESCRIPTION
4.1
BASIC OPERATIONS INVOLVED
In Atmospheric Unit, Crude Oil is separated into various fractions in fractionation

column based on relative volatility, boiling point and condensation temperature ranges of
the various components. These fractions have different properties. Most of them are
lighter then crude accepting the bottom product LR (Long Residue).
Basic operations involved in AU are as follows:
Crude Preheating and Desalting
Crude heating in Charge Heater
Atmospheric Distillation
Naphtha Stabilization
LPG Amine and Caustic washing
Light Naphtha Caustic washing
Kero/ATF Caustic washing
For the sake of simplicity in process description, Atmospheric Unit is divided into a
Number of subsections as given below:
Crude Preheat Train I (old and new)
Crude Desalter
Crude Preheat Train II (old and new)
Crude Charge Heater
Atmospheric Distillation Column
Naphtha Stabilizer
Product Cooling and Run Down system
LPG Amine wash system
LPG Caustic wash system
Light Naphtha Caustic Wash system
60
Kero/ATF Caustic wash system
Chemical Injection system.
4.2 CRUDE CHARGING INTO UNIT

Refer P&IDs 3551-05-02-41-0111 Rev 2
Crude from crude storage tanks in GRE crude offsite area is pumped into Atmospheric
Unit through a 14 header. In the battery limit of AU double block valve and a spectacle
blind is provided for positive isolation. Crude is received at 9.5 Kg/cm 2 g pressure and
ambient temperature. The following instruments are provided in the crude inlet line to the
Unit within Unit battery limit.
Local pressure gauge PG-1101
Pressure Transmitter PT-1102 with DCS indication
PSL-1123 with alarm in DCS.
From the 14 headers, Crude Booster 05-PA-001 A/B/C/D/E take suction and deliver
crude to the preheat Train-I through a 12 discharge header. Provision was made at B/L to
receive LAB plant Return stream along with crude. The following connections are
provided in the suction line of booster pumps inside battery limit.
1 Caustic solution line in order to maintain pH of Desalter effluent.
2 demulsifier solution line to break crude and water emulsion.
10 LR circulation line for start-up purpose.
2 service water line for unit flushing.
3 slop line from CBD Pump Discharge for reprocessing the slop.
The crude booster pumps have a capacity of 261 m 3/hr . The normal discharge pressure of
crude booster pump is 23.87 Kg/cm2 g. Normally two crude pumps will be in operation
and one will remain standby.
The following instruments are provided in the discharge header of crude booster pumps.
Local Temperature Gauge TG-1102
Temperature Indicator TI-1101
PT-1103 with DCS indication and recording
61
Local Pressure Gauge PG-1104
PSHH-1130 with interlock to trip Crude booster pumps
FI-1101 with flow tantalizer and recorder at DCS and sends signals to furnace pass
ratio balancing and also heat duty control
PV-1206/PV-5001 is provided on common discharge line of crude booster pump for

controlling the Desalter pressure through PIC-1206 by Sequential action. A 2 LP steam
connection is provided in the discharge Header of Crude booster pump for air removal of
the system during start-up.
4.3 Crude Preheat Train-I
Refer P&IDs 3551-05-02-41-0111 Rev 2
Crude preheat trains are provided to accomplish the following.
To heat the crude oil and bring it to the required desalting temperature.
To further heat the crude oil after desalting.
To recover heat from out going products and circulating reflux streams by heating the
crude oil, thereby improving fuel economy in operation at unit.
Crude Preheat TrainI is divided in to two parts.

1. Preheat TrainI (Old)
2. Preheat Train I (New).
After PV-1206/PV -5001 Crude is divided in to two parts by H/C 5001 (New train) and
HIC 5002 (Old train). After HIC 5002 Crude is passed through exchanger EE-01, EE-02,
EE-03 (shell side) and then through EE-04 and EE-05 (Tube side). From EE-05crude
goes to EE-06,At EE-06 crude O/L temp. rises up to 135deg.centigrade
Preheat Train I (New) After HIC 5001 Crude passes through exchangers EE-102A/B
(shell side) then Parallel to EE-103A/B/C (tube side) & EE-104A/B (shell side) and it is
heated up to 130 C. Then both streams are joined together and feed to desalter VV-01A
via HIC-5003.
New preheat Train I Temp. Profile
62
After HIC 5001, Crude flows through exchanges EE-102A/B shell side. Crude is
heated up to 74.3 C LGO (Tube side) is cooled from 134.9 C to 65 C.
Crude then passes through EE-103A/B/C/ and EE-104A/B in parallel. Crude

flows in EE-103A/B/C tube side and further get heated from 74.3 C to 120.5 C.
In exchanger EE-103A/B/C shell side LR gets cooled from 165 C to 120 C.
In Exchanger EE-104A/B Crude passes in shell side and gets heated from 74.3 C
to 138.8 C tube side flow is Kero I C.R. and it is cooled from 185.7 C to 128
C.
Combined outlet from exchanger EE-104A/B and EE-103A/B/C then joins with
old Pre-heat Train I stream via H/C 5003.
All exchangers in Preheat Train-I are provided with bypasses to tackle maintenance/tube
Leakage problems. Thermal Safety Valves (TSV) are provided on each of exchanger
outlets on the crude side (cold stream) to take care of pressurization due to thermal
expansion of Local pressure gauges and temperature indications in DCS are provided
across every exchanger for performance monitoring of the particular exchanger unit.
The purpose of heating up crude in preheat train I before Desalter is to improve oils
Fluidity, reduce its viscosity, and to help mixing desalter water thoroughly with it. Here
crude is preheated from 30 C to 127 C for normal Kero Case (for ATF case 123.6 C).
From Crude Preheat Train-I, crude is routed to two stage Crude Desalter. MV-1201 &
MV-1202 are provided just upstream of two stage desalter. Normally desalting water is
added upstream of these mixing valves. Provision exists to add desalting water into crude
upstream of 05-EE-005. The purpose of the mixing valve is to thoroughly mix the crude
and water prior to desalting.
4.4
CRUDE DESALTING
Refer P&ID No. 3551-05-02-41-0112 Rev.2

Crude oil brings along with it salts, particularly those of sodium, Magnesium etc, metals
like Arsenic, Vanadium etc, and mud. Although these are present only in small amounts,
their presence can result in serious problems in down stream equipments viz. Heat
63
exchangers, charge heater and Atmospheric column. Hence the need of their removal is
important before processing.
At high temperatures, Magnesium chloride decomposes and forms Hydrochloric acid,
corroding trays in the top section of column and tubes of overhead condensers etc. The
presence of calcium and sodium salts can cause plugging of heat exchanger and heater
tubes, there by rapidly reducing heat transfer co-efficient. The presence of Arsenic acts as
a poison to platinum catalysts if it is used in down stream process units. Presence of these
salts also promotes coke formation in heater tubes which results in increased pressure
drop as well as less heat transfer rates. The excessive coke formation results in escalation
of hot spots on heater tubes which can have serious and disastrous consequences for
heater tubes. At high temperature salts in crude oil show a tendency to deposit along heat
exchange surface of the equipment.
Caustic injection upstream of desalter in crude is done to neutralize acids present in crude
and convert them into water solvable salts. These salts are then removed by desalter water
in desalter. Caustic injection down stream desalter is provided to neutralize any other acid
traces formed at desalter operating conditions.
Brine is associated with crude both as a fine suspension of droplets and more permanent
emulsion. To break this tight emulsion, Demulsifier is added. This ensures better function
of Desalter. Demulsifier is injected into crude upstream of desalter. Provision also Exists
for injection of Demulsifier into the crude line at B/L for better mixing.
In fact, both caustic solution and Demulsifier are added into the crude before the first
exchanger in the preheat train I.
4.4.1
DESALTERS OPERATION
Two stage crude desalter comprising of two identical desalting units. 05-VV-00-001A/B
has been provided for reducing salt content in crude oil to the level of <0.5 PTB. Two
stage Desalter unit arrangement is provided to handle crude with widely carrying salt
contents. Depending upon salt contents in crude both desalter units can be operated either
in series or Individually but not in parallel. Any of the two desalters can be isolated and
bypassed. Crude desalter operates at 12.5 Kg/cm2 g pressure. It is designed to bring down
64
the salt content of the crude from 165 ppm to less than 0.5 ptb. Also, the water content of
crude is brought down from 0.2% volume to less than 200 ppm at the exit of desalter.
Crude and desalter water enters the Desalter (05-VV-00-001A/B) from its bottom. Crude
outlet from top of the vessel is connected to the Desalted crude pumps (05-PA-00002A/B/C) suction. For draining oily water and handling wash streams, desalter drain
connections to CBD/OWS are provided.
The material that collects at desalter bottom is a thick sludge that is corrosive and often
has a tendency to choke the piping. This material needs to be cleaned periodically. For
this de-sledging arrangements in both the desalter have been provided. Stage-I Desalting
water Pumps 05-PA-00-015A/B discharge is associated with distributors inside both the
desalter. FI-1211A and FI-1210B indicate desludging water flow to 05-VV-001A and 05VV-001B respectively. Desludging is a batch process. When desludging water is injected
in the desalter through distributor, it loosens up the muck collected at the bottom, and
facilitates its easy exit from outlet. Meticulous care should be taken during this operating
as sudden jerk can upset oil water inter phase, leading to water and salt carryover to
CDU. On stage-I desalter 05-VV-001A, inter phase level controller ILIC-1202 is
provided to ensure smooth functioning of the unit. In addition one inter-phase level low
low switch LSLL-1207 along with alarm is provided to prevent inter phase from getting
lost and resulting into oil carryover along with brine from desalter. Another lowlow
level (oil) switch LSLL-1203 with alarm (which in effect is high inter phase level) is
provided. In case of low oil level, amperage in desalter increases due to increased
conductivity and may eventually lead to short-circuiting. On actuation, this switch trips
power supply to desalter to prevent such an eventuality.
Since desalter is liquid filled vessel, the pressure control is achieved by manipulating PV1206/PV5001 provided on crude pump discharge line upstream of preheat train-I. Panel
mounted push buttons (to start PB-1201 A& to stop PB1201B) are provided to control
power supply to desalter. Actuation of LALL-1203 trips power supply to desalter, PSV1201A & 1201 B are provided to protect 1st stage desalter from over pressurization due to
blocked outlet. The discharge of these safety valves is routed to flash zone of
Atmospheric Column. Since this is a liquid discharge, safety valve outlet line is kept free
draining towards atmospheric fractionating column to avoid formation of liquid pockets.
65
Also the PSV 1201A/1201B are located close to the column to reduce the discharge pipe
length where two-phase flow may occur after PSV discharge.
Similar instrumentation and other facilities exist for II stage desalter 05-VV-001B also.
On II stage desalter 05-VV-001B, inter-phase level controller ILIC-1202 is provided to
maintain inter-phase level in the desalter unit. It can manipulate either LV- 1202 on I
stage desalter water pump discharge or LV-1201 on cold brine outlet from 05-VV-001A.
The selection for this is made by SS-1201/Ss-1202. One interphase level low-low switch
LSLL-1208 along with alarm is provided to prevent interphase from getting lost and
resulting into oil carryover along with brine from desalter. On actuation the switch closes
LV-1201 through de-energization of SOV-1201. The selection for this is made by SS1207. Local PG/TG are provided to indicate desalter pressure and temperature. PIC-1206
on desalted Crude line is provided for manipulation of PV-1203/PV5001 on crude charge
pump discharge line. Another low-low level (oil) switch (LSLL-1204) along with alarm
(which in effect is high inter-phase level) is provided. In case of low oil level, amperage
in desalter increases due to increased conductivity & may eventually lead to shortcircuiting. On actuation this switch trips power supply to desalter.
Since desalter are liquid filled vessels, the pressure control is achieved by manipulating
PV-1206/PV5001 provided on crude pump discharge line upstream of preheat train-I.
PSV-1202A &1203B are provided to protect 2nd stage desalter from over pressurization
due to blocked outlet.
To ensure that the crude and water are mixed thoroughly, the mixing valves MV1201/1202 respectively are provided at the upstream of both the desalter.
Depending upon salt content in crude, following three cases for desalter operation are
considered:
1) Both Desalter Stages in operation
2) Only Stage I Desalter in operation
3) Only Stage II Desalter in operation
All these cases are taken up in detail in following pages:
1)
Both Desalter stages in operation in series:

Crude from preheat train I is premixed with desalter water in mixing valve MV-1201 at
upstream of desalter 05-VV-001A. The desalting water drawn from 05-VV-001B is
66
pumped by 05-PA-015A/B (I stage desalting water pumps) under interphase level

controller LIC-1202 of 05-VV-001B to 05-VV-001A. Manual selection for the interphase
control of 05-VV-001B on outgoing brine from it is made by SS-1202. Interphase of 05VV-001A is indicated by ILIC-1201 and is controlled by operating LV-1201 on outgoing
brine from 05-VV-001A. Linking of ILIC-1201 with LV-1201 operation is manually done
by SS-1201. This linking automatically deselects LIC-1202 of 05-VV-001B from LV1201 operation 05-VV-001A. Interphase level low low as indicated by LSLL-1207 is
manually selected by SS-1207 to actuate SOV-1201 and close LV-1201 on outgoing brine
line from 05-VV-001A. This selection automatically deselects LSLL-1208 on 05-VV001B and this acts as mere interphase level low-low alarm only in 05-VV-001B. Crude
from 05-VV-001A overflows to 05-VV-001B for further and final desalting. Water for
desalting in this unit is drawn from 05-VV-005 by 05-PA-016A/B (II stage desalting
water pumps) under flow control FIC-1201, heated in shell side of 05-EE-012A/B/C and
enters through mixing valve MV-1202. Its flow towards MV-1201 is kept completely
closed to receive adequate quantity of desalting water in 05-VV-001B. Brine from 05VV-001B bottom is diverted to suction of 05-PA015A/B and again follows a complete
cycle as described earlier. PIC-1206 on desalted crude outlet from desalter is selected to
maintain its pressure by manipulating PV-1206/PV5001 sequentially.
2) Only stage II Desalter in operation
In this case only 05-VV-001B is put in operation and 05-VV-001A is completely
isolated/bypassed from crude, desalting water and brine networks. Crude from preheat
train I enters 05-VV-001A through MV-1201 and leaves through top to suction of 05-PA002A/B/C/D/E (desalted crude pump suction) under desalted crude outlet pressure
control PIC-1206. This controller manipulates the pressure of PV-1206/PV5001 provided
at crude line before the preheat train I. Water for desalting in this unit is drawn from 05VV-005 by 05-PA-016A/B (II stage desalting water pumps) under flow control FIC1201,
heated in shell side of 05-EE-012A/B/C and enters through mixing valve MV1201. Interphase of 05-VV-001A as indicated by ILIC-1201 is controlled by LV-1201 operation is
manually done by SS-1201. This linking automatically de-select LIC-1202 of 05-VV-001
from LV-1201 operation of 05-VV-001A. Inter-phase level low low, as indicated by
67
LSLL-1207 is manually selected by SS-1207 to actuate SOV-1201 and close LV-1201 on

outgoing brine line from 05-VV-001A. This selection automatically de-links LSLL-1208
of 05-VV-001B from LV-1201 operation.
3) Only stage II Desalter in operation
In this case only 05-VV-001B is put in operation and 05-VV-001A is completely
isolated/bypassed from crude, desalting water and brine networks. Crude from preheat
train I enters 05-VV-001B through MV-1202 and leaves through top to suction of 05-PA02A/B/C/D/E (desalted crude pump suction) Desalter pressure is controlled by PIC-1206
provided at desalted crude outlet line. PIC-1201 controls by manipulating PV1206/PV5001 on crude to preheat train I. Water for desalting in this unit is drawn from
05-VV-005 by 05-PA-016A/B (II Stage desalting water pumps) under flow control FIC1201, heated in shell side of 05-EE-012A/B/C and enters through mixing valve MV1201. Interphase of 05-VV-001B as indicated by ILIC-1201 is controlled by LV-1201.
Finally cooled brine of 05-VV-001B, still appearing as outgoing from 05-VV-001A.
Linking of ILIC-1202 with LV-1201 operation is manually done by SS-1202&SS-1201.
This linking automatically de-selects ILIC-1201 of 05-VV-001A from LV-1201 operation
05-VV-001A. Interphase level low, as indicated by LSLL-1208 is manually selected by
SS-1207 to actuate SOV-1201 and close LV-1201 on outgoing brine line from 05-VV001A. It is important to be noted that actually it is outgoing brine of 05-VV-001A and not
from 05-VV-001B. This section automatically de links LSLL-1207 of 05-VV-001A from
LV-1202 operation.
Some of the parameters that are to be closely monitored to realize operation are:
Water Injection Rate
Chemical Injection Rate
Oil Water Interphase Level
Mixing valve performance (Delta P)
Desalter Pressure
Desalter Temperature
68
Influence of these variables on desalter operation is discussed later in a section discussing

effect of operating variables.
Sample points are provided from crude oil outlet from desalter. Crude oil or water from
respective sample point flows through a coil in sample cooler on outside of which cooling
water flows to cool the hot sample. Sampling cock lines have been provided with a 2 LP
steam flushing line to clean the line of any crude after taking sample. Sample cocks are
provided on each desalter at various elevations of the vessel. These are used to check
interphase level physically against that indicated by corresponding LIC.
4.4.2
Desalter Water System
Water used for desalting is stripped sour water from SRU. As other alternative, DM/SW
can also be used. Sour water or DM water/service water is first collected in desalter water
vessel 05-VV-005. Desalter water drum level is maintained by LIC-1205, manipulating
LV-1205 acting on incoming stripped water line/ DM water line in sequence. Provision of
Caustic solution injection in this drum is there to neutralize acids formed in crude at
elevated desalter temperatures.
Combined desalting water from desalter water drum 05-VV-005 is pumped by Second
Stage Desalting Water Pumps 05-PA 16A/B/C to 05-VV-001B under flow control FIC1201. It is heated up to about 99 C in shell side of 05-EE-012A/B/C by exchanging heat
with brine solution going out from desalter, which gets cooled from 122/118.5 C to 6359.5 C. TI-1208 is provided at the downstream of this exchanger on the desalter water
line. This heated water can join the crude header upstream of crude oil mixing valve MV1202 of desalter 05-VV-001B. Water containing dissolved salts from crude (also called
brine) in 05-VV-001B is pumped out by First Stage Desalting water pump (05-PA015A/B) to 1st stage desalter. This brine joins the crude header upstream of crude oil
mixing valve MV-1201 of Desalter 05-VV-001A. Provision is also available for make up
desalter water from Desalter drum 05-VV-001 to the first stage desalter pump 05-PA015A/B. The brine solution from 1st stage desalter 05-VV-001A is cooled in tube side of
05-EE-012A/B/C and 05-EE-013. Finally cooled brine is sent to brine degasser 05-VV034. From brine degasser it is routed into OWS Selector switches have been provide for
inter-phase controllers of desalter 05-VV-001A & 05-VV-001B to manipulate LV-1201 on
69
outgoing brine. On very low desalter level actuated by an low level alarm, SOV-1201
shall close LV-1201 to stop further withdrawal of water, thus eliminating risk of oil
carryover with brine.
4.5
CRUDE PREHEAT TRAIN - II
Refer P&IDs 3551-05-02-41-0113 Rev 2

Crude preheat trainII is desalter outlet to crude charge heater (05-FF-01). Major
equipments at this section are shell and tube type heat exchangers. Crude preheat train
II can be subdivided to crude preheat train II (old) and Crude preheat Train II (New).
New Preheat Train II
Desalted crude from PA-02A/B/C/D/E is divided in to two streams, via HIC 5005 (new
preheat Train) and HIC 5006 (old preheat train II).
After HIC 5006,. Further, Crude passes through 05-EE07A/B/C in series and exchanges
heat with LR from 05-EE-10B outlet. Again, crude is heated in 05-EE-08A/B and 05-EE09A/B by HGO and LGO CR streams in series. LR from the discharge of PA-51A/B/C is
passes through 05-EE-10A/B/C/D in counter current manner with crude coming out from
EE-09A/B, where heat transfer takes place from LR to Crude. Crude from 05-EE10A/B/C/D combines together and combined stream is joint with the stream of new
preheat train II (i.e. EE-108A/B). And feed to furnace 05-FF-01.
One 10 line from EE-108 o/l to EE-10 inlet is provided. Crude flow to new preheat train
II is measured by 05-PI-5028
Crude Preheat Train II (New) Temp. Profile.
After H/C 5005 desalted crude is divided in to two streams and flows to exchanger 05EE-106A/B/C/D shell side and exchange 05EE-105A/B/C/D/E tube side in parallel.
In exchanger EE-106A/B/C/D crude is heated from 128 C to 184.2 C by exchanging
heat from tube side hot stream LGO product. LGO product is cooled from 282 C to 138
C in exchanger EE-105A/B/C/D/E crude is heated from 128 C to 228.7 C by getting
heat from hot stream LR. LR is cooled from 265 C to 165 C.
70
Combined outlet of EE-106 & EE-105 again divided in to two branches parallely and
pass through exchanger EE-107A/B/C/D and EE-108A/B tube side. In exchanger EE107A/B/C/D crude is heated from 206.8 C to 291 C and hot stream L.R. is cooled from
360.4 C to 265 C. In exchanger EE-108A/B crude is also heated from 206.8 C to 291
C and hot stream HGO CR is get cooled from 326 C to 275 C heated crude @ 291 C is
then joins with EE-10A/B/C/D crude oil line and then fed to furnace FF-01.
4.6
FURNACE
Refer P&ID No. 3551-05-02-41-0114A Rev.3

3551-05-05-42-0114B Rev.3
Major equipment of this section is atmospheric heater, air pre-heaters, ID fan, FD fans
and Steam air decoking pot. Description of atmospheric heater is divided into following
subsections:
Process System
Fuel System
Air Preheating System
Steam-Air Decoking System
These sections are described below in detail:

4.6.1
PROCESS SYSTEM
Crude oil from Preheat TrainII is heated to desired vaporization temperature of 375 C in
crude furnace before entering the atmospheric column 05-CC-001 for fractionation.
Crude enters crude charge heater at the top of the convection zone. Bottom of the
convection zone the coils come out and enter the radiation zone from radiation zone,
crude flows to atmospheric column 05-CC-001.
The heater 05-FF-001 is a box type furnace having four parallel passes of 6 size,
numbered as pass 1 to pass 4.
Flow in each pass is regulated by individual pass flow controller FIC-1401 through FIC1404 (provided on each branch or pass). Ratio of crude flow in a particular pass to total
crude flow is maintained by a ratio controller. The crude flow in each pass is controlled
by a pass balancer in such a way that the weighted average temperature at the outlet of
71
each pass is maintained almost same. Crude flow through each pass is automatically
adjusted by individual pass flow controllers of each pass. Pass balancer receives software
input signals from FIC-1101 controlling crude flow, current values of all crude heater
pass flows and temperature as indicated by FIC-1401 through FIC-1404/TI-1407 through
TI-1410. Pass balancing is an advanced control feature, conceived for future
implementation. Pass balancer output is utilized by atmospheric column duty controllers
on circulating refluxes also. The distribution of crude through each pass should be
adjusted in such a way that the heat duties and hence out let temperature of all the passes
is more or less same. Depending on heat duty variation pass flow will vary. Inequalities
of flow through each pass to the extent of 10% can be tolerated, while operating on
manual mode or pass balancing is not working.
All the four passes of 05-FF-001 join together at the outlet of the radiation zone and then
enter the crude column 05-CC-001. Pressure gauges and temperature indications are
provided at all the external crossover of pass flows from convection to radiation section.
To avoid repetitive description, features of only pass 1 have been taken up. For other
passes identical arrangements exist.
FIC-1401 controls and indicates crude flow through pass 1. Through dual transmitter FT1401 from the same flow element, one flow low-low alarm FAL-1401B has been
provided to indicate vary low flow condition in pass 1. Actuation of this alarm will trip
the fuel supply to all burners of the heater excluding pilots. TI-1432/PI-1308 indicates
temperature/pressure of all pass flow control valves.
TI-1409 indicates coil outlet temperature (COT) of crude at pass 1 outlet High
temperature software alarm on the COT has been provided to alert the operator against
inadequate flow or harder firing in that particular pass. Prolonged high temperature may
lead to cooking up of that particular pass. Software signal of this TI-1409 is utilized by
pass balancer also. Finally heated crude enters a common manifold of 28 size, called
transfer line before entering atmospheric column.
TIC-1416/TI-1413 indicates combined, final coil outlet temperature of the crude. The
temperature indicator controller TIC-1416, which regulates the quantity of fuel to the
furnace, controls the final crude outlet temperature of the common transfer line. PI-1428
indicates pressure at radiation zone outlet in common transfer line. Pressure drop across
72
pass I measured as a difference of PI-1401 & PI-1428 readings is indicated in dc.

Pressure drop across the heater coil is a measure of internal tube condition and increase in
pressure drop indicates tube fouling due to coke formation in the tubes.
Turn down ratio for the heater is spelt out in section 1. Emergency coil steam connection
are give in each pass, down stream of pass flow control valves to displace the crude from
the coil to the column during any emergency or after normal shut down operation.
Soot blowers, using MP steam are provided in convection zone of the heater. Need of
soot blowing will be indicated by poor heat pick up in convection zone and slight
increase in flue gas temperature.
Emergency steam, decoking steam connections are taken from 10 MP steam header.
Snuffing steam (Box purging steam) connection in header boxes and radiation zone of the
heater are provided to extinguish fire and provides steam blanketing LP steam is used for
the above snuffing steam header.
Soot blower steam connections are taken from 4 MP steam header. To facilitate safe
approach to emergency steam even during an emergency scenario like fire in heater area,
common valve on emergency steam and box purge steam has been provided at a safe
distance of at least 15 meters from heater.
4.6.2
FUEL SYSTEM
05-FF-001 is a balanced draft furnace. Both the convection and radiation sections are
used for heating crude. The combustion chamber houses the radiant tubes. In this section
heat is primarily transferred by radiation from the flame and hot combustion products.
The convection section provided at the top of the radiation section serves to increase the
thermal efficiency of the furnace by removing further heat from the flue gas. The
radiation section has four identical cells & each cell has two flow passes. Tubes in
radiation section are arranged vertically along the walls. Convection selection has
horizontal tubes.
05-FF-001 is a dual fired furnace i.e. either fuel gas or fuel oil or both can be used as fuel.
The furnace has 19 burners. Each burner is mounted vertically upward at furnace floor.
Furnace fuel systems are discussed below.
73
4.6.2.A
FUEL GAS SYSTEM
Fuel gas (FG) from battery limit is supplied by a 8 header. The FG line is steam traced to
avoid condensation of heavier components in it inside the line itself and carry-over of
hydrocarbon liquid droplets to the burner. To arrest carry over of foreign particles like
rust etc a 100-mesh strainer is provided on the line.
FG to main burners passes through a shut down valve SDV-1403 whose open or close
position is indicated in control zoom by ZLH-1403 A/ZLL-1403B. Fuel gas flow to the
main FG burners is indicated in DCS by FI-1417. A local temperature & pressure alarm
PAL-1435B and a very low-pressure trip alarm PALL-1424A is provided at the inlet of
fuel gas to the main burners. If fuel gas pressure falls below PALL-1424A set value,
chances of flame failure in burner, accumulation of un-burnt FG in firebox and possibility
of explosion/back fire through heater opening is exists. Actuation of PALL-1424A will
shut the SDV-1403 on fuel gas supply to the main burners of the furnace, eliminating this
possibility. Minimum stop limit to PV-1423 and all valves on similar duty has also been
considered to avoid extinguishment of FG burners on closure of valve due to signal from
COT controller TIC-1416. Fuel gas pressure and hence flow to burners is controlled by
PIC-1423. It can be cascaded with crude oil coil outlet temperature (COT) controller
TIC-1416 through a selector switch SS-1415, COT can be used to select either for fuel oil
or fuel gas as the fuel-controlling COT. A 2 FG tapping upstream of shut down valve
SDV-1403 has been taken for pilot burners. On the pilot fuel gas line, FI-1416 is provided
to measure FG flow to pilot burners. Pressure in the pilot gas line is manually adjusted.
A low-pressure alarm PAL-1419B will alert the operator when pilot gas pressure falls.
PB-1401 has provided in the pilot line, for actuating SDV-1406 when the alarm has
come. PG-1418/PG-1425 indicates FG pressure in main and pilot gas lines in field at
heater battery limit.
4.6.2.B
FUEL OIL SYSTEM
74
Fuel oil (FO) is supplied to atmospheric furnace by a 4 line under pressure control PIC1415.
Flow indicator FI-1420 is provided on main fuel oil supply line and FI-1419B is provided
on the main fuel oil return line from heater. Since this is a closed circuit through which
FO circulation is maintained, the net consumption of fuel oil is measured as the
difference between the two by FDI-1420. Shut down valves SDV-1402/SDV-1401 is
provided on supply & return header of fuel oil. Open and close indications for these
valves are available in control room. A fuel oil pressure low low trip alarm PALL-1427B
and a pre trip alarm PAL-1426A are provide on FO (supply) line. Local PG near heater
battery limit is also provided to indicate pressure the FO in the field for local burner
adjustments.
Since FO is normally a congealable material, it needs to be always maintained in
circulating state. If it is left stagnant and unused in oil burners and piping, it can get
congealed despite the fact that tracing steam of the FO circuit is on. Circulation in heater
area FO piping (forming a closed circuit across all passes called fuel oil ring) is
maintained even when no FO burner is in use. A ratio of 1:1 fuel oil consumption to
return is normally maintained to obtain good control on firing and prevent congealing of
the IFO system. To prevent congealing inside piping, FO circulation past heater as well as
each burner should be maintained. FO is drawn by individual burners through a 3/4
header from main FO supply line and balance quantity is sent to FO return header. This
return header from cells joins a common return header before leaving heater area. When
there is no need of FO firing in the heater, the circulation can be maintained outside
heater, through a 2 header called ring by pass. Purge steam connection is provided on
each oil burner. Pressure gauges are provided on FO and atomizing steam line of each
burner. FO and atomizing steam lines are routed to each burner of the cell. FO burners
should be kept steam purged when idle. 2 flushing oil connection is provided on FO
(supply) line. CBD/OWS drain is provided on FO (Return) line. These provisions are
used to flash the line within battery limit after heater shut down. When fuel oil is fired, it
is atomized or sprayed as a fine mist for releasing complete combustion. The spraying of
FO is done by de-superheated MP steam in FO burners. Atomizing steam is supplied to
75
heater through a 4 header. Atomizing steam pressure is controlled by differential

pressure controller PDIC-1420, taking pressure signals from FO supply and MP steam
headers simultaneously. It maintains the atomizing steam pressure 1.5-2.0 Kg/cm 2 above
fuel oil pressure. Atomizing steam pressure and flow is measured by PI-1421A and FI1418. Local pressure gauge is also provided on the atomizing steam header. To arrest
carry over of foreign particles like rust etc, a 100-mesh strainer is provided on the line
4.6.3
AIR PRE HEATER(APH)
The heat carried away by the flue gas after the convection section is utilized for
preheating the air required for combustion. Atmospheric heater has independent air
preheating system to cater combustion air requirement of its burners. The combustion air
required for heater burners is supplied by two forced draft fans, 05-KA-001 A/B. Pilot
burners are self inspiriting type and do not consume combustion air from FD fan
discharge. The combustion air is preheated by flue gases in pre-heaters CAPH (05-FD001) & GAPH (05-FD-002). Air pre-heater is a shell and tube type heat exchanger. Cold
air from atmosphere is sucked by FD fans and forced through shell side. The hot flue gas
leaving the convection section of furnace is sucked by an ID fan 05-KA-002 from up
stream of stack damper and through tubes of APH. Flue gas exchanges heat with cold air
in tube side of APH. Cold flue gas from Air Pre-heater is discharged back to at D/S of
stack damper and let out to the atmosphere.
4.6.4
COMBUSTION AIR SYSTEM
Combustion air is sucked from atmosphere by the FD fans. Combustion air from FD fan
enters APH. Bypass is provided to divert cold air with the help of hand operated damper
HIC-1462 & HIC-1463 in case APH outlet temp is below 176 OC to avoid corrosion. A
pressure transmitter and thermocouple are provided on the combustion air to F-1.
4.6.5
ID/FD FAN STARTING & STOPPING PROCEDURE
76
The following procedures are to be followed for starting and stopping of ID & FD fans.
4.6.5.1
ID FAN STARTING PROCEDURE
Keep STD open by 100%

Bypass following interlocks
o BPS1418: - ID Fan Circulating Oil Flow Low.
o BPS1415: - ID Fan Speed Low
Start ID Fan from the field. As soon as the motor starts, the indication of motor on
panel changes from red to pink.
Reset HS1456: - ID fan coupling reset. Button is provided near DCS panel
Slowly increase ID Fan suction HIC opening by operating 5PC1451.Incremental
openings of 0.2 to be given. As soon as the motor gets coupled, the coupling
indication on panel turns from red to pink.
When ID suction temperature achieves >160 0 C fully or as per requirement close
STD.
4.6.5.2
ID FAN STOPPING PROCEDURE
Bypass following interlocks

o BPS1418: - ID Fan Circulating Oil Flow Low.
o BPS1415: - ID Fan Speed Low.
Open Furnace Stack Damper completely by increasing 5HC1453 opening
gradually to 100%.
Slowly decrease ID Fan suction HIC opening by operating 5PC1451.The opening
of 5PC1451 to be decreased gradually.
At around 10-15% opening the motor gets decoupled. As soon as motor gets
decoupled, the coupling indication on panel turns from pink to red.
Reduce HIC opening to 0%.
Stop ID fan from the field or by activating 5HS1457C ID Fan Stop Button
provided on DCS panel.
77
As soon as the motor starts, the indication of motor on panel changes from pink to
red.
4.6.5.3
FD FAN STARTING PROCEDURE
Case 1: - No FD Fans Are Running And One FD Fan To Be Started:

Consider the case of FD-1A.Same procedure to be applied for FD-1B.
Open STD by 100%.
Following interlocks to be kept in bypass mode while starting FD fan:
05FSLL1455 - FD1A fan flow low low interlock.
05FSLL1460 - FD1A fan circulating lube oil flow low low

interlock.
05FSLL1453 - Total Air flow low low interlock.
05BPS1412- FD fan1A low speed interlock
Reset SOV1454: - FD1A discharge damper. As soon as it is reset the indication on

motor panel has to change from red color to green color. If it does not changes
into green color I/M to be notified to attend it.
Then, Reset SOV1451: - FD 1A coupling reset SOV. Its indication on panel
remains red.
Start FD. Open slowly 5HIC1451 (by 0.2% MV in steps). At around 15-20% HIC
opening the fan gets coupled with motor. As soon as the motor gets coupled, the
motor indication on panel turns from red to pink. Increase load as per
requirement.
.
Case 2: - One FD Fan is Running And Other FD Fan TO Be Started
Consider the case FD 1A is running and FD 1B to be started
Open STD by 100%
05FSLL1454 - FD1B fan flow low low interlock.
78
05FSLL1463 - FD1B fan circulating lube oil flow low low

interlock.
05FSLL1453 - Total Airflow low low interlock.
05BPS1453- FD fan1B low speed interlock.
Then Reset SOV1452: - FD 1B coupling reset SOV .Its indication on panel

remains red.
Start FD. Open slowly 5HIC1451 (by 0.2% MV in steps). At around 15-20% HIC
opening the fan gets coupled with motor. As soon as the motor gets coupled, the
motor indication on panel turns from red to pink.
Reset SOV1455: - FD1B discharge damper. As soon as it is reset the indication on
panel has to change from red color to green color and airflow is obtained.
Adjust FD1 /FD2 load.
.
4.6.5.4
FD FAN STOPPING PROCEDURE
Consider the case of stopping FD-1A when both FD Fans are running.
05FSLL1455 - FD1A fan flow low low interlock.
05FSLL1460 - FD1A fan circulating lube oil flow low low

interlock.
05FSLL1453 - Total Air flow low low interlock.
05BPS1412- FD fan1A low speed interlock
Reduce 5HC1451 opening in steps of 0.2.Simultaneously increase 5HC1452 so as

to maintain same constant combustion airflow to the furnace.
At about 10-15% opening the fan gets decoupled with the motor. As soon as the
motor gets decoupled, close SOV1454 FD Fan 1A discharge damper.
As soon as the motor gets decoupled, the motor indication on the panel changes
from pink to red.
Then slowly reduce 5HC1451 opening to 0%.
Then stop FD1A by pressing HS1451C button provided on DCS panel.
79
4.6.5.5
FURNACE LIGHT UP PROCEDURE
1. Fully open Stack damper.

2. Check & close all FO / FG / Pilot gas burner valves.
3. Start box-purging steam at a rate such that slight steam is seen coming out from
the stack. Steaming is done to serve two purposes
i)
To purge out hydrocarbons from inside.
ii)
To create a ve draft inside furnace of about 5mm H2O to 3mm

H2O.
4. Keep low pass flow interlock FALL 1401 through FALL 1404 in line.
5. Stop box purging steam after creating a ve draft.
6. Start FD fan.
7. Check all igniters.
8. Reset pilot gas shut down valve SOV1406. Ensure all the individual pilot gas
burner valves at the furnace are closed before opening the SOV. By operating
B/V present in d/s of SOV1406 maintain pilot gas header pressure around 1.0-1.2
kg/cm2, pressure gauge is present in the field and flow indication is on the panel.
9. Pinch the primary and secondary air register of the pilot burner to be taken in line.
If needed pinch the air registers of adjacent burners. This is because if airflow is
very high then it is difficult for the burner to be light up.
10. Light up pilot gas burner with electrical igniter.
11. Once all the pilot gas burners are lighted up, gas burners are to be taken in line.
80
For this, below mentioned procedure is to be followed

a. Bypass PALL1424: - FG low pressure interlock.
b. Now Reset SOV1403: - FG Shut Down Valve. Ensure all the individual
gas burner valves at the furnace are closed before opening the SOV.
c. Take FG c/v 5PC1423 in manual mode. Slowly increase FG c/v opening
manually such that gas pressure at the burner is around 1.5kg/cm2.
d. Then slowly open the gas burner valve to the burner where pilot burner is
in line and light it up.
e. For taking FO burner in line
f. Bypass PALL1427: - FO low pressure interlock
g.
Reset SOV1402: - FO Shut Down Valve. Ensure all the individual oil
burner valves at the furnace are closed before opening the SOV
h. Now Reset SOV1401: - IFO Return shutdown Valve

i.
Open the FO return valve present near Burner Number 19.If this is not
opened then congealing will occur.
j. Maintain 5PC3111 around 8.5 kg/cm2

Take FO c/v 5PC1415 in manual mode. Slowly increase FO c/v opening
manually such that oil pressure at the burner is around 4 kg/cm2.
k. Do steam flushing of the burner by means of flushing steam line present in
each burner.
l. Once steam flushing is over slowly take FO burner in line and light it up.
4.6.5.6
FURNACE CUTOFF PROCEDURE
1. Open Furnace Stack Damper completely by increasing 5HC1453 opening

gradually to 100%.
2. Stop ID Fan as per ID Fan stopping procedure.
3. First bypass following interlock FO Low Pressure Interlock PALL1427.Take FO
c/v 5PC1415 in manual mode.
4. Cut off first oil burners one by one & flush with steam.
5. Keep IFO circulation on
81
6. Close gas burners one by one except one. For putting off the last burner isolate
gas at main isolation valve. By this FG header to furnace will be depressurized,
then close the burner block valve. Get 5PC1423 & SDV 1403 closed, bypassing
inter lock.
7. After all the gas burners are off, cut off pilot gas burners by closing the main
isolation valve. After putting off all pilot burners, isolate individual burner valves.
8.
4.6.5.7
Blind FG and Pilot gas lines.
FURNACE INTERLOCKS
Following interlocks are provided to trip the furnace:

1. Fuel Gas pressure at the inlet of furnace goes very low as sensed by PALL-1424A
when the furnace is operating on fuel gas. It will close SDV-1403 on fuel gas line
to main burners of FF-001 only.
FUEL GAS PRESSURE LOW LOW: PALL-1424---BPS 1407---FUEL GAS
SDV CLOSE
2. Fuel oil pressure at the inlet of furnace goes very low as sensed by PALL-1427
when the furnace is operating on fuel oil. It closes SDV-1402/SDV-1401 on fuel
oil supply & return lines.
FUEL OIL PRESSURE LOW LOW: PALL-1427---BPS-1407---FUEL OIL
SDV CLOSE
3. Crude oil flow through individual passes to the furnace goes low as sensed by any
of FALL-1401 to FALL-1404. It will close both fuels to heater excluding pilot FG
05-FC-1401-PASS FLOW LOW LOWFALL 1401
1.Furnace cut
off IFO SDV
82
1402 close
BPS-14052.IFO return
SDV1401
close
3. FG supply
SDV1403
Close.
4. Actuation of emergency push button shall stop fuel oil/gas to heater.
5. Very low total combustion air flow (FALL 1453)

Fuel Oil SDV 1402 close
FALL-1453---BPS 1409---- Fuel Gas SDV 1403 close
Fuel Oil return SDV 1401 close.
6. Very high arch pressure (PAHH 1452)
ARCH PRESSURE HIGH HIGHPAHH1452---BPS1410---STACK DAMPER
OPEN
If stack damper doesnt open with in 30 sec, furnace will cut-off.

7. 05-KA-01A (FD Fan) Circulating Oil flow low low (FALL 1460)
FALL-1460BPS 1416---FD 1A TRIP
8. 05-KA-01B (FD fan) Circulating Oil flow low low (FALL 1463)
FALL-1463BPS 1417---FD 1B TRIP
9. Very low speed of 05-KA-01A (FD Fan)
FD FAN 1A SPEED LOW---BPS 1412---FD FAN 1A TRIP
10. Very low suction air flow of 05-KA-01A (FD fan)
FD FAN 1A SUCTION AIR FLOW LOW---BPS 1412---FD FAN 1A TRIP
11. Very low speed of 05-KA-01B (FD fan)
FD FAN 1B SPEED LOW---BPS 1413---FD FAN 1B TRIP
12. Very low suction air flow of 05-KA-01B (FD fan)
FD FAN 1B SUCTION AIR FLOW LOW---BPS 1413---FD FAN 1B TRIP
13. 05-KA-02 (ID Fan) Circulating Oil flow low low (FALL 1457)
83
FALL-1457---BPS 1418---ID FAN WILL TRIP

14. Very low speed of 05-KA-02 (ID Fan)
ID FAN SPEED LOW---BPS 1415---ID FAN TRIP
15. CAST APH O/LET TEMP. HIGH
TSHH-1497----STACK DAMPER OPEN
4.6.6
DECOKING SYSTEM
Steam air decoking (SAD) of atmospheric heater tubes is done to remove coke deposit
from inside heater tubes with the help of steam and air. Removal of coke results in clean
heater tube internals & improves heater performance by better heat transfer to process
field. SAD also achieves low-pressure drop through heater tubes and reduces chances of
hot spot on heater tubes. Increased pressure drop and hard firing in furnace indicates
requirement of steam air decoking of the heater tubes. For this operation a dedicated
arrangement called SAD arrangement is provided. It comprises of decoking pot 05-VV017 and piping for Plant Air, Service Water and MP Steam connections to each pass flow
are provided to dislodge coke film deposit from inside the heater tubes. Local and control
room DCS mounted flow indications (FIC-1410, FIC-1412, FIC-1413, FIC-1414) are
provided on each steam connection. Plant air is injected to burn the remaining coke film
deposit clinging inside heater tubes and achieves final cleaning of the tubes. FIC-1409
indicates total flow of plant air into MP steam lines for SAD. Service water quench
provision is given on 05-VV-017 as well as flue gas line to quench the contents before
letting out to atmosphere.
To carry out SAD, pass flow inlet and outlet of the furnace 05-FF-001 are isolated from
process network and connected by means of swinging elbows with the decoking network.
Heater pass flow outlets are connected to the Decoking Drum 05-VV-017. MP steam is
introduced in heater passes and it is fired from outside. Thermal shock caused by flame
cracks coke scales inside tube and flowing steam dislodges them. These are carried to 05-
84
VV-017 after being quenched in flue gas line as well as decoking pot by service water
from where it is drained out. This operation is called spalling. When no more coke is
removed by spalling as indicated by relatively clear colour of effluent, Air along with
steam is introduced into pass flow to burn the coke of inside tube while firing from
outside. Coke is burnt by oxygen of air and thus tube cleaning is achieved. Burning of the
coke is indicated by increased tube metal temperature and presence of CO/CO 2 in flue
gas. Number of passes selected for spalling and coke burning is largely dependant on
limitations posed by steam availability and piping network. Sudden release of coke
during spalling may result in choking of the piping handling effluent or as hot spots on
tube during burning. SAD of only one pass at a time should be done if limitations in
steam and SAD piping are experienced. During SAD utmost care should be taken so that
heater tube temperature does not exceed the limit provided.
SAD of other heaters can also be planned along with CDU heater subject to limitations in
steam availability & case of monitoring.
4.7
MAIN FRACTIONATING COLUMN
Please Refer P&ID 3551-05-02-41-0115 Rev.2

The crude after final heating in furnace is fed to the Atmospheric Column for separation
of products by fractionation. Atmospheric column CC-001 contains 51 valve type trays
for side stream withdrawal. The column has a stripping section at the bottom. It has lower
diameters at top and bottom sections than middle to cater to higher vapor load in middle
section. Local pressure gauges and DCS mounted TI are provided to indicate
pressure/temperature profile inside the column.
Description of entire column has been taken up zone wise.
4.7.1
FLASH ZONE
Heated and partly vaporized crude feed coming from fired heater enters the flash zone of
the column above tray no.6 at 375 C. Hydrocarbon vapors flash in this zone and get
liberated. Non-flashed liquid moves down ward, which is largely bottom product, called
Long Residue. Certain degree of over flashing of crude is desirable for proper
stabilization of LR and fractionation of gas oil components. Over flash is achieved by
85
setting up COT at slightly higher than actually required. This over flashed material is
washed with gas oil coming down from below of 15 th tray. It strips out heavier vapor
components coming up which otherwise would move-up & cause coloration of gas oil
stream. Tray 7th to 14th forms the wash zone section of atmospheric column along with
LR. Flow of over flash liquid can be increased by both increasing COT and condensing
more material on 7th tray gas oil draw off. However, this will result in less gas oil yield
and higher energy consumption without any advantage. Too large flow of over flash
liquid may result in drop in bottom temperature and lighter bottom product, LR.
Over flash flow and temperature is indicated by FI-1504/TI-1527. Flash zone temperature
and pressure is indicated by TI-1502/PI-1525. Min. 1000 mm piping elevation is
provided between liquid entry nozzle on 6th tray and U loop bottom tangent line over
which FE-1504 is mounted. This elevation provides adequate liquid build up on up
stream of FE and ensures un-flickering, steady flow through orifice. Additionally it
provides some back pressure which is required to prevent flashing just down stream of
flow orifice due to pressure drop. One line of 3 is provided above 8 th tray to release
uncondensed components from over flashed liquid.
MP steam is introduced in the column below tray 1, at approximately 3.5 Kg/cm 2 g and
2300 C for stripping of LR. Steam stripping helps to remove lighter constituents from the
bottom product LR by reducing their partial pressure and vaporize without requiring
addition heat. Hydrocarbon vapors liberated by flashing move up along with steam in the
column for further mass transfer at trays in upper section. Steam flow to column is
controlled by FIC-1506. Steam flow to column is regulated based on outgoing LR
quantity to FPU/Storage. SS-1501 is provided for cut-off the LR Pump 05-PA-051A/B to
storage if LIC-1501 i.e. atmospheric column bottom low level. Desalters PSVs are
released to above 6th tray of fractionating column (CC-01).
4.7.2
OVERHEAD SECTION
Refer P & ID No. 3551-05-02-41-0116 Rev.2

The overhead vapors of Atmospheric Column C-01 at 1120 C/1150 C passes through the
overhead air condensers 05-EA-001 A-H (Fin fan cooler) and trim condenser 05-EE-
86
0016A/B/C/D/E/F. The condensed Naphtha & steam are accumulated in crude column
overhead reflux drum 05-VV-002.
Top pressure of atmospheric column is maintained by PIC-1504, manipulating PV-1504A
on outgoing uncondensed gases from 05-VV-002 to flare or PV-1504B on incoming FG
from fuel gas header. Condensed hydrocarbons are allowed to settle in reflux drum where
steam condensate settles in vessel boot and is pumped by P42A/B to desalter water drum
05-VV-004 or sour water stripper of SRU unit under inter phase controller LIC-1602.
Sour water flow is measured by FI-1801 & its pH is indicated by PHI-1601. On actuation
of boot level alarm low (indicated b LAL-1603) SOV-1601 shall be closed by operation
and the flow has cut off. A part of accumulated hydrocarbons in 05-VV-002 is be pumped
back to atmospheric column as top reflux by Column reflux pumps 05-PA-005A/B/C
under flow control FIC-1505 to control top temperature. This flow controller can be
cascaded with atmospheric column top temperature controller TIC-1501 for precise
control of column top temperature.
Ahuralan is dozed at the top of column to arrest corrosion and ammonia solution is dozed
O/H vapor outlet line to maintain sour water PH level @ 6 to 6.5.
Excess quantity of Naphtha in reflux drum is pumped by stabilizer feed pumps 05-PA06A/B/C to stabilizer as feed. Reflux drum level controller LIC-1606 can be cascaded
with discharge of stabilizer feed pump flow controller, FIC-1701.
Minimum flow protection controllers FI-1610B/FI-1611B are provided for discharge of
reflux pumps & stabilizer feed pumps respectively. In the event of low flow in reflux or
stabilizer feed lines due to throttling of control valves, minimum continuous flow to each
pump, this arrangement prevents heating of pump due to closed discharge operation &
resultant damage to pump.
4.7.3
MIDDLE SECTION:
Middle section of the column has circulating refluxes and product withdrawal network. In
order to maximize heat recovery and balance the column loading for maintaining proper
temperature profile across the column, three circulating refluxes (CR) systems are
provided viz. Heavy Naphtha CR, Kero/ATF CR, and Gas Oil CR. These circulating
87
refluxes are drawn from their respective product draw off trays and are routed to preheat
recovery trains for heat recovery before entering back to the column again.
Duty controllers are provided on CR circuits to control CR flow rates to column. These
duty controllers take corrective action based on actual CR duty & desire CR duty. For a
particular type of crude and crude through put, the CR under reference will have certain
duty. This will be governed by total crude flow and specific heat of CR and is called
desired CR duty. Actual CR duty is also computed by duty controller based on real time
measurement of temperature difference between CR draw off and CR return stream, CR
flow rate and specific heat of CR. Total crude flow, CR temperature difference and CR
flow are measured by various instruments. Specific heat of CR is fixed by operator in
software for computation purpose and no on line measurement for this property is
available. Actual and desired CR duty is calculated in the duty controller as under:
Actual CR duty = Measured CR flow X CR temp. Difference X sp. Heat of CR
stream
Desired CR duty = (Desired CR duty/Desired total crude Flow) X Actual Crude
flow
Inputs to be manually configured by operator are specific heat of CR stream and ratio
(Desired CR duty/ Desired total crude flow) for each crude. Desired CR duty should be
estimated on pro-data feed rate basis to CDU. This is typical to all such duty controllers
on circulating reflux lines. Desired CR duty is compared with actual CR & the flow of
CR is varied to achieve desired CR duty.
4.7.4
BOTTOM SECTION (RCO CIRCUIT)
Please Refer P&IDs 3551-05-02-41-0115 Rev.2

3551-05-02-41-0111 Rev.2
3551-05-02-41-0113 Rev.2
3551-05-02-41-0118 Rev.2
Long Residue product is collected at bottom of the column. Column bottom level is
indicated and controlled by LIC-1501. Column bottom level control can be done either by
manipulating LR flow to FPU/Storage during normal operation or by manipulating LR
88
flow. LR at a temperature of 365 C is pumped out from the bottom of the column by LR
pumps 05-PA-051A/B/C to LR Storage (or) FPU through (i) 05-EE-010A/B/C/D, 05-EE007A/B/C, 05-EE-004, 05-EE-021 and 05-EE-022A/B/C/D. (ii) 05-EE-107A/B, 05-EE105A/B/C/D/E, EE-103A/B, EE-111A/B. Independent level control LIC-1501 with high
& low level software alarm is provided to have redundancy of indication. SS-1501
selector switch is also provided for cutting the LR flow to LR Storage/FPU when the
atmospheric column level is low. A low level switch along with alarm LSLL-LALL-1504
is also given. Bottom temperature and LR pump suction temperature are indicated by TI1522. MOV-1501 also provided at column bottom LR line. ZLH-1501A & ZLL-1501B
limit switch connected through the MOV-1501 for open (or) close indication to DCS.
Pushbutton PB-1501A & PB-1501B are provided to close the MOV-1501 and to trip the
LR pump 05-PA-051A/B.
4.7.5
CIRCULATING REFLUXES/PUMP AROUND CIRCUITS
Three circulating refluxes are described below.

(1) Top CR (2) Kero CR (3) G.O. CR.
(1) Top CR Drawn from tray 43 to pumps PA-07A/B @ temp ~ 150 C PA-7A/B
discharge to exchangers 05-EE-02 tube side EE-02 tube outlet stream returns back to
column CC-01. Top CR flow is controlled by 05-FC-1501
Kero C.R.- Drawn from tray 25 to pumps PA-10A/B/C (KeroII CR) and PA-102A/B
Kero-I CR) @ temp 200 C to 220 C.
Kero-I CR Pump P102A/B discharge flows through exchanger EE-104 tube side. CR
flow is controlled by 05-FC-5008 located at D/S of EE-104 outlet to CC-01 line.
Kero-II C/R Pumps 05-PA-10A/B/C discharge flows through EE-06A/B shell side, EE05 shell side and ultimately to column CC-01. Flow is controlled by FC-1502 situated
between EE-05 shell out let to CC-01 line.
Kero CR temperature is controlled by temperature controller TC1116 placed across EE06A/B. Kero-I CR and Kero-II CR are joining together and enter back to CC-01 on tray
No. 28.
G.O. CR - Drawn from tray-16 to pump PA-12A/B/C (LGO Cr Pumps) and pumps
104A/B (HGO CR pumps) at temperature ~ 300 C to 315 C.
89
LGO Pump PA-12A/B/C discharge flows through EE-09A/B shell side, EE-14 (CC-05
re-boiler), EE-15 (CC-02 re-boiler) and then enter back to column via flow controller FC1503 on tray-18.
HGO CR pump PA-104A/B discharge flows through exchange EE-108A/B shell side and
then joins with LGO CR line at d/s of FC-1503 via flow controller FC-5010.
C5 bottom temperature is controlled by FC1704 casketed with TC 1707 situated across
E14. Whereas Heavy Naphtha stripper C2 bottom temperature is controlled by FC 1507
casketed with TC 1538 situated across E15.
4.7.6
PRODUCT DRAW OFF TRAYS:
Heavy Naphtha, Kero/ATF, Gas oil products (are withdrawn) flow by gravity from 34 th,
26th and 15th trays of atmospheric column to respective strippers 05-CC-002/05-CC-003
and 05-CC-004 (under respective level control of strippers). Draw off temperature of HN,
Kerosene/ATF, Gas oil is indicated by temperature indicators TI-1526/1509/1510
respectively in DCS. Vapor return lines from HN, Kerosene/ATF, GO strippers goes back
to fractionators column are provided joining at 36th, 28th and 17th tray of the atmospheric
column. TI-1503/TI-1504/TI-1505 provided on vapor return lines from HN,
Kerosene/ATF, GO strippers indicate Vapor return temperature. 3000 mm elevation
difference from 05-CC-001 column nozzle to upstream of each level control valve for its
smooth functioning 1500 mm elevation down stream of the level control valve ensures
sufficient back pressure to prevent flashing just down stream of control valve &
consequent two phase flow in product draw off piping.
4.8
PRODUCT STRIPPERS
Refer P & ID No. 3551-05-02-41-0115 Rev. 2

There are three side strippers for stripping out side draw off products from atmosphere
column, viz. Heavy Naphtha, Kero /ATF and GO.
They are described as under:
4.8.1
HEAVY NAPHTHA STRIPPER
Ten valve type trays are provided in HN stripper 05-CC-002. Local PG and LP steam
connections are also provided on this stripper. LP steam is used to purge the column
90
during M&I S/D. HN to be stripped is admitted on 10th tray of 05-CC-002 under its level
control LIC-1506. Minimum 1500 mm elevation difference is provided between stripper
entry nozzle and LV-1506 piping to provide back pressure and prevent flashing in piping.
HN in 05-CC-002 bottom is re-boiled in re-boiler 05-EE-015 by HGO C/R. HN is
stripped off by its hot vapors generated in re-boiler 05-EE-015. Mass transfer between
down coming HN liquid from tray 10 to bottom and uprising HN vapors takes place on
each tray. Finally stripped HN is drawn by 05-PA-008A/B and sent to product cooling
section. Outgoing HN temp. Is indicated by TI-1512. Stripped light vapor goes back to
36th tray of atmospheric column.
Gas oil CR supplies heat to Heavy Naphtha Stripper Re-boiler 05-EE-015 through F/C
1502. F/C-1502 is cascaded with TIC-1538. Pumps 05-PA-8A/B get suction from CC-02
bottom. PA-08A/B discharge line is divided into two branches.
In one branch it can be routed along with LGO through EE102 A/B via FC 5001. The
other part is cooled in cooler E20. After that, it flows through coalescer to remove carried
over water, and it can be routed to SKO R/D, LN R/D or BS2, Euro-III header of HSD.
PA-8A/B EE-13D/E/FE-20 (Cooler) . Coalescer for injection to SKO / G.O /

LN.
PA-8A/B 05-FC-5001 EE102 (LGO)
C1LC1506 C2 P8A/B E20 (cooler) Coalescer PC2011 LN
FC2011
SKO
FC1807
GO
(EURO3)
FC5001 E102A/B (LGO)
GO
(BS2)
4.8.2
KERO/ATF STRIPPER
Six valve type trays are provided in Kero/ATF stripper 05-CC-003. Local PG and LP
steam out connections are also provided on this stripper. Kero/ATF to be stripped is
91
admitted on 6th tray of 05-CC-003 under its level control LIC-1508. Minimum 1500 mm
elevation difference is provided between stripper entry nozzle and LV-1508 piping to
provide back pressure and prevent flashing in piping. MP steam is used as stripping
medium in this stripper. Steam flow is regulated by FIC-1508 on steam line. It regulates
MP steam flow to 05-CC-003 based on per unit mass of Kero/ATF product outflow, as
indicated by FY-2203. Steam to product ratio is decided by operator and configured in
software for routine control. MP steam reduces partial pressure of hydrocarbon
components inside stripper and helps them vaporize at relatively low temp. Mass transfer
between down coming Kero/ATF liquid from tray 6 to bottom and uprising vapors takes
place on each tray. Finally lighter end stripped Kero/ATF is drawn by 05-PA-009A/B and
sent to preheat train I for exchanging its heat to crude in 05-EE-001. It is further cooled in
cooler E-23 / 24 before routing to caustic wash system. Provision is made for Pump PA01A/B getting suction from same suction header of PA-09A/B, which discharges to
cooler EE-109. Flow of this stream is controlled by 05-FIC-5007 located on EE-109
outlet line. Out let of both the circuits joins together & flows to caustic wash system.
Stripped light vapors goes to 28th tray of atmospheric column & its temperature is
indicated by TI-1504.
Combined kerosene flows to caustic wash vessel V13 through mixing valve
HIC2001.Continuous 10% caustic solution is circulated to neutralize H2S and light
mercaptans present in it. Outlet of V13 goes to water wash vessel V14 through HIC 2002.
Continuous water circulation is maintained in this vessel to wash out carried out caustic
along with it. After caustic wash the stream is passed through coalescer V15 to remove
carried over water particle along with it. It is then passed through a vessel containing rock
salt to absorb moisture from it.
Design data: salt to load: 61 Mt.
Inlet moisture: 1300-1500 ppm.
Outlet moisture: <200 ppm
SKO/ATF R/D flow is maintained FC2206 located U/S of salt dryer. It can be routed to
SKO/ATF/LABFS R/D as per requirement. Provision is also there to route SKO to HSD
or LR for which tapping is taken at upstream of salt dryer, its flow is controlled by FC
1807.
92
C1LC1508 C3 P9A/B E01 E24/E23C (cooler) HC2201

V13 HC2202 V14 V15 (coalescer) FC2206 Salt dryerSKO /
LABFS / ATF
FC1809 HSD/LR
4.8.3
GO STRIPPER
Six valve type trays are provided in GO stripper 05-CC-004. GO to be stripped is

admitted on 6th tray of 05-CC-004 under its level control LIC-1510 Minimum 1500 mm
elevation difference is provided between stripper entry nozzle and LV-1510 piping to
provide to back pressure and prevent flashing in piping. It regulates MP flow to 05-CC-004
based on per unit mass of GO
. product outflow, as indicated by FY-1804. Steam to product ratio is decided by operator

and configured in software for routine control MP steam reduces partial pressure of
hydrocarbon components inside stripper and helps them vaporize at relatively low
temperature. These vapors move up in the stripper column Mass transfer between down
coming GO liquid from tray 6 to bottom and uprising MP steam hydrocarbon vapors
takes place on each tray.
Finally stripped GO is drawn by PA-011A/B and sent to Crude Preheat Train II for
exchanging heat with crude in 05-EE-008A/B (Gas Oil/Crude Exchanger II) and then it
is sent to Crude Preheat Train I for exchanging heat with crude in 05-EE-003 (Gas
Oil/crude). It is further cooler in cooler E23A/B/C and its flow is controlled by FC1804.
LGO product pumps 05-PA-103A/B get suction from same suction header of pumps 05PA-1A/B. LGO flow passes through exchanger 05-EE-106A/B in a parallel way. EE106A/B outlet flow is controlled by 05-FC-5009. Then LGO flows through exchanges
05-EE-102A/B. It is than further cooled in coolers 05-EE-110A/B before is mixed with
HGO stream at D/S of 05-PC-1804. TI-1516 measures the outgoing GO stripped vapor
temperature, which enters to 17th tray of atmospheric column.
C1LC1510 C4 P11A/B E8A/B EE03 E23A/B/C (cooler)
FC1804 **
93
P103A/B E106A/B FC5009 E102A/B E110A/B
FC 5003 R/D
** V-301
PC 5003 R/D
Mixed HGO & LGO from E110A/B and FC 1804 together enters the gas oil coalescer V301 to remove water carried over with it. Water accumulated in coalescer is controlled by
LC-5LV-0301 which is drained out to OWS / CBD. Gas oil from Coalescer outlet is
controlled by 1010FV5003 and 1010PV5003. Fixed quantity can be routed to desired
R/D tank and rest amount can be routed to other tank under PC control. HSD R/D can be
routed to as follows
Euro-III header
BS-2 header
GHC gas oil R/D header.
DHDS feed tank (At FCCU area)
Design data for HSD Coalescer: inlet water @ 600 ppm

: Outlet water <20 ppm.
4.9
NAPHTHA STABILISER
Refer P&ID No. 3551-05-02-41-0117 Rev.2

Naphtha obtained in atmospheric column overhead Naphtha reflux drum 05-VV-002
contains some light ends like C3 and C4, which vaporize at normal atmospheric
conditions. This naphtha if stored as such in storage tanks will release lot of hydrocarbon
vapors and can create unsafe conditions and pressurization of the storage. To avoid these
problems, the lighter components from naphtha are removed. This process is called
Naphtha stabilization.
94
Naphtha stabilization is carried out in naphtha stabilizer 05-CC-005 where C1/C2/C3 and
C4 hydrocarbons are removed from naphtha. Stabilizer column has 43 nos. of SS-410
valve type trays. The column is provided with a set of safety valves PSV-1701/1702 set at
15-kg/cm2 g. Their discharge is routed to flare header. MP steam connection is provided
on 05-CC-005 for steam purging of the column during shut down. DCS mounted
temperature indication of top outlet; tray 38, tray 5 and bottom outlet are provided. Local
PG at tray 43, and below tray I is also provided to monitor pressure profile in the column.
Un-stabilized naphtha feed to the stabilizer is first heated up to 119 0 C in feed/ Stabilizer
Bottom Exchanger 05-EE-018A/B & 05-EE-018C/D parallel by exchanging heat with
outgoing stabilized naphtha product stream from stabilizer bottom. Feed from 05-VV-002
enters the column on the 20th tray under flow control FIC-1701 that is normally cascaded
with 05-VV-002 level controllers LIC-1606. Local PG, TG and TI-1701/TIC-1702 are
also provided on feed line to monitor feed temperature pickup.
Wild naphtha from DHDS, LAB plant & MSQ plant and drag stream from CRU are fed
to stabilizer along with its feed. DHDS Wild naphtha & CRU drag stream fed through 2
line each and joins at B/L. Wild naphtha from MSQ & LAB lines were commissioned
and wild naphtha enters the B/L through 2 line each joins at D/S of feed C/V FC1701.
The stabilizer overhead pressure is maintained by pressure controller PIC-1701. This
PIC-1701 acts on the control valve PV-1701 on outgoing line from stabilizer reflux drum
to fuel gas system. In case of increase of stabilizer pressure above set valve PV-1701
shall open and allow more fuel gas vapor to FG system. This will cause drop in stabilizer
pressure. Closure of this valve will increase stabilizer pressure due to less vapor flow
through condenser and resultant less condensation. One hot vapor bypass of 4 size has
also been provided across 05-EE-017A/B/C/D. It can be used to maintain stabilizer
pressure in case of rapid fall of stabilizer pressure. HV-1701 can be made to act for this.
TI-1729 indicates 05-CC-05 overhead vapor temperatures. Overhead vapors from
stabilizer go to the stabilizer overhead condenser 05-EE-017A/B/C/D. The condensed
liquid at 40 C is collected in the stabilizer reflux Drum 05-VV-003. This is LPG stream,
consisting of C3 and C4 hydrocarbons. It is pumped out by naphtha stabilizer reflux/LPG
product pumps 05-PA-014A/B under 05-VV-003 level control of LIC-1704. Part of it is
used as reflux to 05-CC-005 to control top temperature. Its flow is controlled by FIC-
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1703, which can be cascaded with 05-CC-005 top temperatures Controller TIC-1703.
Uncondensed light hydrocarbons from 05-VV-003 top (C1/C2 component) termed as fuel
gas are routed to fuel gas system. FIC-1702 measures net FG flow from 05-VV-003. PIC1701 controls the pressure of 05-VV-003, acting on outgoing FG line. FI-1710 indicates
LPG minimum flow to 05-PA-014A/B. LPG is run down to LPG wash section under flow
control FIC-2503.
Sour water collected in the boot of 05-VV-003 is sent to CBD under vessel pressure.
High water level in boot may result in water carry over with LPG and can make the
stabilizer upset. The level in stabilizer reflux drum boot is indicated by LG-1705. Water
draining from boot is done manually. Independent low-level alarm switches are provided
in the boot. On actuation of level alarm low is boot, as indicated by LAL-1709, SDV1701 provided on sour water outlet line shall close. This feature shall prevent escaping of
LPG with sour water during water draining. PSVs 1703/1704, set at 15.0 Kg/cm 2 g are
provided on the stabilize reflux rum 05-VV-003, whose discharge is routed to flare
header. It prevents vessel from getting over pressurized in case of external fire. 2 line
connecting flare header with upstream of PSVs has been provided to depressurize the
column to flare. 2 service water connection is provided on 05-VV-003 LPG outlet line to
fill the vessel and wash the atmospheric column with water during shutdown.
One stabilizer re-boiler 05-EE-014 is provided at stabilizer bottom to supply necessary
heat duty for boiling the un-stabilized naphtha. Heating medium for this re-boiler is Gas
Oil CR from 05-EE-009A/B. FIC-1704 provided at GO CR supply line to 05-EE-014
controls GO CR flow to re-boiler. Tray 5 temperature controller TIC-1704 can be used to
control re-boiler duty with the help of FV-1704. It is to be noted that only one
temperature control i.e. either top vapor outlet temp. or tray 5 temp. Should be used for
stabilizer operation. While operating with relatively heavier un-stabilized naphtha stocks,
tray 5 temperature is normally more sensitive and results in more energy efficient
operation. One Baffle of adequate height inside column is provided. Height of baffle is so
selected that it ensures availability of adequate liquid head, which will be necessary to
cause gravity flow of colder liquid through re-boiler. Difference in densities of lighter and
colder liquid establishes circulation through re-boiler. TI-1706/TI1726 measures the
temp. Of GO CR supply and return respectively. Un-stabilized naphtha from column
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bottom flows to re-boiler under gravity and is re-boiled in 05-EE-014. Heated and partly
vaporized naphtha from re-boilers enters below chimney tray. Lighter components from
un-stabilized Naphtha move up in the tray in vapor form and condense in overhead
condensers. Composition of re-boiler outlet liquid and liquid collected in column bottom
on either side of baffle is considered same. Stabilized naphtha overflows to other side of
baffle inside the column bottom. This is cooled in tube side of 05-EE-018A/B & EE18C/D then routed to product cooling section. 05-FI-5033 shows the light naphtha flow
from stabilizer bottom to feed/bottom exchanger 05-EE-018A/B & 05-EE-018C/D. The
temp. control valve TV-1702 has been provided at the bottom line and it has cascaded
with TIC-1702 provided at feed line to stabilizer. TI-1716 measures the outlet temp. of
light naphtha.
Stabilizer column bottom level is maintained by LIC-1702, acting as master controller to
FIC-2004 (Light Naphtha to storage). Independent high and low level alarm switches are
provided on column bottom. On actuation of level alarm low low in column bottom, as
indicated by LAL-1707, SDV-1801 provided on bottom outlet line shall close. This
feature shall prevent vapor break through i.e. escaping of vapors from stabilizer to caustic
wash section.
To cater the requirement of higher benzene & MS production, provision is made to
process AU5 Light Naphtha without caustic wash to AU1 naphtha splitter section via
5FC5106. Accordingly modification is made & tapping is taken at D/S of Light Naphtha
SDV.
Two separate LN R/D line from battery limit is provided to cater requirement to route
light naphtha to different rundown tanks.
4.10
LPG-AMINE ABSORPTION SECTION
Please refer P&IDs 3551-05-02-41-0126 Rev.2

LPG mixture from Naphtha Stabilizer reflux drum 05-VV-003 is sent to LPG surge drum
05-VV-020 by 05-PA-014A/B under flow control FIC-2503. Sour LPG from outside
battery limit (from AU4 (or) AU-3) also joins at down stream of FV-2503. The surge
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drum pressure is maintained at 10.0 Kg/cm2 by PV-2501, releasing to fuel gas system i.e.
upstream of FG K.O. Drum. The level of the surge drum should always be maintained at
50%. Combined streams passes through a shut down valve SDV-2501 whose open or
close position is indicated in control room by XL-2501B/XL-2501A. Separate high level
switch LSHH-2501/LALL-2501 is provided to trip the combined stream flow to surge
drum by closing SDV-2501.
A low level switch LSLL-2502 along with LALL-2502 is also provided. LIC-2504 along
with LAH/LAL has been provided for level control purpose. Interlock has been provided
along with LSLL-2502 to trip the pump 05-PA-050A/B.
The LPG from the surge drum is pumped by the LPG booster pumps (05-PA-050A/B) to
the bottom of LPG Amine absorber column (05-CC-006) under flow control of FIC-2501.
FIC-2501 is cascaded with LIC-2504 level of surge drum. FIC-2501 indicates total LPG
flow from surge drum. FIC-2502 indicates minimum flow protection to 05-PA-050A/B.
PSVs 2501B set at 15 Kg/cm2 are provided on the top of surge drum 05-VV-020, whose
discharge is routed to flair header. It prevents vessel from getting over pressurized in case
of external fire. 2 line connecting flare header with upstream of PSVs has been
provided to depressurize the drum to flare.
In this LPG absorber column LPG is brought into contact of lean amine solution counter
currently under flow control FIC-2601. The lean amine is available at 35 C from the
Amine regeneration unit in the existing GHP Sulphur block, which is taken to the column
on flow control. LPG Amine absorber column has 10 nos. of trays. The column is
provided with a set of safety valves PSV-2601A & 2601B. Their discharge is routed to
flare header.
Separate high pressure switch PSHH-2601 along with PAHH-2607 is provided in column
top for controlling the column pressure by the way of lean amine flow cut off. A low level
switch LSLL-2605, SDV-2602 (whose open/close position ZLH-2602B/ZLL-2602A at
DCS) provided on bottom rich amine line shell close on very low C06 level.. This feature
shall prevent escaping of LPG with rich amine during low level. FI-2602 measures rich
amine quantity from absorber column to ARU.
The H2S in LPG is transferred to the amine and rich amine is sent back to ARU unit for
regeneration through column bottom level control LIC-2602.
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Amine washed LPG is sent to amine settler 05-VV-004. In this settler Amine is separated
in the boot and washed LPG the top is sent to caustic wash. Amine collected in the boot
05-VV-004 is drained to Amine blow down (or) OWS. The level in Amine settler boot is
indicated by LI-2603 has provided with LAH/LAL software alarms. Amine draining from
boot is done manually. On actuation of level alarm low in boot, as indicated by LALL2602, SDV-2601 provided on amine outlet line shall close. This feature shall prevent
escaping of LPG with amine during amine draining.
4.11
PRODUCT COOLING AND RUN-DOWN SYSTEM
Refer P&ID No:I) 3551-05-02-41-0118 Rev.2

II) 3551-05-02-41-0120 Rev.2
Light Naphtha product from 05-EE-018A/B/C/D) is cooled from 79 C to 40 C in cooler
E19A/B. Cooler O/L temperature can be seen by. TI-1801 shows in DCS. Light Naphtha
from the cooler is fed to Light Naphtha caustic wash drum VV9. SDV-1801 is provided
at the outlet line of product cooler. This product line is provided with additional tapings
to slops header.
Heavy Naphtha from the bottom of its stripper is drawn by 05-PA-008A/B and pumped at
184 C. The product is cooled in heavy naphtha cooler 05-EE-020 up to a temp.of 40 C.
From the heavy Naphtha cooler (05-EE-020) it is sent to Heavy Naphtha Coalescer.
Heavy Naphtha Coalescer 05-VV-025 is provided for reducing saturated water content in
Heavy Naphtha from 0.8 wt% to 100 ppm. Coalescer element is provided inside the
vessel to meet the above-mentioned parameter. Retention time is 4 hours for enabling
water droplets to settle in coalescer
LI-2010B shows the coalescer level in DCS. FI-2010 measures net Heavy Naphtha
quantity from coalescer. From the coalescer, the product is sent to Light Naphtha Storage
under pressure control PIC-2100. In the common product line, 3 tapping are provided for
different destinations.
The HN product can be sent to Gas Oil storage under flow control of FIC-1807
The HN product can be sent to Kero R/D line under flow control of FIC-2011
1 line tapping has provided from common HN product line for corrosion inhibitor
drum
99
Water collected in the boot of 05-VV-025, is sent to OWS under level control. Water
draining from boot is done manually. On actuation of level alarm low in boot, as
indicated by LALL-2100, SDV-2003 provided on outlet water line shall close. This
feature shall prevent escaping of product during water draining. Two PSVs 2005/2006 set
at 15 Kg/cm2 are provided on the coalescer 05-VV-025 whose discharge is routed to flare
header. It prevents vessel from getting over pressurized in case of external fire. A 2 line
connecting flare header with upstream of PSVs has been provided to depressurize the
vessel to flare.
Kero-II product flows from 05-PA-09A/B to EE-01 exchanger. Then it flows through
cooler EE-024. After cooler kero-II product flows through caustic wash vessel VV-13,
water wash vessel VV-14 and coalescer VV-15. Coalescer o/l is routed to R/D via salt
dryer (SKO / ATF / LABFS) & FC 2206. Kero is injected to G.O. via FC-1809.
Gas Oil from old & new circuit at 107.6 C/113 C is further cooled in 05-EE-023A/B/C &
E110A/B (Gas Oil Coolers) up to a temp. of 40 C and sent to RD through FV-1804 under
flow control of FIC-1804, TI-1804 measures the GO outlet temp. This product line is
provided with additional tapings to slops header and DHDS unit and flushing oil, product
G.O can be routed to three locations.
G.O. to FCC units. (2) G.O. to GHC HSD R/D (3) G.O. to BS2 and (4) GO to EuroIII
Kero can be injected to G.O. (either to O.M&S. or to FCC) through FC 1809.
Kero can be injected to RCO R/D as carter stock
HN to G.O. injection ( Both Euro-II & BS2 separately)
G.O. can be routed to slops-header.
G.O. can be taken to FLO line for flushing purpose.
Long residue from 05-PA-051A/B/C at 363.9 C/364.2 C sent to crude preheat trains II &
I for exchanging heat with incoming crude through 05-EE-010A/B/C/D (LR/Crude
Exchanger III), 05-EE-007A/B/C (LR/Crude Exchanger II), 05-EE-004 (LR/Crude
Exchanger I), and EE-107A/B/C/D/E, EE-105A/B, EE103A/B/C. The outgoing LR
temperature is around 143 C/ 134 C. After this the LR is cooled at LR cooler 05-EE-021
& EE-110A/B up to 120 C outlet of this cooler one portion has sent to FPU storage under
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flow control FIC-1805 through FV-1805. Remaining LR product sent to further cooling at
LR cooler 05-EE-022A/B/C/D up to the temperature of 80 C. After that the product has
sent to LR storage under flow control FIC-1806 through FV-1806. Product tapings for
slop header and LR circulation to unit crude pump suction for unit start up is also
provided.
Provision is made to route Hot LR to VDU as hot feed via 5FC1805 in June 2006 and a
2 line tapping is provided to route FPU-2 Heavy gas oil to cold LR rundown at battery
limit as carter stock.
4.12 CAUSTIC/WATER WASH FACILITIES
Refer P&ID No.: I) 3551-05-02-41-0120 Rev 2
II) 3551-05-02-41-0119 Rev 2
III) 3551-05-02-41-0122 Rev 2
Caustic wash is generally used to remove Sulphur components like hydrogen sulphide
and/ or methyl & ethyl mercaptan. Equal volumes of hydrocarbon liquid & caustic
solution are mixed / re-circulated. During this operation, caustic hydrocarbon emulsion is
formed which is allowed to settle in a vessel. Typical retention time is 90 minutes to 45
minutes. Naphtha, Kerosene and ATF are washed with 10% caustic solution to remove
CS2, H2S, phenols and mercaptan which may be present or can be generated during
processing. Caustic solutions are hazardous wastes. Traces of caustic are removed by
water washing of these streams. The caustic water wash systems are described below:
4.12.1.A LPG CAUSTIC WASH SYSTEM
LPG from Amine Wash Unit is routed for caustic water wash. LPG is admitted in LPG
Caustic wash vessel 05-VV-006 through a static mixer 05-JV-002. LPG caustic wash
circulation pump 05-PA-017A/B, takes suction from bottom of 05-VV-006 and
discharging into 05-VV-006 through mixer. 10-vol% caustic solutions is circulated by
these pumps where it is mixed with LPG. Mixing in the static mixer results in conversion
and transfer of H2S, mercaptan & other chemicals to sodium sulphides. Depending on
efficiency of mixing in the mixer, reduction of above chemicals shall take place. Mixing
of the two streams can be improved by throttling the mixer rotation. Hydrocarbon phase
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separates out from caustic in 05-VV-006 due to adequate availability of residence time.
LPG overflows from top of 05-VV-006 to water wash vessel 05-VV-007 through another
static mixer 05-JV-003. Caustic solution settled in 05-VV-006 bottom is re-circulated
again. On repeated circulations, strength of caustic goes down to less than 7.5% of its
initial strength due to picking up of compounds mentioned above. This is called spent
caustic and is drained out through 2 line to spent Caustic water Wash drum 05-VV-006.
Spent caustic draining from the bottom of the vessel 05-VV-006 is done manually.
Independent low-level alarm switches are provided in the vessel. On actuation of level
alarm low in the vessel is indicated by LALL-1903, SDV-1901 provided on spent caustic
outlet line shall close. This feature shall prevent escaping of LPG with spent caustic
during spent caustic draining.
During Caustic make up, normally caustic circulation should no be stopped and strength
of spent caustic solution should be increased by gradual draining and equivalent make up
by 05-PA-025A/B. Quantity of caustic make up in indicated by FI-1901B.
PSV-1901 & 1902 are provided on 05-VV-006 top, whose discharge is routed to flare
header. It prevents vessel from getting over pressurized in case of external fire. LI-1901B
with LAL has been provided for measuring the level of the vessel. 05-VV-006 always
operates with full of liquid, without any vapor space.
Spent Caustic degasser 05-VV-016 is a vertical vessel connected with flare. It receives
caustic from LPG caustic wash, Light Naphtha, Kero/ATF wash system. Vapors
disengaged from caustic solution escape to flare and spent caustic is pumped out to ETP
by spent caustic pumps 05-PA-043A/B. LI-1911 with LAL/LAH has been provided for
measuring level in the vessel. Independent low level alarm switches are provided in the
vessel. On actuation of level alarm low in the vessel is indicated by LALL-1914, SDV1904 provided on spent caustic degasser outlet line shall close. This feature shall prevent
escaping of hydrocarbon vapors with spent caustic during pumping.
4.12.1.B
LPG WATER WASH SYSTEM
LPG carries with it fine droplets of caustic solution which can make product corrosive if
stored as such. Therefore to remove these traces of caustic solution LPG water wash
vessel 05-VV-007 is provided. LPG water circulation pump 05-PA-018A/B takes suction
102
from 05-VV-007 bottom and discharges water back to vessel through the static mixer 05Jv-003. Circulating water flow measures through FI-1903B in DCS.
Water mixes with LPG in 05-JV-003 results in its water saturation. An inter phase of
alkaline water and water washed LPG is formed in 05-VV-007. LI-1904B with LAL
shows the level of the vessel. Water washed LPG floats on top of water in the vessel.
Water saturated caustic free LPG is routed to LPG coalescer 05-EE-008.
Water entering with LPG settles down in lower portion of 05-VV-007. This alkaline water
draining from the bottom of the vessel 05-VV-007 is done manually. Independent low
level alarm switches are provided in the vessel. On actuation of level alarm low in the
vessel is indicated by LALL-1906, SDV-1902 provided to arrest escaping of washed LPG
with water during draining. Quantity of water make up to 05-VV-007 by 05-PA025A/B is
indicated by FI-1904B.
PSVs 1903/1904 are provided on 05-VV-007 top to prevent it from over pressurization
due to exposure of vessel in the external fire. 05-VV-007 always operates with full of
liquid, without any vapor space.
From the LPG Water Wash vessel 05-VV-007 the top portion is sent to LPG Coalescer
LPG Coalescer 05-VV-008 is provided for reducing saturated water content in LPG from
0.2 wt% to 80 ppm. Coalescer element is provided inside the vessel to meet the abovementioned parameter. Retention time is 4 hours for enabling water droplets to coalescer
and separate efficiently from LPG. LI-1910B shows the coalescer level in DCS. From the
Coalescer, the product is sent to LPG storage under pressure control of PIC-1912 through
PV-1912. In the common product line there is a product tapping for LPG Vaporizer. FIC1906 measures net LPG quantity from coalescer to storages.
Water collected in the boot of 05-VV-008, is sent to OWS/CS under level control. Water
feature shall prevent escaping of product with during water draining. Two PSVs
1905/1906 set at 15 Kg/cm2 are provided on the coalescer 05-VV-008, whose discharge is
routed to flare header. It prevents vessel from getting over pressurized in case of external
fire. 2 line connecting flare header with upstream of PSVs has been provided to
depressurize the vessel to flare.
103
4.12.2.A LIGHT NAPHTHA CAUSTIC WASH SYSTEM
Light Naphtha from light naphtha cooler 05-EE-019 is routed for caustic wash.
Light Naphtha is admitted in Light Naphtha caustic wash drum 05-VV-009 through a
mixing valve HIC/HV-2001 Caustic circulation pumps 05-PA-019A/B, taking suction
from bottom of 05-VV-009 and discharging into 05-VV-009 through mixing valve HV2001 are provided. 10% vol caustic solution is circulated by these pumps where it is
mixed with Naphtha. Mixing results in conversion and transfer of H2S, phenols
mercaptan & other chemicals to caustic solution. Depending on efficiency of mixing in
the mixing valve, reduction of above chemicals shall take place. Mixing of the two
streams can be improved by throttling the stream valve with the help of HIC-2001.
reduced port opening of the mixing valve increases stream velocity through the valve,
resulting in better energy transfer to streams for mixing. However, impact of additional
pressure drop due to mixing valve throttling on run down control valve and upstream
system should be carefully evaluated and monitored. Hydrocarbon phase separates out
from caustic in 05-VV-009 due to adequate availability of residue time. Naphtha over
flows from top of 05-VV-009 to water wash vessel 05-VV-010 through another mixing
valve HIC-2002/HV-2002. Caustic solution settled in 05-VV-009 bottom is re-circulated
again on repeated circulations, strength of caustic goes down to less than 75% of its
initial strength due to picking up of compounds mentioned above. This is called spent
caustic and is drained out through 4 line to spent Caustic water degasser 05-VV-016.
Spent caustic draining from the bottom of the vessel 05-VV-009 is done manually.
Independent low level alarm switches are provided in the vessel. On actuation of level
alarm low in the vessel is indicated by LALL-2003, SDV-2001 provided on spent caustic
outlet line shall close. This feature shall prevent escaping of fresh caustic solution with
spent caustic during spent caustic draining.
During Caustic make up, normally caustic circulation should not be stopped and strength
of spent caustic solution should be increased by gradual draining and equivalent make up.
Quantity of caustic make up is indicated by FI-2003B.
PSV 2001/2002 are provided on 05-VV-009 top, whose discharge is routed to flare
104
with LAH/LAL has been provided for measuring the level of the vessel 05-VV-009
always operates with full of liquid, without any vapor space.
Spent caustic degasser 05-VV-016 is a vertical vessel connected with flare. It receives
caustic from LPG caustic wash, hydrocarbons vapors disengaged from caustic solution
escape to flare and spent caustic is pumped out to ETP by spent caustic pumps 05-PA043A/B. LI-1911 with LA/LAH has been provided for measuring level in the vessel.
Independent low level alarm switches are provided in the vessel.
On actuation of level alarm low in the vessel is indicated by LALL-1914, SDV-1904
provided on spent caustic degasser outlet line shall close. This feature shall prevent
escaping of hydrocarbon vapors with spent caustic during pumping.
4.12.2.B
LIGHT NAPHTHA WATER WASH SYSTEM
Caustic washed naphtha carries with it fine droplets of caustic solution, which can make
product corrosive if stored as such. Therefore these caustic solution traces need to be
removed from naphtha before sending it to storage. For this purpose, through water wash
is given to Naphtha. Naphtha water wash vessel 05-VV-010 is provided for this purpose.
Light Naphtha water circulation pump 05-PA-020A/B takes suction from 05-VV-010
bottom and discharges water back to vessel through HV-2002. Circulating water flow
measure through FI-2002B in DCS.
Water mixing with Naphtha in HV-2002 results in its water saturation. An inter phase of
alkaline water and water washed naphtha is formed in 05-VV-010. LI-2008B with
LAL/LAH shows the level of the vessel. Water washed naphtha from the top of the
vessel (caustic free) is routed to light naphtha storage by Light Naphtha Product pump
05-PA-041A/B under flow control of FIC-2004 through FV-2004. Stabilizer bottom level
controller LIC-1702 can also be cascaded with this flow controller to maintain level in
the stabilizer bottom.
Water entering with Naphtha settles down in lower portion of 05-VV-010. This alkaline
water draining from bottom of the vessel 05-VV-010 is done manually. Independent low
level alarms switches are provided in the vessel. On actuation of level alarm low in the
vessel is Indicated by LALL-2007, SDV-2002 provided on alkaline water line to spent
105
caustic water degasser shall close. This feature shall prevent escaping of washed naphtha
with spent caustic during water draining. Quantity of water make up to 05-VV-010 is
indicated by FI-2005B.
liquid, without any vapor space.
4.12.3.A
KERO/ATF CAUSTIC WASH SYSTEM
Kero/ATF from Kero/ATF cooler 05-EE-024 / 23C is routed for caustic water wash.
Kero/ATF is admitted in Kero/ATF caustic wash vessel 05-VV-013 through a mixing
valve HIC/HV-2201. Kero/ATF Caustic circulation pumps 05-PA-023A/B, taking suction
from bottom of 05-VV-013 and discharging into 05-VV-013 through mixing valve HV2201 are provided. 10-vol% caustic solution is circulated by these pumps where it is
mixed with Kero/ATF. Mixing in the valves results in conversion and transfer of H 2S,
phenols, mercaptans & other chemicals to caustic solution. Depending on efficiency of
mixing in the mixing valve, reduction of above chemical shall take place. Mixing of the
two streams can be improved by throttling the mixing valve with the help of HIC-2201.
Reduced port opening of the mixing valve increases stream velocity through the valve,
resulting in better energy transfer to streams for mixing. However, impact of additional
pressure drop due to mixing valve throttling on rundown control valve and upstream
system should be carefully evaluated and monitored. Hydrocarbon phase separates out
from caustic in 05-VV-013 due to adequate availability of residence time. Kero/ATF
overflows form top of 05-VV-013 to water wash vessel 05-VV-014 through another
mixing valve HIC-2202/HV-2202. Caustic solution settled in 05-VV-013 bottom is recirculated again. On repeated circulations, strength of caustic goes down to less than 75%
of its initial strength due to picking up of compounds mentioned above. This is called
spent caustic and is drained out through 2 line to spent Caustic/water degasser 05-VV016. LI-2202B measures the level in the Kero/ATF Caustic Wash drum 05-VV-013. Spent
Caustic draining from the bottom of the vessel 05-VV-013 is done manually. Independent
low level alarm switches are provide in the vessel. On actuation of level alarm low in the
vessel is indicated by LALL-2203, SDV-2201 provided on spot caustic outlet line shall
106
close. This feature shall prevent escaping of hydrocarbons with spent caustic during spent
caustic draining. During Caustic make up, normally caustic circulation should not be
stopped and strength of spent caustic solution should be increased by gradual draining
and equivalent make up. Quantity of caustic make up is indicated by FI-2201B.
PSV 2201/2202 are provided on 05-VV-013 top, whose discharge is routed to flare
with LAL has been provided for measuring the level of the vessel. 05-VV-013 always
operates with full of liquid without any vapor space.
Spent Caustic degasser 05-VV-016 is a vertical vessel connected with flare. It receives
caustic from LPG caustic wash, Light Naphtha, Kero/ATF vapors disengaged from
caustic solution escape to flare and spent caustic is pumped out to ETP by spent caustic
pumps 05-PA-043A/B. LI-1911 with LAL/LAH has been provided for measuring level in
the vessel. Independent low level alarm switches are provided in the vessel. On actuation
of level alarm low in the vessel is indicated by LALL-1914, SDV-1904 provided on spent
caustic degasser outlet line shall close. This feature shall prevent escaping of hydrocarbon
vapours with spent during pumping to ETP.
4.12.3.B
KERO/ATF WATER WASH SYSTEM
Caustic washed Kero/ATF carries with it fine droplets of caustic solution, which can
make product corrosive if stored as such. Therefore these caustic solution traces need to
be removed from Kero/ATF water wash is given to Kero/ATF. Kero/ATF water wash
vessel 05-VV-014 is provided for this purpose. Kero/ATF water circulation pump 05-PA024A/B takes suction from 05-VV-014 bottoms and discharges water back to vessel
through HV-2202. Circulating water flow measures through FI-2203 B in DCS.
Water mixing with Kero/ATF in HV-2202 results in its water saturation. An inter phase of
alkaline water and water washed Kero/ATF is formed in 05-VV-014. LI-2205B with LAL
shows the level of the vessel. Water washed Kero/ATF floats on top of water in the
vessel. Water saturated with caustic free from Kero/ATF settles down in lower portion of
05-VV-014. This alkaline water draining from the bottom of the vessel 05-VV-014 is
done manually. Independent low level alarm switches are provided in the vessel. On
actuation of level alarm low in the vessel is indicated by LALL-2206, SDV-2202
107
provided on alkaline water line to Spent Caustic/water degasser shall close. This feature
shall prevent escaping of washed Kero/ATF with spent caustic during spent caustic
draining. Quantity of water make up to 05-VV-014 is indicated by FI-2204 B.
liquid without any vapour space.
From the Kero/ATF water wash vessel (05-VV-014) the top portion is sent to Kero/ATF
Coalescer. Kero/ATF Coalescer 05-VV-015 is provided for reducing water content in
Kero/ATF 0.2 wt% to 100ppm. Coalescer element is provided inside the vessel to meet
the above-mentioned parameter. Retention time is 4 hours for enabling water droplets in
coalescer and separate efficiently from Kero/ATF. LI-2210 B shows the coalescer level in
DCS. From the coalescer, the product has sent to Kero/ATF storage under flow control of
FIC-2206 through FV-2206. in the common product line, product tapping for Kero/ATF
to Gas oil rundown has provided. FI-2205 measures net Kero/ATF quantity from
coalescer to storage.
Water collected in the boot of 05-VV-015, is sent to OWS under level control. Water
feature shall prevent escaping of product with during water draining. Two PSVs
2205/2206 set at 15 Kg/cm2 are provided on the coalescer 05-VV-015, whose discharge is
routed to flare header. It prevents vessel from getting over pressurized in case of external
fire. 2 line connecting flare header with upstream of PSVs has been provided to
depressurize the vessel to flare. Kero/ATF from coalescer (VV-15) sent to Kero/ATF salt
dryer for better removal of moisture/water from the kerosene. In Kero salt dryer,
Kero/ATF goes in at the bottom and exits at the top of the dryer. Continuos removal of
brine water is carried out once in a shift to avoid accumulation of water in dryer. For
further details, please refer to kero/ATF salt dryer chapter.
4.13
CHEMICAL INJECTION FACILITIES
Refer P&ID No: 3551-05-020-41-0124 Rev.5
108
Hydrochloric acid from the salt in the crude and hydrogen sulphide dissolved in the crude
(or formed from the dissociation of heavy Sulphur compounds present in crude)
concentrates in the overhead system. Both form of acid solutions, which are corrosive.
Measures must be taken to over come their effects. The overhead system including
condensers and reflux drum is made of carbon steel. In order to protect this section,
caustic solution, ammonia solution and corrosion inhibitors are added at various points.
The purpose of injection caustic at the outlet of desalter is to achieve better mixing of
these chemicals with crude and neutralize the acids and salts, mainly HCL and H 2S as
soon as they are formed (at a temp. Of 120 C and above) the reaction products i.e. sodium
and ammonia salts go along with reduced crude. The balance acids and acid gases if any
will go up to the overhead system where ammonia is injected in the overhead vapor line
to neutralize. Amount of ammonia should be controlled in such a way that pH of reflux
drum water remains at 6.5+0.2.
Injection of caustic at the outlet of desalter should be maintained in such a way that the
salt formation should be low in the overhead circuit, which might scale up the overhead
condenser tubes.
A slightly acidic condition of the overhead system is desirable to keep ammonium salts in
solution, which if precipitates would foul and plug the condensers. Corrosion against
slightly acidic conditions is minimized by adding corrosion inhibitors in the overhead
vapor line. The inhibitor is also added in reflux line. Top section of the column is also
benefited from the injection of corrosion inhibitors mainly in the reflux line. These
inhibitors are high boiling compounds and can perform satisfactorily at higher column
top temperature also.
The amount of inhibitor injected depends upon the type of inhibitor used and generally
specified by the vendor. However slight adjustment is made by operating personal
depending upon iron content in the reflux drum water. These inhibitors are filming
organic compounds, which cover entire metal surface of the system with a thin film. This
prevents contact of corrosive water with metal surface.
Various points of chemical injections are listed below:
4.13.1
CAUSTIC INJECTION
109
Caustic solution having strength of 47% is received from off sites through 3 header. It is
diluted to two different strengths for use in unit. Five caustic tanks are provided within
battery limit. One strong tank 05-TT-001 stores strong caustic solution with strength of
47% two tanks 05-TT-002A/B provided to store weak caustic solution with strength of 10
%.& two tanks, 05-TT-006A/B provided to store weak caustic solution with strength of
3.5% Each storage tank is provided with DM water connection for dilution purpose. LIs
and overflow lines are provided on each tank. Care should be taken to ensure that tanks
are not pressurized due to inadequate relieving of air through tank vent.
Strong Caustic solution from 05-TT-001 is pumped by caustic make up pump 05-PA-033
to 10% caustic dilution tank 05-TT-002A/B from 05-TT-002A/B is pumped by caustic
make up pump 05-PA-032A/B to following destinations.
To Kero/ATF caustic wash
To LPG Caustic wash
To Light Naphtha Caustic wash
Dilute caustic solution from 05-TT-006A/B is pumped by Caustic injection pumps 05PA-031A/B to following destination:
To suction of Crude charge pumps 05-PA-001A/B/C/D/E
To Caustic Mixer (05-JV-001) connected from discharge of desalter outlet to desalter

crude pumps 05-PA-002A/B/C. Caustic injection to upstream of desalted crude
pumps (PA-02A/B/C/D/E) was stopped to avoid the continuous fouling of preheat
train-II (New & Old).
To upstream of desalters 05-VV-001A/B
4.13.2
AMMONIA SOLUTION INJECTION
Ammonia gas drawn from ammonia cylinder, brought from out side agency, is injected at
reduced pressure into ammonia solution vessel 05-VV-018A/B. DM water connection is
provided on ammonia vessel for preparing solution. Ammonia solution vessel is a vertical
vessel with a water seal on its vent to prevent escaping of ammonia while preparing
solution. Water seal will blow off during excess pressure build up in the vessel. Finally
prepared ammonia solution is injected by ammonia solution injection pumps 05-PA-
110
026A/B to Crude column overhead line. FI-2411 measures the net quality of ammonia to
crude column overhead.
4.13.3
Dissolved demulsifier chemical is pumped out by 05-PA-027A/B and is injected to the

following destinations FI-2405 measures the net quality of demulsifier from 05-PA027A/B for consumption.
To suction of crude charge pump 05-PA-001A/B/C/D/E
To upstream of desalters 05-VV-001A/B
4.13.4
CORROSION INHIBITOR/AHURALAN SOLUTION INJECTION
Corrosion inhibitor (Ahuralan) is received in drums and transferred to ahuralan solution

making drum 05-VV-019A/B, and it is diluted with heavy naphtha. Nitrogen sparger is
provided in both tanks for making better mixed solution while preparation of ahuralan
solution. 05-VV-019A/B is vertical drum operates at atmospheric pressure. Local level
gauge, Sample point and draining arrangements to OWS/CBD are also provided on
vessel. Corrosion inhibitor chemical is unloaded into 05-VV-019A/B with the help of
hand pump. Diluted ahularan is pumped out by 05-PA-029A/B and is injected into crude
column overhead lines and stabilizer overhead lines. FI-2406 measures the quantity of
Ahuralan consumed at crude column, FI-2407 measures the quantity of Ahuralan
consumed at Naphtha Stabilizer overhead lines.
4.13.5 WASH WATER SYSTEM
DM Water is received and stored at Wash water make up tank 05-TT-005. LI-2408 with
LAH/LAL and overflow lines is provided in the vessel. From 05-TT-005 wash water is
pumped by wash water makeup pumps 05-PA-040A/B to the following destinations for
water wash purpose.
Light Naphtha water wash vessel
111
LPG Water wash vessel
Kero/ATF water wash vessel
4.14
EFFECTS OF OPERATING VARIABLES
It is important that the operation of process units should be conducted to produce

products of desired quantity. At the same time appropriate controls should be exercised
on certain parameters to prolong the length of continuous run and life of the equipment.
The effect of varying operating variables should be evaluated in totality, particularly for a
complex operating system like fractionation. The effect of a particular operating variable
may not remain limited to only those aspects as discussed below, but usually has a
cascading effect on other operating variables and other aspects of operation, however the
significance of only major changes caused by variation in operating parameters are
discussed here.
In following discussion, it is assumed that operating variable under reference only is
varied, keeping all other parameters unchanged in real situation it may not be possible to
change a variable in isolation. The effect of operating variables is indicative only.
The following general guidelines describe effect of the process variables and measures to
be taken to achieve desired results:
4.14.1 DESALTER OPERATING VARIABLES
Only operating experience with desalter can determine optimum operating conditions. No
two crude behave alike at the same desalting conditions, but all are affected similarly by
change in desalting conditions.
3.14.1.A
WATER INJECTION & PRESSURE DROP
Water injection should be started only after the crude temp. reaches specified desalting
value and power is switched onto the grid. Initially the injection rate should be limited
between 2-6% of crude flow rate and point of injection should be just upstream of the
mixing valve. If crude is Napthenic, water injection should be considered upstream of
preheat trains.
112
The pressure drop across mixing valve should be adjusted to give the required degree of
desalting. The higher the total pressure drop (inclusive of mixing valve and desalter), the
more efficient the contact between the salt in the crude and the injection water. Too highpressure drop will result in excessive emulsification and poor separation of oil and water,
resulting in carry over of water in the desalted crude. A pressure drop between 1 to 2
Kg/cm2 is normally sufficient, which can be adjusted by manipulating mixing valves at
desalter inlet.
Optimum water injection rate and pressure drop across mixing valve should be
established to get the desired desalting of crude. Once this is done, the conditions should
be maintained steady and should be varied only for changes in feed rate and feed
quantities.
4.14.1.B
OIL/WATER INTERPHASE LEVEL
The oil-water interface level should be maintained below the centre line of the desalter
vessels to avoid escaping of water and sludge along with the crude, if sudden pressure
surge takes place. Incorrect operation of the interface level controller can result in more
water in desalted crude due to less hold uptime available for oil(high interface level) and
more oil carry over in brine water due to less hold uptime available for water (low water
level). Also too high an interface level may push battery mixture up between the
electrodes and cause them to short circuit.
4.14.1.C
DESALTER VESSEL PRESSURE
The normal pressure in the vessel should be maintained at about 13 Kg/cm 2g or as

specified by desalter vendor. A low pressure may cause vaporization of crude fractions at
prevailing desalting temp. High pressure may result in popping of the safety valve on the
desalter.
4.14.1.D DESALTER TEMPERATURE
Desalting temperature is another important variable, which affects oil water separation in
Desalter. Most crude oils have an optimum-operating temp. range of around 127 C for
Kero case and 123.5 for ATF case. Lower the temp. higher the viscosity of the oil that
113
slows down the separation rate. As crude conductivity and solubility of crude in water
increases with temperature operating beyond this range will lead to drop in grid voltage
and high amperage which imposes limitation on good separation. Excessive amperage
will eventually cause the circuit breaker to open, tripping the electric grid and rendering
the electrical system inoperable until the thermal relay is closed. Very high temp may lead
to vaporization of crude in the desalter.
4.14.1.E
Tight crude water emulsions can be broken by use of demulsifying chemicals. The
amount of chemicals required to break the emulsion dependents on the nature of the
emulsion, type of crude and other operating conditions like residence time, temp. etc.
Required emulsification chemical injection rate should be established empirically for
optimum operation of desalting unit. Demulsifier soluble in Kerosene has been
considered for use in the unit.
4.14.1.F
VOLTAGE AND AMPERAGE
The desalter electrical panel typically houses pilot lights, a voltmeter and ammeter. The
voltmeter gives the voltage across the primary circuit of the transformer. The ammeter
gives the current flow. These meters give an indication of the performance of the grids
inside the desalter. In case, crude water emulsion is too tightly bound or if the interface
level is too high there will be flickering of the pilot light, the amperage will increase and
the voltage will drop. Take corrective action to break the emulsion or reduce the interface
level.
For more details about the operation of desalter the vendors operating and maintenance
manual should be referred.
4.14.2
HEATER COIL OUTLET TEMPERATURE (COT) AND OVER FLASH
The quantity of crude oil vaporized during its passage through the atmospheric heater
depends on transfer temperature and the pressure at the flash zone of the column. In order
to achieve proper separation i.e. desired recovery of distillates a little over flash is
maintained by keeping the transfer temperature slightly on higher side. This quantity is
114
measured by FI-1504 and at normal capacity the flow is about 25/20 M 3/hr (about 6 to
9% vol. on crude charge feed). This also indicates the presence of liquid level in the trays
down below the GO draw off section. Dry operation of these trays should be avoided to
minimize coke-forming tendency. Maintaining excessive over flash flow will result in
more consumption of energy without any advantage & more RCO generation.
Lower heater coil outlet temperature will effect product quality more in lower section of
the column e.g. gas oils & below (by making then off spec due to carry of heavier
components from LR) and lowering down recovery as well as LR will contain more
lighter components. Yield & quality of products drawn from upper section of the column
may not be affected much.
Higher than normal coil outlet temperature enhance crude cracking possibility inside
heater tubes, leading to coke deposition and higher pressure drop. This may reduce
overall run length of the unit and may force a planned shut down. At the same time
specification of heavy products may not met and higher recovery may be experienced at a
given temp.
4.14.3
MAIN FRACTIONATING COLUMN PRESSURE
The effect of column top pressure is more pronounced on lighter streams. Lower column
top pressure aids in greater vaporization of all streams, particularly lighter streams.
Column operation with lower top pressure will make all side draw products and top
stream slightly heavier. There will be more load on overhead condensers and loss of
lighter components may take place from reflux drum to maintain normal operating
pressure. Higher than normal top pressure will have reverse effects.
Increase in column top pressure will increase column flash zone pressure also. Increased
flash zone pressure will result in lower product yield of all side off streams. The effect
will be reflected in LR also (bottom most stream) which will become lighter.
It is important to note that column pressure is largely dependent upon equilibrium
conditions in reflux drum. Efforts should be made to operate the column at the intended
design pressure only, depending upon type of crude. During normal operation total
condensation of overhead stream is expected and thus both the control valves of split
range pressure controller (on FG make up side as well as flare side) shall remain shut.
115
4.14.4
MAIN FRACTIONATING COLUMN TOP TEMPERATURE
The column top temperature is controlled by regulating amount of overhead reflux

through FC-1505 cascaded with TIC-1501. Increasing the top temp. at same operating
pressure will result in increase of FBP and make of light naphtha will increase. IBP of
HN shall also increase. Similarly reduction of top temp. will reduce FBP and yield of
light Naphtha. IBP of first side draw off (Heavy
Naphtha) shall also come down. To
overcome effect of change in top temp. HN draw off should be suitable adjusted to
maintain its draw off temp.
Too low top temp. will start steam condensation at the top section of the column, which
may increase rate of corrosion in the top section of the column.
4.14.5
CIRCULATING REFLUXES FLOW
The circulating Reflux mainly removes heat form the column and reduces the vapour
load in the particular section of the distillation column. The flows of the three circulating
refluxes: Heavy Naphtha CR, Kero, CR and GO CR are controlled by respective duty
controllers respectively. Increase of circulating reflux flows will result in higher crude
preheat temp. by greater heat recovery in heat exchanger train.
Even through various CR return temperature will be governed by functioning of
respective duty controllers, these may be maintained by operating the bypass of
respective exchangers also. Any change in circulating reflux affects quality and quantity
of its own product and those products, which are immediately above and below it. The
effect of change of CR variation on other streams is not discussed, as it is not that much
pronounced.
A higher than normal Heavy Naphtha CR flow will remove more heat from column in
HN CR zone. When this heat removal becomes excessive, column top temp. shall also
show a tendency of decline, requiring lower top reflux flow. This will cause lower liquid
transport between top tray and HN draw off, causing poor fractionation between overhead
and HN. It will come down, as there will be less overhead product to condense. The
kerosene cut will be correspondingly lighter.
116
High GO CR flow will tend to lower the temp. resulting in lighter product on this tray.
Thus GO will be lighter and Kerosene will also be lighter.
Likewise a high GO CR will tend to lower the draw off temp. of GO product, making GO
and LR lighter.
4.14.6
PRODUCT WITHDRAWL TEMPERATURE
The withdrawal (Draw off) temperature of the products is controlled by withdrawal rate
of the streams. Increase in product withdrawal temperature makes it heavy. An increase in
withdrawal rate of one side stream increases the withdrawal temperature and boiling
ranges of all side streams down below in the column unless their withdrawal rates from
the column are also reduced correspondingly.
For example, if kerosene product withdrawal rate is increased, the internal reflux in the
trays below the draw off tray will be reduced. Thus end point of kerosene is increased.
Increased kero draw off will have a tendency of lowering availability of material on GO
tray, requiring corresponding reduction in GO draw off to maintain same FBP. If GO
withdrawal rate is not reduced to maintain its draw off temp. its boiling range will shift
upwards.
Similarly reverse action takes place when withdrawal temp. is lowered by reducing the
quantity of withdrawal.
4.14.7
4.14.7.A
STRIPPING STEAM
STRIPPING STEAM IN FRACTIONATING COLUMN
Super heated MP steam is used to strip kero/ATF and GO at the bottom of the crude
column. The stipulated bottom steam rate should be maintained by FIC-1508 & FIC-1509
for economical stripping and normally it should not be varied. Lowering the steam rate
below the specified optimum value may leave some GO in the LR and this is undesirable.
Exceeding the design steam rate might cause entrainment of LR into the GO because of
excessive vapour velocity. Also it will ultimately overloads the overhead condenser
system.
117
4.14.7.B
STRIPPING STEAM IN STRIPPERS
The flash points (IBP to some extent) of Kero/ATF and GO products can be controlled by
varying the stripping steam rate to respective strippers.
It is advisable not to exceed the steam/ vapour flow rate beyond the design value in any
of product strippers viz. HN, kero and GO strippers as this will tend to lift some of the
high boiling material into atmospheric column. If the desired flash point could not be
obtained by designed rate of stripping steam, the draw off of product just above it may be
increased to enhance its IBP. Use of MP steam in any of the strippers shall cause
reduction of partial pressure of hydrocarbon and may result in evaporation of lighter
components from the stock. This may also be reflected in terms of flash point of the
product.
Stabilizer removes the majority of butane and lighter hydrocarbons from the naphtha
stream. These are recovered as overhead fuel gas product. High stabilizer top temp. will
make overhead product heavy; even C5, C6 components may be carried into fuel gas and
condensing in the distribution line after wards. Lower top temp. attained by increasing
top reflux will reduce heavier ends in fuel gas.
RVP of LPG may go up on account increased presence of C3 and lower components. To
correct the situation, stabilizer top pressure should be lowered a bit. Too low bottom
temp. may result in higher than allowable vapour pressure (RVP) of naphtha and at the
same time it will reduce yields of overhead streams.
Low stabilizer top pressure in the column will cause higher amount of hydrocarbon
compounds (C3 and C4) to escape into overhead system. This has got similar effect as
that of higher temp. in the column.
4.15
NORMAL OPERATING CONDITIONS
CURDE TYPE
LS
HIGH
NIGERIA
SULPHU
N
Total Flow m3/hr 510
Tput: MT/D
10500
CIT
263
R
520
10800
274
118
BH
FARCADOS
510
10500
264
530
10800
263
COT
365
COT Maintained 365
Furnace
(FF01)
FC-1401 M3/Hr
FC-1402 M3/Hr
FC-1403 M3/Hr
FC-1404 M3/Hr
Top
141
151
150.3
141.3
Press 2.3
Kg/Cm2
TOP Temp 0C
114
Withdrawal Temp
HN
156
SKO
208
GO
304
Withdrawal Rate
HN
30
SKO
120
GO
125
CC-05
TOP 64
TEMP. 0C
CC-05 Top Pres. 10.5
375
375
365
360
351
370
150
161
153
144
141
153
151
141
154
151
156
147
2.3
2.3
2.3
111
114
113
150
210
311
154
208
304
157
211
302
25
95
111
67
30
110
120
65
36
74
177
10.5
10.5
10.5
Kg/Cm2
4.16
CRITICAL OPERATING PARAMETERS AND INSTRUMENTS
Sl.
No
1
Equipment
Critical
Parameter
Furnace Pass 80-140
flow
m3/hr
Furnace COT
365 375 C
Instrument
Provided
FRC
pa
TC
cascaded
with PC on
oil or PC on
gas
119
Remarks
1)Ensure flow above low alarm limit
2)Ensure equal pass flow through all
passes
1)Ensure steady oil temp.
2)Ensure steady oil pressure.
3)Ensure steady gas pressure
4)Ensure steady atomizing
steam pressure.
5)Ensure
healthy
burner
Column
Pressure
top 2.3 Kg/Cm2
Column (CC- 108-1200C

01)
top
Temperature
Over Flash
15-20 m3/hr
Column
Bottom Level
40-50%
Furnace O2
02-03%
Furnace arch -5 to
pressure
mmwc
condition
PC
split
1)Ensure controller tuning

range
2)Ensure
good
desalter
between FG operation
& Flare
3)Ensure steady top temp.
4)Ensure boot water level

TC

cascaded
2)Ensure normal reflux temp.
with
top
3)Ensure steady top pressure

reflux
4)Ensure boot water level

FI
Maintain Over flash flow of 56 vol% by adjusting Gas Oil draw as

per HSD recovery / pour point
LI / LCV
1)Maintain 40-50% level
cascaded
2)High level may colour gas oil
with bottom
3)Low level may vapor lock
R/D flow bottom pump. In some column SDV is
provided, which cutoff bottom draw at
low level.
O2 analyser
1)2 to 3% excess air
requirement should be maintained
2)More excess air means

energy loss
3)Less than required air will

lead to smoky burner & burner tip
coke up.
+2 PI
Furnace arch 850

temperature
9000C
10
Furnace stack < 2500C

temperature
Desalter Inter- 30 to 40%
phase Level
11
to TI
TI
LDIC
120
1)Chance of back fire is there

in case of high arch pressure
2)Inter lock is provided to cut
off furnace in case STD does not open
at high arch pressure.
3)Open more ID suction vane
4)Reduce Excess air
5)Open STD
1)Adjust burner flame height.
2)Adjust air requirement
3)If required reduce Tput
1)Ensure furnace is not hard fired
2)Arrange for APH cleaning
1)Ensure that 30-40% level is
maintained
2)At high level desalter load

will increase, resulting poor desalter
operation
3)At low level chance of crude

draining along with brine is there
Ammeter
1)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.
2)Increase demulsifier rate &

reduce mixing valve pressure drop.
12
Desalter
Amps
< 5 amps
13
Desalter
Pressure
11.5 to 12.5
14
Reflux drum 40 to 50%

boot level
15
Caustic
/ 40 to 50%
water
wash
vessels inter
phase level
LCV
16
Boot Water
Chloride
content
High
Fe content
High
PG / PC on

pre desalter
2)Ensure that pressure is well

crude pump below PSV set point
discharge
3)Ensure furnace pass flows
line.
are steady.
LCV
1)Ensure 30-40% level.
2)At low-level naptha may

drain along with sour water.
3)At high-level water will

carry over with reflux, resulting
column condition upset.
4)Ensure
desalter
good
operation
1)Ensure 30-40% level
2)At low-level objective will
not solve. Feed H2S may not get
removed
3)At
high-level
caustic
solution will be carried over to storage
tank & wll result in failure of Cucorrosion test.
1)Increase caustic dozing &

adjust ammonia to maintain boot
water PH of 6-6.5 & Cl_ of < 3 ppm
ppm
dozing
121
2)For control Fe content < 2

increase corrosion inhibitor
CHAPTER-5
UTILITIES SYSTEM
122
UTILITIES SYSTEM
5.1
INTRODUCTION
Please refer following P & IDs for major utility distribution description:
3551-05-02-41-0141 Rev.2 LP steam, SW, PA System
3551-05-02-41-0142 Rev.2 CW, DMW Distribution Systems
3551-05-02-41-0143 Rev.2 Instrument Air, Fuel oil, Fuel Gas distribution system
3551-05-02-41-0144 Rev.1 MP Steam/HP Steam/BFW system
3551-05-02-41-0145 Rev.2 Flare System
3551-05-02-41-0146 Rev.2 CBD System
3551-05-02-41-0147 Rev.1
Flushing Oil Distribution
3551-05-02-41-0148 Rev.2 Amine Drain Distribution System

The utility system consists of Instrument Air (IA), Plant Air (PA), Cooling Water (WC),
Service Water (WS), DM Water, Boiler Feed Water, LP Steam, MP Steam, HP steam,
Fuel Oil, Fuel Gas & Flushing Oil.
Closed Blow Down (CBD), Flare and Oily Water Sewer (OWS) system are provided
within unit.
5.2
INSTRUMENT AIR
Refer P & ID No. 3551-05-02-41-0143 Rev.2

A 4 instrument air header supplies instrument air to the unit. This header is provided
with an isolation valve and a spectacle blind at unit battery limit. PI-4306 indicates the
pressure of instrument air at the battery limit, in DCS. A local pressure gauge is also
provided on this line. Instrument air consumption rate in unit is indicated by FI-4302 in
123
DCS. Various instrument air tapping are taken from this header. Instrument air is used as
motive force for pneumatically operated control valves.
5.3
PLANT AIR
Refer P & ID No.3551-05-02-41-0141 Rev.2
A 4 plant air header supplies plant air to the unit. The header is provided with an
isolation valve and a spectacle blind at the unit battery limit. The pressure of the PA at the
battery limit is indicated by PI-4104. FI-4102 indicates PA flow to unit. A number of
utility Hose stations are provided for plant from this 4 header. For decoking of crude
furnace separate 4 tapping are taken from main header. 1 size plant air tapping is
provided to seal pot.
5.4
COOLING WATER
Refer P & ID No.3551-05-02-41-0142 Rev.2

24 supply and return cooling water headers to the unit are tapped from underground
headers running on the side of the unit. Isolation valves with down stream spectacle blind
have been provided at the battery limit of the unit, on the both the headers. The CW
supply line is provided with PI-4202, FI-4201 & TI-4202 to indicate pressure, flow &
temp. at battery limit. Local pressure/temp. indicators are provided on CW (supply &
return) lines. TI-4402 & PI-4207 are also provided on CW (Return) line.
Cooling water header serves the following equipments in AU-5 unit:
05-EE-020
Hy. Naphtha Cooler
05-EE-019
Light Naphtha Cooler
05-EE-022A/B/C/D
LR cooler II
05-EE-021
LR cooler II
05-EE-111A/B
LR cooler I
124
05-EE-023A/B/C
Gas oil cooler
05-EE-024
Kero/ATF cooler
05-EE-016A/B/C
Atm. Column OVHD trim condensers
05-EE-017A/B/C
Stabilizer OVHD condensers
05-VV-038
Pump Coolant pump
05-VV-030
CBD Drum
05-FF-001 & APH SECTION
Furnace
05-EE-019B
LN cooler
05-EE-016A/B/C/D/E/F
CC-01 O/H Trim condensers
05-EE-017A/B/C/D
CC-05 O/H condenser
05-EE-110A/B
LGO coolers
05-EE-109
Kero I cooler
05-EE-13A/B
Brine cooler
Above all, CW supply is provided for all pumps bearing & seal flush cooling in the unit.
5.5
SERVICE WATER
Please Refer P & ID No.3551-05-02-41-0141 Rev.2

A 4 service water header supplies service water to the unit. It is provided with isolation
valves and spectacle blind along with a local pressure gauge at the battery limit. A flow
indicator FI-4103 has been provided in DCS. The service water header supplies water to
various hose sections in the plans. Service water connections have been provided for
cleaning of lines through the suction of the pumps. These pumps are listed below:
05-PA-031A/B
Caustic Injection pump
05-PA-032A/B
Caustic Circulation pump
05-PA-005A
CC-01 Reflux pump
05-PA-014A
CC-05 Reflux pump
Service water serves the following equipments in AU-5

05-VV-030
CBD Drum
05-VV-034
Brine Degasser
125
05-FD-001
For APH washing
05-FD-002
For APH washing
5.6
DM WATER
Refer P & ID No.3551-05-02-41-0142 Rev.1

A 4 Dm water header supplies DM water to the unit form off sites. It is provided with an
isolation valve & spectacle blind, a local pressure gauge, temp. gauge and flow indicator
FI-4202 at the battery limit. From this header tapping have been taken to 05-EA-001 A-H
(Atmospheric Overhead Condensers), 05-VV-018A/B (Ammonia Vessels), Caustic
Vessels (05-TT-002A/B, 05-TT-006A/B, 05-TT-005) and 05-VV-005 (Desalting Water
Drum).
5.7
BOILER FEED WATER
Refer P & ID No.3551-05-02-41-0144 Rev.1

Boiler feed water (WB or BFW) is supplied to unit through a 2 line. It is used for
pressure reduction of HP steam at Super-heater. TG-4405 indicates BFW temperature at
battery limit FI-4403/PI-4405 indicates BFW flow & pressure battery limit. Boiler feed
water is routed to desalted crude outlet line from desalter.
5.8
LP STEAM
Refer P & ID No.3551-05-02-41-0141 Rev.2

Low Pressure steam header of 14 size has been provided to the unit with isolation valves
and spectacle blinds at battery limit. Local pressure, temperature & flow checking
element is provided in the battery limit of the unit. Following major headers are branched
off from the 14 main header:
To 05-VV-029/05-EE-29
To LP Steam heating coil
To 05-VV-001A
Sample point purge steam
To 05-VV-001B
Sample point purge steam
To 05-CC-001
Body steam for steam out
To 05-CC-002
126
To 05-CC-003
To 05-CC-004
To 05-CC-005
To 05-CC-006
To 05-PA-051A/B/C
As quench steam for pump mech. Seal
To 05-PA-011A/B
To 05-PA-007A/B
To 05-PA-012A/B/C
To 05-PA-010A/B/C
To 05-PA-002A/B/C/D/E
To 05-PA-09A/B
As quench steam for pump mech.seal
To 05-PA-102A/B
To 05-PA-103A/B
To 05-PA-104A/B
To 05-PA-45A/B
05-FF-001
As snuffing steam
To Air Pre-heaters
05-VV-035
05-VV-030
05-VV-026
Steam for tracing of process line
Steam for utility hose stations
5.9
MP STEAM
Refer P & ID No. 3551-05-02-41-0144 Rev.2

A 12 Medium pressure steam MP steam header to the unit is provided with isolation
valve, spectacle blind & local pressure temperature gauges at battery limit PI-4401, TI4401 & FI-4401 are provided to indicate pressure temp. & flow of MP steam to unit.
127
16 size Mp steam header serves following equipment.
To Crude charge heater 05-FF-001 as:
Emergency steam to coils
Soot blowing steam
Decoking steam
Atomizing steam
To 05-CC-001, 05-CC-003/-004/-005 as stripping steams.
To coil steam in IFO surge drum (05-VV-21)
MP to LP steam
5.10
HP STEAM
Refer P & ID No. 3551-05-02-41-0144 Rev.2

A 6 High-pressure steam MP steam header to the unit is provided with isolation valve,
spectacle blind & local pressure temp. gauges at battery limit. PI-4403, TI-4403 & FI4402 are provided to indicate pressure temp. & flow of HP steam to unit.
6 size HP steam header serves following equipment:
4 HP Steam to de-superheat by Boiler Feed Water injection in steam de-superheater 05-MD-001. The TIC-4406 maintains MP Steam temperature at de-superheater outlet by manipulating BFW injection into de-super-heater.
5.11
To 05-EE-028A/B/C/D (HP steam/FO heat exchanger) for heating media.

FUEL GAS
Refer P & ID No. 3551-05-02-41-0143 Rev.2

Sour fuel gas from various units i.e. from 05-VV-002 column over head reflux drum, 05VV-003 stabilizer reflux drum and 05-VV-020 LPG Surge drum is admitted into fuel gas
knock out drum (KOD) 05-VV-028. When no FG is being produced in unit or during first
start-up LPG can be backed to the LPG vaporizer from off sites through run down line.
128
LPG can be vaporized in LPG vaporizer 05-VV-029 with the help of LP steam to produce
FG. LPG flow to 05-VV-029 is indicated by FI-3202. It is admitted into vaporizer under
level control LIC-3202. Independent high & low-level alarms are also provided on LPG
vaporizer. LPG vaporizer pressure is maintained by 05-PIC-3202 by manipulating PV3202 on LP steam flow to vaporizer. Vaporized LPG is admitted into fuel gas KOD 05VV-028. FG from combined FG header is also being routed directly into 05-VV-028 for
condensate de-entertainment. FG from this KOD is taken out for distribution through a
12 header under pressure control PIC-3204. PSV-3201 & PSV-3202 are provided to
protect 05-VV-029 & PSV-3203/3204 is provided to protect 05-VV-028 from over
pressurization. Drain of 05-VV-029 & 05-VV-028 are normally routed to flare due to
flashing nature of streams handled.
FG consumption in AU-V is indicated by FI-4304. PI-4304 measures pressure of the FG
header at battery limit. Local pressure & temperature gauge have been provided at battery
limit. Fuel gas is delivered to crude charge heater (05-FF-001) as fuel and Atmospheric
Column reflux drum (05-VV-002) & fuel oil surge drum (05-VV-026) to maintain
pressure. It is also connected as purge to flare header. AU-V LPG vapouriser can be used
as a fuel gas to CRU fuel gas system, in case of requirement.
Modification is made to use AU5 LPG vaporizer to cater the requirement of GR Fuel gas
system. Its flow is maintained by 5FCV 257A. A new line has also been laid out to cater
the fuel gas requirement for MSQ plant during commissioning via 5PCV0204.
5.12
FUEL OIL
Refer P & ID No. 3551-03-02-41-0143 Rev.2

IFO from battery limit along with 2 Long Residue from 05-EE-004 is sent to fuel oil
surge drum 05-VV-026 under level control of LV-3103. FI-3103A measures the combined
stream flow to 05-VV-026. MP steam is used for heating medium in05-VV-026. Fuel oil
from surge drum is filtrated and is sent to FO high pressure steam heater 05-EE028A/B/C/D through 05-PA-045A/B. Provision to divert IFO to slop header from PA
045A/B is also there. From heater FO is again sent to filters 05-GN-002A/B. Filtered
fuel oil is sent to fuel oil supply header of AU-5 for distribution. Fuel oil is supplied to
fire heater of the unit through a 4 header. Local pressure gauge and temperature gauges
129
have been provided near respective heaters. Fuel oil flow to heaters is measured by flow
meter on respective FO (supply) header. A return fuel oil line has been provided from
furnace. Return line has been provided with a globe valve, shut down valve & flow
meters. About 50% of the supply fuel oil allowed to return through this line. This
circulation of fuel oil to atmospheric furnace is recorded by flow differential recorder.
Fuel oil return header with bypass has been provided from supply line to allow
independent FO circulation for the furnace.
5.13
FLUSHING OIL
Refer P & ID No. 3551-05-02-41-0147 Rev.2

Flushing oil is normally light oil with boiling range & properties comparing well with
diesel oil. It is used at flushing medium for displacing heavy, congealing & viscous
material from equipment piping sections during unit shutdown or for other maintenance
job requiring freeing of equipment from such hydrocarbons. Flushing oil to unit is
received from off sites through a 4 header. Provision to divert unit gas oil R/D to
flushing header is also there. 4 size combined flushing oil from unit & off site runs
through out pipe rack of unit & supplies FLO to following equipment shown in P & IDs
listed below: a) 05-PA-051A/B/C
Suction line
b) 05-EE-022A/B/C/D
Shell side
c) 05-EE-021
Shell side
d) 05-EE-010A/B/C/D
Shell & Tube side
e) 05-EE-009A/B
Shell side
f) 05-EE-007A/B/C
Shell & Tube side
g) 05-EE-006A/B
Shell side
h) 05-EE-001
Shell side
i) 05-EE-002
Shell side
j) 05-EE-003
Shell & Tube side
k) 05-EE-004
Shell & Tube side
l) 05-EE-005
Shell side
130
m) 05-EE-028A/B/C/D
Shell side
n) 05-PA-002A/B/C/D/E
Suction line
o) 05-PA-001A/B/C/D/E
Suction line
p) 05-PA-045A/B
Suction line
q) 05-EE-102A/B
Shell side
r) 05-EE-103A/B
Shell & Tube side
s) 05-EE-103C
Shell & Tube side
t) 05-EE-104A/B
Tube side
u) 05-EE-105A/B
Shell & Tube side
v) 05-EE-105C/D
Shell & Tube side
w) 05-EE-105E
Shell & Tube side
x) 05-EE-106A/B
Shell side
y) 05-EE-106C/D
Shell side
z) 05-EE-107A/B
Shell & Tube side
aa) 05-EE-107C/D
Shell & Tube side
ab) 05-EE-108A/B
Tube side
ac) CBD End cover

5.14
ELECTRIC SYSTEM
Electrical load for AU-5 is anticipated as 3220 KW. In the event of power failure back up
Emergency power supply arrangements has provided. Electrical system of AU-5
compromises of a Number of sub-systems. They are briefly described as under.
5.14.1
ELECTRICAL POWER FOR PUMPS
Motors above 160 KW ratings are fed with 6.6 KV switchboards.

Following pump motors are fed by High Tension feeder at 6.6 10% KV AC from Unit
substation, individually for each of following motors:
05-PA-001A/B/C/D/E
Crude charge pumps
05-PA-002A/B/C/D/E
Desalted crude pumps
05-PA-51A/B/C
RCO pumps
131
Above motors are termed as HT motors. Remaining all other motors are fed by lowtension feeder at 415 5%V, and 230 5%V, 3 phase, AC power.
Motor start/stop push buttons and local Ammeters are provided at local control station for
motors in field. However, local Ammeters are provided only for motors with rating 55
KW and above. All LT motors feed through switch fuse contractor are provided with
240V AC control supply. 110 V DC control supply is provided for all HT motors & motor
having rating exceeding 75 KW, & power motor control centre. Running status lamps for
pump are provided on control room auxiliary console panels as per P & ID for critical
motors with potential free contacts, similar to control room instruments.
5.14.2
PLANT ILLUMINATION
All plant lightings are provided with 230 10% V AC power. For maintaining emergency
lighting, emergency lighting fixtures are fed with 110 V DC power feeder, so that in the
event of power failure, minimum light in critical areas such as control room, sub-station
escape route etc. are sustained.
4.14.3
INSTRUMENTATION POWER SYSTEM
Main features of electrical instrumentation power system are described below:
Through a battery bank in main unit sub-station, 110 V DC supply is available to

all solenoid valve infield and auxiliary consoles in Control Room. On auxiliary
consoles are mounted Push Buttons, Running Status, Lamps & Selector Switches
to PLC interlocks etc. few spare outlets of 110 V DC supply are also provided in
control room to carry out miscellaneous testing jobs etc. battery back up will
remain available for a period of 1 hour for UPS & other Instrument requirements.
110 V AC power supply (uninterrupted) is available to all Hard Wire Alarms,

Hooters, Multipoint. Digital Temp. indicators (TJI), Density Analyzers,
Supervisory Computers, Printer, Video Hot copier, DCS monitor (CRT) & hand
indicator controllers.
In the event of power failure, 110 V AC supply will remain available for a
maximum period of 60 min to above instrument to facilitate safe shut down of
process units. If power from main feeder is still not resumed plant instrument will
132
assume safe shut down position according to logic built in PLC. After power is
resumed DCS system and supervisory computer should be booted before reverting
back to normal operations.
5.15
EFFLUENT SYSTEM
All off-spec. hydrocarbon streams contaminated with water, water contaminated with
hydrocarbons/chemicals and such liquid streams that can not be disposed off directly are
collected & treated either for recovery of hydrocarbons or to render them harmless to
receiving stream or for both the purpose. For this purpose, slop system, CBD system,
OWS system, Sewer Water (SWS) and Amine drain system are provided.
These systems are described sequentially as under:
5.15.1 SLOP
Those off-spec. hydrocarbon streams that are not contaminated with water and need to be
disposed off are termed as dry slop. 10 size slop header is provided in the unit to collect
slop from AU-5 that can be routed to GRE /OMS slop tank.
5.15.2 CLOSED BLOW DOWN (CBD)
Refer P & ID No. 3551-05-02-41-0133 Rev.2
3551-05-02-41-0146 Rev.1
Those Hydrocarbon Streams that are either free of water or only slightly contaminated
with water are received in closed Blow Down (CBD) vessel, 05-VV-030. Such
Hydrocarbon streams are generated especially during shut down periods when equipment
& systems are drained under gravity to clear hold up oil. The hydrocarbon in the CBD
vessel should be received at a temp. Well below flash point of lightest component present
inside.
Closed Blow Down network helps reducing amount of hydrocarbon finding its way to
effluent treating facility via OWS during equipment draining. Uncontaminated
hydrocarbons from equipment draining is collected & routed to CBD vessel via CBD
system covering entire unit equipment.
133
Two 6line closed blow down headers run across plot AU-5. These are provided with
clean out pit at header ends with Flushing oil connection to flush heavy congealing
hydrocarbon material accumulated in header, if any. One utility connection is also
provided on each CBD header end, close to FLO connection to flush CBD headers with
any other utility. However, care should be taken to avoid steaming of CBD header, as line
is not designed for steam out conditions due to absence of expansion provisions.
05-VV-030 is provided within AU-5 battery limit. CBD drum is a horizontal drum
located underground in a pit. The drum is provided with a coil through which cooling
water or LP steam can be passed. Hydrocarbons mixed with slight water are allowed to
enter in this drum from where Hydrocarbon is pumped out by CBD pump 05-PA-046 to
existing crude/slop header. LAH-3302 and LAL-3302 are provided to auto start and auto
stop the CBD pump. LI-3301B indicates the level of the drum. TI-3301 & PI-3301
indicates the temp. of the contents in the CBD drum & pressure inside drum. Under
normal condition, it is expected to remain at atmospheric pressure. A small purge of
steam is provided at the vent of the drum to guard against lighting and static electricity
hazards.
One coil is provided inside CBD drum through which either cooling water can be
circulated or LP steam can be introduced. Cooling water shall be introduced to bring
down temp. of hot material drained & accumulated inside vessel while LP steam can be
introduce in the same coil after isolating cooling water to decongeal/heat-up accumulated
heavy material inside vessel & bring it to pump-able viscosity. TI-3302 indicates temp. of
contents going out of CBD vessel.
4.15.3 OILY WATER SEWER (OWS)
This system is also called OWS system is mainly to collect water contaminated with
hydrocarbon oils. Such streams are usually generated during equipment draining &
flushing during routing operation. Streams suitable for OWS are also generated as a result
of floor washing, cleaning of spilled oils etc. Streams suitable for OWS should never be
routed to CBD as it may ultimately lead to receipt of lot of water in slop tanks. Drained
streams at ambient temperature received through OWS fennels etc. are routed to ETP
134
through a combined header. All equipments having CBD connections are normally
provided with OWS/SWS connection on following basis:
All continuous draining (HC bearing streams) having CBD connections are
provided an additional connection to OWS.
All intermittent draining (HC bearing streams) are provided a CBD connection
and connections to OWS.
All non-HC streams are connected to OWS.
Pump base plates, TSV discharges and floor washing are also routed to OWS. Care
should be taken that at no time any spark reaches vapour space of OWS fennels. This
may result in explosion immediately there or elsewhere in network wherever explosive
mixture of Air & Hydrocarbon vapours is present is appropriate for explosion.
5.15.4
SEWER WATER SYSTEM
SWS are similar to OWS and are routed to ETP separately through underground piping.
AT ETP provision to route SWS to OWS is also provided. The SWS thus shares the OWS
load as & when necessary.
Those effluent streams that contain only traces of hydrocarbon or are completely free of
oil should be diverted to SWS.
Storm channel around the plant is an open channel. As streams of storm channel leave the
plant without any separation or treatment, free Hydrocarbons should not be allowed to
escape in storm channel. Elaborate arrangement exists to handle oil free effluent of unit.
Effluent finally escaping through storm sewer without any treatment must meet statutory
specifications for safe disposal.
5.15.5 AMINE DRAIN SYSTEM
Refer P & ID No. 3551-05-02-41-0148 Rev.2
Drained Amine streams from amine absorber (05-CC-006) and Amine
135
Settler (05-VV-004) that is either free of water or oil or slightly contaminated with water
is received in 05-VV-033 (Amine Sump). Amine sump is provided within AU-5 battery
limit.
Accumulated / drained amine is pumped out by Amine pump 05-PA-048A to
Amine Regeneration unit. LI-4801 with LAL/LAH indicates the level of the sump. TG4802 shows the temperatures of the contents in the amine sump.
One coil is provided inside amine pump through LP steam can be introduced to boil out
the contaminated water in amine. TG-4801 and PG-4801 indicates the temp. and pressure
of contents going out of Amine drain sump.
4.15.6 FLARE SYSTEM
Refer P & ID No. 3551-05-02-41-0133 Rev.2, 3551-05-02-41-0145 Rev.1.
In the event of abnormal operating conditions/emergencies, the hydrocarbon operating
system may get pressurized. In order to prevent this pressure form shooting up and
crossing design valves of respective system/equipment and causing accident and/or
equipment damage, it may become necessary to relieve some amount of non-condensable
hydrocarbon vapors to system that renders them harmless. For this purpose, a network of
flare headers is provided for collection of vapors in unit to which all relevant equipments
are connected.
Flare lines should be tested pneumatically because of line support considerations. Entry
of steam and condensate in flare headers should be avoided as it may lead to
extinguishing of main flare
The combined flare header enters flare knock out drum 05-VV-032 for de-entrainment of
condensate droplets. Local instrument is provided on 05-VV-032. LI-032 with LAH/LAL
is provided on flare KOD to indicate high and low condensate level. LSHH/LAHH-3308
also provided in the vessel. It will open SDV-3310 on vessel bottom outlet. Similarly,
LALL-3307 will close SDV-3301 & avoid vapor break through it. CBD vessel requires
manual draining. One isolation valve with a spectacle blind in between has been provided
on flare header at battery limit of the unit. A 2 fuel gas connection has been given to the
flare header for purging purpose RO-4502 is provided on FG purge line to flare to
maintain & control FG pressure entering flare header. The FG purge is provided in flare
header to prevent vacuum formation due to condensation of condensable hydrocarbons
136
on account of to weather temperature change, chilling etc. & to maintain certain

minimum velocity inside flare header.
One 24 flare header serves to collect the pressure relief valve discharges form the AU-5
equipment & certain piping in Hydrocarbon services. Following equipment PSV are
connected with this flare header:
Spent Caustic degasser
05-VV-016
LPG Surge drum
05-VV-020
FO surge drum
05-VV-026
Kero/ATF water wash vessel
05-VV-014
Kero/ATF caustic wash vessel
05-VV-013
Kero/ATF Coalescer
05-VV-015
LPG Coalescer
05-VV-008
LPG water wash vessel
05-VV-007
LPG caustic wash vessel
05-VV-006
Heavy Naphtha coalescer
05-VV-025
Light Naphtha water wash vessel
05-VV-010
LPG drum
05-VV-029
Fuel Gas KOD
05-VV-028
Light Naphtha caustic wash vessel
05-VV-009
Atm. Distillation column
05-CC-001
Naphtha stabilizer
05-CC-005
LPG Amine Absorber
Atm. Column Reflux drum
05-VV-002
Stabilizer Reflux drum
05-VV-003
05-CC-006
Following equipments of AU-5 are also connected with same 24 flare header:
137
Stabilizer OVHD Condensers
05-EE-017A/B/C/D
Atm. Column Reflux pumps
05-PA-005A/B/C
Stabilizer feed pumps
05-PA-006A/B/C
Stabilizer OVHD pumps
05-PA-014A/B
Heavy Naphtha product pumps
05-PA-008A/B
Light Naphtha product pump
05-PA-041A/B
138
CHAPTER-6
NORMAL START-UP PROCEDURE
NORMAL START UP PROCEDURE

6.1
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 of all the units 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 contacting 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 vapor or mists are mixed in flammable proportions and
come in contact 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. Extensive costly down
time on process unit may result. Fires usually follow if the explosive bursts lines or
vessels. Following are the highlights of the operation of AU-5. Operating conditions
given here are for AM crude case. Suitable changes in operating conditions should be
made as per operating conditions given in sec. 5.6.1 for specific of operation.
6.2
BRIEF START-UP PROCEDURE
Start up summary for various process sections is given in following pages to develop a
quick comprehension of start up strategy to be adopted. After mechanical completion of
the unit, it is steam purged for expelling air and kept under fuel gas pressure. After water
draining, cold crude circulation is established and water in the system is swept out. Crude
Charge Heater 05-FF-001 is fired. About 50% of normal flow is maintained through
heater coils. Transfer temp. is raised insteps to 120 C at a rate of 40 0 C/hr. The COT is
maintained for about four hours to remove residual water from the system by
evaporation. The transfer temperature is then further raised to 250 0 C at 300 C/hr. Hot
bolting of flanges and manhole covers likely to remain in hot service is carried out at this
stage by holding the temperature at around 2500 C during this activity.
Top temp. of the column will gradually rise. When the column top temp. reaches more
than 100 C steam will escape from the column and condense in overhead naphtha
condensers. As top temperature rises further, column pressure is slowly raised to its
normal value. Higher pressure will help in better condensation of vapors. As level starts
building up in atmospheric column reflux drum, refluxing can be started after draining
water.
05-FF-001 COT is then further raised to 300 C. The column top temperature and pressure
are maintained constant. When naphtha make increases that is indicated by rising level in
crude column overhead reflux drum V-02, it can be routed to the naphtha stabilizer
column or else it can be slopped. Stripping steam to crude column is admitted at this
stage and unit is brought out of circulation. When levels appear in the crude column side
stream strippers, line up circulating reflux circuits, and maintain strippers levels at about
50%. Water is to be drained before starting the circulating reflux pumps. 05-FF-001 COT
is then further raised to normal value of 375 C. Flow and temp. of all CR streams are
adjusted to maintain proper temp. Profile in the column. Line up all product circuits up to
battery limit. Start respective product pumps when level appears in the strippers. Route
all products to slop header initially.
Start diverting un-stabilized naphtha-to-naphtha stabilizer column. Once sufficient level
(about 70%) is built up in stabilizer column bottom, stabilizer column will be brought on
stream by gradually cutting in the heating medium (gas oil CR) in re-boiler. As
temperature of the stabilizer column rises, pressure will increase and level will appear in
the stabilizer reflux drum. When level appears in the stabilizer reflux drum, start
refluxing. Stabilized naphtha from stabilizer bottom is routed to storage tanks through
naphtha coolers. & LPG from stabilizer top is routed to Horton sphere after amine &
caustic wash.
LR at outlet of atmospheric column bottom is routed to slop header/ storage via product
cooler. When the normal transfer temp. of 375 C has been attained at normal crude feed
rate make necessary adjustments and normalize the operating conditions in atmospheric
section.
6.3
DETAILED START-UP PROCEDURE (AFTER M&I SHUT DOWN)
Preparation for start-up needs a complete review of the start-up procedure by the
operating crew. Activities of atmospheric Unit V should be co-ordinate with off sites,
utilities and other units.
Start up of the unit involves the following consecutive phases.
Preliminary Preparation of the unit
Removal of air for the process systems
Tightness testing to prevent leakage
Fuel gas backup to prevent air ingress
Crude & RCO circuit fill up.
Cold circulation for removal of water
Hot circulation
Bringing the unit on stream
Unit start-up steps are described below:

6.3.1
PRELIMINARY PREPARATION
Prior to actual commissioning of the plant, it should be established that all preparatory
works have been successfully completed and all instrument/equipment are ready to
function. It is to be ensured that:
Blinds are installed as per master blind list. Each removal and insertion of a blind
should be noted and installed by the in-charge.
All vessels, piping, equipment are pressure tested, flushed and ready for service.
All rating equipment such as pumps, motors etc. have undergone functional test
successfully.
All instruments have been checked and calibrated. Controls should be kept on
manual as far as possible.
Instrument loop checking is done.
All safety valves are in position after setting lock open position. Spare valves
should be kept isolated as per P & ID stipulation.
All utility headers are charged.
Flare, amine drain, closed blow down, sewer and flushing oil systems are in
operable condition.
All related units are informed of the start-up plan (RSM / OMS/TPS/Water block)
All pre-commissioning activities are completed.
Fuel oil and fuel gas blinds are removed and both headers charged.
Tracing stream flow to the lines is established.
Tightness, vacuum test and heater refractory dry out will form part of pre-commissioning
activities for the first start-up. For subsequent start-ups the tightness test and vacuum test
can be done in conjunction with the step of elimination of air.
Procedure of commissioning of Utilities / FO / FG / FLARE
1. STEAM
Deblind Battery valve limit U/S flange.
Line all steam trap & its bypass
Slowly open battery limit valve, two thread
Drain out all condensate.
Check for any hammering sound. If it is there reduce steam in take.
When dry steam starts coming from trap bypass, increase battery limit valve
opening.
Close trap bypass.
Keep all the coolers & condensers isolated.
Open battery limit I/L valve.
Open vent of return line.
When total air is displaced, close the vent.
Line up I/L & O/L valve fully.
Commission by the same procedure all coolers & condensers after displacing air.
2. FUEL OIL
This is to be commissioned after FG & Flare header is commissioned.
Check for completeness of all the job.
Keep all the isolation & bypass valves of V26 split range pressure C/V.
Provide steam hose connection at (1) V26 LG drain.(2) at P 45 A/B discharge PG

(3) at furnace IFO PG point Drain.
Line up total IFO circuit.
Close individual FO burner valve.
Bypass Low pressure inter lock.
Open I/L & O/L SOV. & PIC.
Start steaming total circuit & the surge vessel.
Drain condensate from all LPDs and Vent through all HPVs & Vessel vent.
Steam for at least 4 hr to displace air/ maintain system pressure @ 1 kg/cm2
Check for any leak & fix it.
Back up gas in the system by opening V26 make up PIC bypass valve, at the same
time stop steam injection & close all vent & drains.
Bring system pressure to 1.5 Kg/Cm2
Drain water from all LPDs of the circuit & from V26.
Commission V26 PIC.
Take Gas oil in V26.
Establish IFO circulation & continue for 2 hrs.
Drain out water from all LPDs.
Blind/cap all LPDs/HPVS
Stop circulation. Allow to settle water for 2 hr. Drain V26 to minimum level.
Receive VR in V26.
Establish circulation.
Commission HP steam heater & maintain temperature as required.
3. FG COMMISSIONING
Deblind FG In / Out line battery limit valve.
Furnace FG should remain blinded.
All line connected to FG header should be kept isolated by valve.
Provide steam hose connection at LG drain of VV28 FG KOD & of VV29 LPG
drum.
Provide steam hose connection at V26 PIC bleeder.
Start steaming through the all above points. Drain & vent from all available LPDs
& HPVs, & from filter drain.
Steam for 4 hr to displace air / maintain system pressure @ 1 kg/cm2
Check for any leak & fix it.
Back up gas in the system by opening battery limit valve at the same time stop
steam injection & close all vent & drains.
4.
Bring system pressure to 1.5 Kg/Cm2
Drain water from all LPDs of the circuit & from V28/V29
Blind/cap all LPDs/HPVS
FLARE COMMISSIONING
Provide steam connection if is not there at the furthest end of the system
Isolate all PSV/ lines connected to flare header.
Introduce steam & purge the system to flare for 2 hrs, drain condensate from
KOD drain, from B/L valve U/S flange W/O & U/S bleeder.
Maintain pressure 0.5 Kg/Cm2. Check & fix if any leakage is there.
Reduce steaming to minimum & get the B/L valve deblinded
Increase steaming rate & continue for 4 hrs.
Stop steaming & back up gas by opening battery limit valve.
Isolate all drains & vents and get it blinded/capped
Drain water from KOD.
6.3.2
AIR REMOVAL FROM THE PROCESS SYSTEM
Air from various equipment piping etc. is eliminated by steaming of various sections of
the unit can be carried out simultaneously or in a convenient sequence. The following
basic points should be taken care during steaming of the equipment systems.:
Cooling water to the condensers and product coolers to be isolated and water
should be drained out from the condensers, coolers etc.
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.
For the purpose of air removal unit is divided into following circuits for steaming: 1. Crude Preheat Train I Circuit Before Desalter
1a) Old preheat train I before desalter consisting of
PA-01 5HC5001 EE-01 EE-02 EE-03 EE-04EE-05EE-06 Desalter
1b) New preheat train I section before desalter consisting of
EE-103A/B/C
5HC5002 --EE-102A/B
Desalter
EE-104A/B
2. Crude Preheat Train II Circuit After Desalter

2a) Old preheat train II after desalter consisting of
Desalter PA-02 5HC5005 --- EE-07A/B/C EE-08A/B EE-09A/B E10A/B/C/DFurnaceColumn

2b) New preheat train II after Desalter consisting of
EE-105A/B/C/D/E
PA-025HC5006
EE-106A/B/C/D
EE-108A/B
F01 C01
EE-107A/B/C/D
3. CC-01 OVERHEAD CIRCUIT

CC-01 EA001A-H EE16A-F V V-02 PA05- 5FC1505 CC-01
PA6 -FC1701-EE18A-D-C05
4. COLUMN CR CIRCUIT
4a) Top CR Circuit
CC-01 PA-07 EE-02 5FC1501CC-01
4b) SKO CR Old Circuit
CC-01 PA-10 EE-06A/B EE-05A/B - 5FC1502 -- CC-01
5TC1116 is between EE-06A/B and EE-05A/B. This loop also to be steam flushed to
expel air.
4c) SKO CR New Circuit
CC-01 PA-102 EE-104A/B - 5FC5008 CC-01
4d) HSD CR Old Circuit
CC-01PA-12 EE-09A/B 5TC1707 (5FC1704) EE-14 5TC1538(5FC1507)
EE-155FC1503 CC-01.
Both TC 1538/1704 loop flushing to be ensured.
4e) HSD CR new Circuit
CC-01 - PA-104A/B -- EE-108A/B 5FC5010 CC-01
5) PRODUCT RUNDOWN AND SLOP CIRCUIT
5a) LN Product circuit
EE-18A/B
LN from C-5 Bottom5TC1702
EE-19A/B**
EE-18C/D
FC 5106 AU1 rerun Section
HN to LN
**SOV1701HC2001BVV-09HC2002BVV-10PA041A/B5FC2004
LN to AU-I rerun section
LN R/D
5TC1702 loop flushing also is to be ensured.

VV-09 and VV-10 bypass lines also to be steam flushed to expel air
5b) Hy. Naphtha Product Circuit
C1LC1506C2PA-08A/B 5FC5001 EE-102A/B GO R/D (new circuit)
PA-08A/BEE-13D/E/FEE-20VV-25 5FC1807 -HSD
OM&S r/d.
5FC2011 SKO r/d.
5PC2011 LN r/d.
HN r/d to Slop.
5c) SKO Product Circuit
C1LC1508C3PA-09EE-01EE-24/23C-HC2201V13**
**HC2202V14 V15 5FC2206 Salt DryerSKO/LABFS/ATF
FC1809HSD
LR
(While steaming SKO circuit SKO drier to be by passed. SKO drier I/L and O/L B/V to
be thoroughly closed)
5d) HSD Product Circuit
HSD Product Old Circuit
HN / SKO
C1LC1510C4PA11EE-08A/BEE-03EE-23A/B/C
5FC1804
HSD Product new Circuit

C1LC1510C4PA-103EE-106A/B 5FC5009 EE-102A/B- EE-110A/B
coalescer
Coalescer FC 5003 BS2 header
DHDS feed tank
GHC R/D
PC 5003 Euro-III
5e) LR Product Circuit

Old Circuit
PA-51 EE-10 A/B/C/D EE-07A/B/C EE-04 EE-21
New Circuit
PA-51EE-107A/B/C/DEE-105A/B/C/D/EEE-103A/B/C E111A/B
New & old joins together FC1805 hot RCO R/D
SKO / Hy.HSD ex FPU2
E22A/B/C/D FC1806 cold LR R/D
Unit circulation
6)
STABILIZER FEED CIRCUIT

EE-18 A/B
PA-06
**
5FC1701 CC-05
EE-18 C/D
** CRU drag stream, DHDS / Lab / MSQ unit wild Naphtha are joining at D/S of
Fc1701.
9) LPG PRODUCT CIRCUIT
LPG circuit is divided into following circuits
C5 top HIC 1701 E17 A-D V3
V03 top PRC 1701 FG system
V03 bottom PA-14A/B FC1703 C5 reflux
AU4 LPG
V03 bottom PA-14A/B - 5FC2503 SDV2501 VV-20
V20 top PC2501 FG
VV-20 Bottom PA-50 5FC2502 VV-20 (min. cir)
5FC2502 CC-06
C6 top VV-04 VV-06 VV-07 VV-08 5PC1912 LPG r/d
FI 3202 Vaporizer
Amine to and from C06 line steaming is also steamed.
The condenser bypass line through HIC 1701 also to be made air-free.
LP system connections are given at appropriate places on piping & equipment to
introduce LP steam in above sections. Before introducing steam, water to all coolers and
condensers should be isolated and drained. 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. LP steam from hose stations can also be used
to boost up external steam supply. Initially there may be condensation of steam inside
unit equipment due to cold equipment internals. In such conditions, LP steam supply may
need augmentation of small quantity of MP steam through heater pass flows and other
available points. Care should be exercised while using MP steam for steaming to ensure
that none of equipment is subjected to operating conditions exceeding their design
parameters. The low point drains of pipes and equipment should be kept open to remove
condensate. During initial steaming, line rust etc. may frequently keep coming and
chocking the drains may be rather frequent. 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. Once system warms up, less steam will
condense in the system and few steam points may be pinched. Steaming is done till clear
steam stars coming out from all vents. Clear steam venting for at least four hours shall be
an indication of fairly good air removal. Excessively high steaming rate may dislodge
column internals and cause damage. Hence it is a good practice to keep a watch on steam
consumption during steaming.
No steam condensate should be allowed to get accumulated inside unit equipment.
Vigorous steam venting from various points of the unit is described below till be
continued for about 4 hours. It is expected that oxygen will be eliminated at the end of
this period. Samples may be checked from different locations to check that 02 content is
less than 1%.
During the period of steaming, systems should also be checked for leakage. Attend the
leaks by depressurizing the system. Reset and purge as applicable.
When sufficient steam comes out from all the vents and drains reduce steam inlet to
maintain positive pressure.
Following major points may be followed for steaming out of the unit:
a) Admit steam into the feed system by connecting temporary hoses to the crude oil
feed line at the battery limit of unit.
b) Open steam slowly into the system and allow piping and equipment to gradually
warm up. Drain condensate frequently from low points. Steaming should be done
up to crude charge pump suction. Eliminate air through all exchanger vent points
and drain out condensate from all exchanger low points. Flushing oil header
should also be streamed out.
c) A steam hose connection should be provided at the discharge of crude charge
pump for steaming the preheat section up to desalter.
d) Introduce steam into preheat train I/II connection using 2 LP steam downstream
of crude charge pump. Keep watch on desalter pressure, which should be
maintained around 0.5 Kg/cm2 g. If necessary, throttle steam purge desalter safety
valve inlet lines also. Air should be completely purged out from both inlet and out
let lines of each safety valve. Desalter water circuit should not be included for
steaming out. However lines up to mixing valve, and chemical injection lines up
to first isolation valve from desalter should be included for steaming. Allow steam
to vent from desalter top and other high point vents.
e) Line up atmospheric column overhead condensers, and atmospheric column
reflux drum with the column. Ensure water to condensers is isolated and water is
drained out. Open vents of overhead naphtha reflux drum and crude column. Line
up heavy naphtha, Kero, GO strippers and product circuit, and circulating reflux
circuits up to the respective pumps. Keep pump suction and discharge valves
closed for same reasons reason as explained above. Introduce LP steam in the
circuit from permanent steam connections as well as Stripping steam at a
controlled rate to warm up the system.
f) Slowly open some MP steam also into all the passes of atmospheric heater coils
through emergency steam connections (provided at down stream of pass flow
control valves) and in crude column bottom. Also open steam to the crude column
bottom and side strippers via strippers steam lines. MP steam is used as
augmenting stream to adequately carry out steam out. Too high a flow rate of
steam may dislodge the column internals and damage them.
g) Vigorously steam for at least 4 hours and then shut off crude column vent. Allow
steam to vent from atmospheric column reflux drum.
h) Maintain 1.0-1.5 Kg/cm2g pressure in column flash zone by regulating the
quantity of steam being introduced into the system. Drain condensate from low
points and allow system to warm up. Regulate the steam flow to heat up the
system gradually. Continue purging till steam comes out from the top of the crude
column, crude column reflux drum and side stripper vent connections. For
steaming out heavy Naphtha and Kero side strippers, back-up steam form crude
column and vent through 2 utility connection in these strippers. Release
condensates through pump suction strainer flanges, wherever applicable.
i) Back up steam from atmospheric column to preheat train I/II. LP steam from
hose stations can also be connected in desalted crude pump discharge circuit to
boost up external steam supply. Back-up steam from charge heater to preheat
trains-II. Increasing C-001 pressure slightly if required. LP steam from hose
stations can also be connected to pre-flashed crude pump discharge to augment

external steam supply.
j) Line up stabilizer overhead condenser and reflux drum to stabilizer column. Open
vent valves of stabilizer column and its reflux drum, and other high point vents in
piping. De-blind utility LP steam connection at the stabilizer column bottom.
Admit steam slowly by connecting a steam hose. Drain condensate from low
points and allow the system to worm up.
k) When steam comes out from stabilizer top vigorously steam for about half an
hour. Then shut off this vent and allow steam to come out of reflux drum vent.
l) Maintain stabilizer column pressure at 1.0-1.5 Kg/cm 2g by regulating the quantity
or steam. Open the pressure control valve and globe valve on its by-pass line.
Steam for about half an hour then shut off the control valve and the globe valve
mentioned above. Back-up steam into the reflux line and vent from the bleeder
valve up stream of flow control valve.
m) Purge feed line by backing up steam stabilizer column and vent from the bleeder
valve, up stream of feed control valve. LP steam should be backed in stabilizer
feed line up to NRV by connecting a temporary steam hose connection at
conveniently available low point and by by-passing minimum flow control valve
of stabilizer feed pump. During stabilizer purging do steaming of wild DHDS /
LAB naphtha and CRU drag stream up to battery limit by backing from the
column keeping battery valve closed, drain condensate from the bleeder present at
the D/S of battery limit valve.
n) Purge stabilizer bottom outlet circuit up to battery limit.
o) Purge all product and pump around circulating reflux circuits by backing up steam
from respective column. Steam the product circuit up to battery limit and vent
through sample points or any convenient low point drains. It may be necessary to
augment steam supply at the discharge of product pump by connecting temporary
hoses to vent so drain points in the lines. Battery limit valve flange may be wedge
opened for good steaming. Box up the flange under slight steam pressure.
p) Excessive condensation of steam in cold circuits and problems of removing steam
condensate from heater coils, in particular may cause hammering during
steaming. In such cases, it may become necessary to fire the heater at the time of
steaming itself for evaporating water. Commission flare header and fuel gas
header to furnace after removing battery limit blind. Fire the heater at a small rate.
Heater is fired to avoid condensation in tubes and subsequent hammering when
steam is introduced in cold tubes. Maintain firebox temp. at about 250 C. Pilot
burners will be lighted initially. Main burners can be lighted afterwards, if
required. Keep open the vents at crude column top and crude column reflux drum.
q) Steam out LR circuit and all LR product lines up to isolation valve at the battery
limit.
r) Air elimination from product run down circuits in off sites should be done by
filling water in line and displacing the same by products when the same are
available except for water sensitive products like ATF whose run down temp. is
high.
s) Air elimination from water circuits and chemical dosing circuits need not be
carried out except up to first isolation valve where these lines may be subjected to
hydrocarbons.
6.3.3
TIGHTNESS/PRESSURE TEST
For leak testing, tightness test is to be done. Ensure that all piping & equipment vents and
drains closed. Pressurize the system up to 1.0 Kg/cm2 g with LP steam or air and check
for any leak through the flanges / instruments.
Usually for a very big system, pressurization by steam for tightness test proves
convenient. Limitations posed by design pressure design temp. should be strictly adhered.
The leakage identification is normally done visually when steam is used and by soap
bubble test when air is used.
Liquid soap solution may be sprayed poured on all the joints one by one and check for
any bubble formation. If a bubble is formed on joint or flange, there is an air leakage.
Leaks are to be attended after depressurizing. Big leaks can also be identified by pressure
drop identification. In view of large number
of joints requiring leak test by soap
solution, it is suggested that only those systems should be taken up for tightness test by
air which should not be subjected to steaming or are likely to get exposed to vacuum
during vacuum test & normal operation.
Tightness of other systems may be done along with steam purging & pressurizing by
steam. Thus tightness test by air and steam purging tightness test by steam can be carried
out almost parallel, depending on availability of manpower & ease of monitoring.
6.3.4
FUEL GAS BACKUP
Fuel gas is available from off sites for start-up of the unit. Purpose of fuel gas backing
into the system is to drain steam condensate from unit equipment as well as replace steam
with fuel gas. It the absence of fuel gas, condensation of steam may result in vacuum
formation inside unit equipment; most of which may not be designed for such full
vacuum or part vacuum conditions.
I. Steam in system is cut-off slowly and fuel gas is backed in. cutting off steam
results in condensation of steam inside unit equipment due to heat loss from bare
piping and equipment surface. Fuel gas can be backed from separate headers into
atmospheric column, stabilizer. It is advisable to back in fuel gas section wise.
This helps in better monitoring of operation and excessive withdrawal of fuel gas
from FG pool. Adjust gas-backing rate in such a way that fuel gas system is not
disturbed resulting in low fuel gas pressure due to excessive withdrawal during
this operation. Pressure surges during fuel gas backing-up should be avoided.
Ensure that all vents are closed and properly capped / blinded before FG back up.
II. Open the low point drain one by one and drain out condensate completely. Check
list to be prepared to ensure that all drains are made free of condensate. A log
should be kept for drain check showing the time of check, absence of condensate
and initials of the person who made the final check on the drain. Each drain must
be closed and capped / blinded as soon as gas issues form it.
III. Build up pressure in the columns @ 0.5 Kg/Cm2
IV. Back-up gas from column to all the product run down lines through internal and
circulating reflux lines from the column.
V. Drain out water from the following points:
a. Preheat exchangers
b. Transfer line
c. Pump around and reflux lines
d. All product circuits up to battery limit
e. All pumps
f. All exchangers and coolers
VI. Repeat draining operation every half an hour till no more condensate is drained.
Maintain the whole system at 0.5 Kg/cm 2g fuel gas pressure. Ensure all vents are
closed and capped off. Shut all drain points and cap off.
VII. After all the sections have been floated on fuel gas, water is drained from low
point drains. Positive pressure in the system will facilitate draining residual water.
VIII. Air from all the hydrocarbon system must be removed thoroughly before
proceeding for fuel gas back up.
IX. Before backing in fuel gas into the system, flare header inside the unit should be
charged and flare should be activated. Fuel gas purge to flare header should be
established. Fuel gas into furnace fuel piping should be charged at this stage only
if proper monitoring is available. Cooling water circulation is started through all
coolers and condensers.
X. Removal of water from the system is an important step for smooth start-up.
XI. Before admitting fuel gas into the system, all vents and drains in hydrocarbon
service will be closed. Steam entering the system is throttled slowly. Furnace fire
are cut off. Cooling water is commissioned to the overhead condensers and
coolers and air coolers started. During gas backing ensure that vacuum is not
formed in the system due to condensation of steam.
XII. As the system cools, condensate will accumulate. The drain at each low point is
opened and the condensate is drained. Never leave open drains unattended. Each
drain, which is opened and checked, should be listed in the start-up procedure. A
log should be kept for the draining activities showing time of check and absence
of condensate. Each drain must be closed as soon as gas issue out from it. When
the draining is complete the system is ready to take crude oil.
Major steps for fuel gas backing into the systems are as under:
i)
Reduce steam to the various points in all the columns,

furnace coils & at points receiving steam through
temporary hoses. Close all drains and vents except any
one vent at a convenient point to approach and operate
for venting steam to maintain system pressure.
ii)
Close all the vents one by one. Adjust steam inlet rate to
maintain system pressure about 0.5 Kg/cm2g cap off all
vents properly to avoid leakage of gas through these
points. Throttle the drain valves to allow only condensate
to flow to keep the system hot. Keep watch on the system
pressure. Adjust steam inlet if necessary.
iii)
Commission flare header and flare header should now be

lined up to various equipment.
iv)
Open any of the pressure control valves at FG lines on

atmospheric column reflux drum, stabilize reflux drum, in
normal mode to admit fuel gas into the system. Excess
FG pressure may be released to flare as and when
required by operating the control valve to flare. Close the
vent valve which was kept open to a convenient point as
selected and described at point (I) above to maintain
system pressure and let out non condensable.
v)
Maintain the pressure in the system around 0.5/1.0

Kg/cm2g.
6.3.5
COLD CIRCULATION
The purpose of cold circulation is further water removal from piping network and bottom
of equipment, which could not be removed during water draining. Cold oil carries liquid
water into low points of the circuit. During circulation drain at low points (preferably
from desalter and column bottom pump) must be opened frequently to ensure that no
more free water is drained. The circulation rate must be sufficiently high to sweep the
water and not merely flow over it. All plugged drains must be cleared for draining during
circulation. While draining water, unnecessary loss of oil to OWS should be avoided for
reasons of safety and economy. Normally one hour of settling time is allowed after every
four hours of circulation. Settling time may be reduced progressively at advanced stages
of cold circulation. Cold oil circulation gives further opportunity of trying out various
pumps and control systems prior to going up on temp. in sequence of start up. All
instruments should be commissioned during cold crude oil circulation. It should be
ensured that flow rate during cold circulation remains well above minimum continuous
flow through various pumps involved, as suggested by pump vendors. Similarly flow
through control valve should be maintained above minimum flow stipulated in control
valve data sheets to avoid possible chattering.
6.3.5.1 Crude Distillation Unit

For atmospheric crude distillation unit, crude oil is used for cold oil circulation. Crude
oil flow in the equipment and piping carries away free water with it from crude as
elaborated ahead. Water carried away by crude can be separated from crude in crude tank.
Following major points may be followed for cold circulation in the CDU section:
(a)
Receiving crude in the Unit
Crude tank that will feed the unit will be prepared in advance by through draining of
water. Sample will be analyzed and dips will be taken. It will then be lined up to the unit.
i)
Open suction & discharge valves of off sites crude

transfer pumps and crude charge pumps 05-PA001A/B/C/D/E.
ii)
Slowly charge crude from the crude tanks.
iii)
Crude will begin to flow under gravity into the line and
displace gas. This gas is vented out from the crude pump
vents and other high point vents of piping in off sites

between crude tank outlet & crude pump suction.
iv)
In subsequent start-ups this operation may not be

required, as offsite crude line up to the battery limit will
always remain full.
v)
Make sure that electrical supply to desalter is cut off.

Open the discharge valve of crude charge pump and
allow the crude to flow to the desalter.
vi)
Alternatively, desalter can be kept filled with gas and oil

by passed. Desalter shall be commissioned separately.
vii)
Fill the circuit up to crude charge heater via crude preheat

trains and desalted crude pumps. Vent the trapped gas
from each of the crude preheat exchangers through hose
connected to the vents on the heat exchangers.
viii)
When flow of crude oil in off sites piping is no longer

possible under gravity, start off site crude transfer pump,
crude charge pump and then the desalted crude pump.
Continue charging crude oil at a slow rate to atmospheric
column bottom via atmospheric heater.
ix)
Regulate the crude flow through heater coil in such a way

that crude flow to unit. Also divide the flow equally
through all crude pre heat exchanger trains by operating
respective FV & HV.
x)
Release displace fuel gas into the flare from atmospheric

column reflux drum, and do not exceed column pressure
beyond 1.0 Kg/cm2g. Operation all the pumps above their
respective minimum continuous flows is essential.
xi)
If desalter is included in circulation, care fully operate

desalter (second stage) pressure controller PIC-1206 on
manual and build up a pressure of 8 to 9 Kg/cm2g in the
second stage desalter outlet line.
(b)
Establishing Cold Circulation
Once level in the crude column has been built up, establish cold circulation as per the
lineup given below.
Crude Tank --->Crude Booster Pump in Offsite ---- Crude Pump in Unit PA-01 -->
Crude Preheat Train Circuit Before Desalter (including both New and Old Preheat Train)
----> Desalter ----> Crude Preheat Train Circuit After Desalter (including both New and
Old Preheat Train) -----> Furnace -----> Column -----> Column Bottom Pump PA51RCO R/D circuit Crude Pump suction
i. Stabilize the second stage desalter pressure at around 9.5-11.5
Kg/cm2g and put PIC-1206 on auto. Observe the performance of
all control valves in the circuit. Crude oil will gradually displace
fuel gas and build up level in crude column. Crude oil passes
through crude preheat train I, desalter, crude preheat train II,
atmospheric furnaces and then to atmospheric column bottom.
ii)
Long Residue pumps take suction from material

accumulated in atmospheric column bottom. When
sufficient level is built up in the column bottom open
suction and discharge valves of LR pumps. Fill up all the
LR circuit exchangers by crude with gravity displacing
the trapped gas from each of the LR exchangers through
hose connected to the vents on the heat exchangers.
iii)
Line up LR rundown circuit up to R/D Control valve.

Keeping battery limit side valve closed, line up for
circulation (To P01 pump suction line). Start LR pump,
circulation should be continued for at least 6-8 hours to
displace free water. Ensure that there is no flow of crude
oil to LR storage.
iv)
Keep watch on crude column level and maintain it around

50% by adjusting the LR pump discharge flow rate.
Crude stream flow can be controlled by manipulating
flow and level control valves falling on presently selected

crude circulating circuit.
v)
Maintain crude column top pressure between 0.5 to 1.0

Kg/cm2g during cold circulation. By operating PIC-1504
(05-CC-001 top pressure controller) acting on incoming
FG line to reflux drum and outgoing flare line from reflux
drum, column top pressure can be maintained to desired
valve. Displaced FG will be released to flare form reflux
drum.
vi)
Desalter and few heat exchangers can be bypasses during

initial commissioning.
vii)
Active exchanger by passes & control valve by passes

also to displace free water trapped in these sections.
viii)
After establishing and maintaining cold crude oil

circulation for 4-6 hrs. Stop all pumps in circulation
service and allow settling for 2-4 hours. Carry out water
draining from all the low points in the system including
column and exchangers. Restart cold crude circulation.
Repeat the operation till all the free water in the system is
removed. This operation of circulation, stopping, settling
and draining will be repeated till no further water
separates out. A check of water content of circulating
crude oil is useful information.
6.3.6
HOT CIRCULATION
Line up CDU for the hot circulation as per the following.

6.3.6.1 Atmospheric Section
CDU commissioning can be accomplished by completing following steps once cold
circulation has been established and units are ready for hot circulation.
Firing the Heater
Raising Temperature to 120 C
(a)
Raising Temperature to normal COT
Commissioning of Desalter
Firing the Heater
When the cold circulation has been well established and water in the atmospheric system
has been thoroughly drained out, 05-FF-001 firing will be done as per recommended
procedure spelt out in heater operating manual
Following to be ensured again which pertains primarily to commissioning of utilities and
proper lining up of unit before firing the header:
i)
Cooling water flow is established in all product coolers. Cooling

water flow to overhead condensers should be done gradually to
avoid sudden condensation of fuel gas leading to subsequent
depressurization of column/strippers etc. Fuel gas purge to be
augmented if required.
ii)
Tracing steam is commissioned. Before warming up the stand-by

pump of any hot service through the 3/4 warm-up line across
NRV of stand-by pump, it is to be ensured that suction valve of
stand by pump is kept crack open or fully open. This is to avoid
pressurization of the pump and its suction line to the discharge
pressure of running pump. This operation ensures flow of hot fluid
back to pump suction, thus attaining good warm-up of pump body.
iii)
Set level controllers of HN, Kerosene, GO strippers in auto mode.

Check that level control valves remain open, as there is no level in
the strippers.
iv)
All safety valve isolation is kept lock opened. Spare to be kept

isolated as per P & ID stipulations.
v)
Charge atomizing steam header to the heater. Commission fuel oil

supply and return lines and establish FO circulation.
vi)
All safety interlocks/trips on combustion air circuits, heater pass

flow and heater body should be made operation. However, few
selective trips may be bypassed appropriately for short duration
only to achieve steady operating condition. The bypassed trips

should again be taken inline at earlier opportunity. Proper
recording and communication should b e maintained regarding
bypassed or in effective trips.
vii)
Exchangers subjected to hot crude shall have TSV protection; it is

better to keep isolation valves on other heating media open to
allow thermal relief to liquid still not in operation.
(b)

i)
Fire the pilot burners of atmospheric heater one by one as

per heater start up procedure. After warming up the
heater, main FO or FG burners can be lit up. The rate of
increase of transfer line temperature will be restricted to
30 C per hour. When the transfer line temperature reaches
120 C at heater outlet hold firing rate to maintain this
temperature for four hours. At this COT, column bottom
temperature shall be around 90-100 C.
ii)
Bring down column pressure to 0.5 Kg/cm2g or less to

facilitate water removal as steam hydrocarbon vapor
mixture from the column overhead. Keep watch on
column pressure. The excess pressure will be released to
flare. Higher column pressure may interface with
evaporation of hydrocarbons and water vapor. Monitor all
flow, temp. and pressure readings of atmospheric column
and heater.
iii)
While raising the temp. it will be observed that crude

passing through preheat train I, II is gaining heat from the
LR. Check for presence of water in product and
circulating pumps suction and drain out according to
requirement.
iv)
Watch performance of LR pump as its performance may

become unsteady initially with rise in crude oil temp.
v)
Maintain crude column level by matching LR pump

discharge rate with crude in take to the unit crude flow to
be maintained at about 50% to 60% of normal through
put.
vi)
At the end of four hours, carry out test for water content
in circulating crude oil. Water content equal to or less
than that of tank sample is indication of good water
removal. A value of about 0.2% wt. of water content is
often obtained at this stage of hot circulation & is
acceptable.
c) Raising Temperature to 250 C

i)
Purpose of raising the temp. to 250 C and holding at this value is to

try out all equipment, instruments and controls in actually hot service
and rectify the faults if any. After holding the temp. at 120 C for four
hours, transfer temp. will be further raised at a rate of 30 C/hr to 150
C and held at this temp. for four hours with column top pressure held
at 0.5 Kg/cm2g. Most of water in circulating crude shall be evaporated
during this period. Then raise COT to 250 C at a rate of 30 C/hr.
ii)
Closely watch all instrument reading and check their performance. Recalibration of few of the instruments may be necessary.
iii)
Hold crude column at about 50% bottom level. Vary LR pump

discharge rate if necessary to maintain bottom level.
iv)
Top temp. of the column will rise gradually. When it reaches more
than 100 C steam in the atmospheric column will not condensate and
will escape from column top. It will finally condensate in the column
overhead condensers and accumulate in reflux drum.
v)
When level appears in the reflux drum check for presence of water and
drain it out. Local check for levels must be made.
vi)
As top temp. Rises further, slowly raise column pressure a little at a

time to its normal valve of 1.5/2.14 Kg/cm2g. After steadying out
column top pressure, put pressure controller PIC-1504 on auto to
maintain this pressure. Higher pressure will help in condensation of
vapor that would otherwise escape to flare. Increase of column top
pressure will result in increase of top temp. due to increase in boiling
point and dew point temp. of the vapors, provided all other parameters
are constant.
vii)
Check for appearance of oil level in atmospheric column reflux drum.

Start total top refluxing when oil level builds up. Watch water and oil
levels in column reflux drum. Commission water and oil level
controller LIC-1602 and LIC-1606 and put them on auto to hold about
50% level in vessel and boot respectively. Watch performance of these
instruments closely.
viii)
Care is to be taken so that water does not go in the top reflux stream.
Refluxing will be started at a small rate.
ix)
Start hot bolting in the transfer line, LR circuit, column bottom

manhole and other flanges in hot service which were disturbed during
S/D where normal operating temp. exceeds 200 C.
x)
(d)
Cap off all drains securely that were used to drain water.
Raising Temperature to 300 C/Normal COT

i. When hot bolting of the portion where temp. reaches to 200 C is
over, start raising the transfer temp. at 30 C/hr and continue hot
bolting in other areas where temp. touches 200 C. Hold the
column bottom temp. around 280 C till hot bolting in all the
flanges is over.
ii)
Regulate top refluxing to maintain a column top temp. at 110 C.

When naphtha make increases as indicated by rising oil level in
reflux drum, route this product to slop till stabilizer column is
commissioned.
iii)
See column top temp. and pressure reaches its normal value, line
up all circulating reflux circuit, starting from HN to GO CR in
descending order. Ensure that there is no water in any of
circulating reflux circuits by draining. Start refluxing at minimum
flow rate after draining water from pump drain. This operation
shall gradually stream line temp. profile in the column.
iv)
When level appears in inside strippers, drain water from respective

pump suction and line up product pump discharge (HN, Kerosene,
GO) to slop header. Heating medium (GO CR) to stabilizer reboiler 05-EE-014 should not be commissioned. When sufficient
level is built up in the side strippers (about 40%) start withdrawing
off spec. products to slop header through respective product
coolers, which is ultimately lined up to crude storage tank. When
flows stabilize, all level control loops in HN, Kerosene, GO (LIC1506/1508/1510) CRs can be put on auto.
v)
At the time of commissioning circulating reflux flows, hot media

will be flowing through the heat exchangers of crude preheat train
I, II This will necessitate the flow adjustment of crude flow
through preheat trains I, II to bring parity between outlet temp. of
both the sections of same train.
vi)
Activate atmospheric column bottom stripping steam header by

draining condensate from drain points provided.
vii)
100
compliance
to
ensure
condensate
is
properly
drained from the stripping steam headers.

viii)
When crude column bottom temp reaches 300 C admit stripping

steam, about 250 Kg/hr in each step and bring unit out of
circulation.
ix)
With the introduction of stripping steam, amount of vapor flowing

to the upper section will go up. Adjust cooling water to overhead
condenser to maintain reflux temp. at about 45 C. Introduction of
stripping steam at crude column bottom will establish proper mass
transfer profile. Sour water circuit from reflux drum needs to be

rechecked for its heating at this point of time. Steam to product
strippers can also be introduced.
x)
LR should be finally cooled in 05-EE-021 & 05-EE-022A/B/C/D

before sending to storage. Divert all other side products to slop
tank through the slop header.
xi)
Watch column top pressure and temp. read just circulating refluxes
and top reflux if necessary. Raise the circulating reflux by
adjusting to 60-70% of its normal flow rate. Adjust return temp. of
top reflux, top CR, kerosene CR, GO CR at 40,94/95,140.6/138.4
and 71.1/170.7 C respectively by manipulating respective
exchanger by pass valves. Various duty controllers should not be
put in operation till steady state operating conditions are
established.
xii)
Start adjusting withdrawal rate of HN, Kerosene/ATF, GO by

regulating FIC-1507, FIC-1508, FIC-1509 for maintain proper
draw off temp. of HN, Kerosene and GO respectively.
xiii)
When the coil outlet temp. reaches its normal value 375 C, put
TIC-1416 on auto/cascade with fuel oil / gas firing controller and
make all operating conditions steady. Commission hot medium to
HN stripper re-boiler. Normalize stripping steam flow to Kero/ATF
and GO stripper. Ensure that condensate is already drained before
allowing steam flow to the strippers.
xiv)
The HN liquid is stripped off its lighter by GO product stream as

re-boiling medium and its flow is regulated by FIC-1507.
xv)
Adjust cooling water, if necessary to all product coolers to

maintain run-down temp. of HN, Kerosene, GO at around 40 C.
Care should be taken to ensure that combined slop temp. ex CDU
does not exceed 60C while leaving the unit or else it can lead to
boil over in crude tank.
6.3.7
COMMISSIONING OF DESALTERS
Desalter can be brought into service at this stage. Stabilize desalter pressure at about 9.511.5 Kg/cm2g by PIC-1206. Control the desalter temp. at about 130 C by adjusting the all
hot medium streams passing through preheat train I. Variation in Hy. Naphtha CR,
Kero/ATF CR GO temp. Due to above adjustments by way of operation of exchanger
bypass will be taken care of by respective product coolers.
i)
Check oil water interface level through the try lines and
check for any presence of vapour
ii)
Switch on the power supply to desalters. Voltmeters and

ammeters should indicate high voltage and low amperage
respectively.
iii)
Line up service water/stripped water injection at desalter

inlet and start injection at about 4% (by volume) of crude
throughput or as per specification of desalter vendor. Also
line up effluent water circuit.
iv)
Start caustic injection pumps and inject caustic solution

into the crude fed to CDU, to maintain a pH of about 7 in
the effluent brine from the desalters.
v)
Start Demulsifier injection pump and inject Demulsifier

at crude feed to CDU at the rate of about 1.5 to 2 ppm on
crude
charge.
The
rate
of
injection
to
be
confirmed/readjusted based on actual operating data.

vi)
Commission desalter level controllers ILIC-1201 and

ILIC-1202 and route desalter water to effluent treatment
plant via brine coolers.
vii)
Take samples of crude before and after desalter for

getting following performance:
a) Salt content as NaCl at the outlet should be <0.5 ptb of
salt content of raw crude whichever is greater.
b) The insoluble water content in desalted crude should
be less than 0.2% (max) by volume and the effluent
brine should have oil content less than 200 ppm.

6.3.8
NORMALIZATION OF OPERATING CONDITIONS
At this stage normal operating conditions are established for atmospheric section at turn
down capacity of normal throughput of the plant. All products are routed to their
respective storage tanks/down stream plants.
Feed rate of the plant is to be raised to its normal capacity in steps as outlined below.
i)
When the atmospheric heater transfer line temp. of 375 C

has been attained maintain this temp. and make further
adjustments. Adjust heater firing to maintain 375 C at
heater outlet at turn down operating conditions.
ii)
Increase stripping steam to side stream by adjusting

individuals FICs to achieve designed ratio of steam to
hydrocarbons. Make adjustment in the stripping steam
flow to the atmospheric column bottom also.
iii)
Adjust draw off flows of HN, Kerosene and GO to

maintain respective draw off temperatures. Raise
circulating refluxes proportionately to maintain column
temp. profile.
iv)
When conditions have become steady take all remaining

controls on auto one by one. Particular care should be
taken in case of heater control. Safety shutdown system
for low fuel gas pressure (which was on bypass initially)
should be made operative.
v)
Make adjustment on operating parameters to bring the

products on spec. check samples of all products. Check
for normal product run down temp.
vi)
When products are on spec. rout them to respective tank

own stream units as per agreed routings with off sites
section. These routings should be recoded meticulously
and should be known to unit operators. If any product
goes off spec. divert it to slop tank (except LPG) and

make adjustments as detailed under operating variables to
bring the product to specification.
vii)
Raise the throughput further only when all products are

on spec. raise the throughput in steps in accordance with
the procedure outlined. Establish steady operating
conditions in each step. Increase the throughput to normal
rate, as per requirement and maintain the parameters as
given in the section. Steady out transfer temp. of
atmospheric furnace at 375 C check all furnace controls
for proper functioning raise the feed to atmospheric
furnaces by 25 M3/hr.
viii)
Check local temp. pressure , flow and level of different

equipment and streams please keep watch on running
equipment such as pumps, heaters and other equipment .
Look for leaks, hot spot and any other abnormalities.
ix)
Record and analyses two hourly log readings and report

any abnormal conditions to the next higher decisionmaking supervisor immediately.
6.3.9
BRINGING UP NAPHTHA STABILISER SYSTEM
Commission PIC-1701 (stabilizer top pressure) on auto, with set point at about 9
Kg/cm2g. PIC-1701 being controller with characteristics so selected that initially the
control valve PV-1701 will remain full closed. If pressure increase still persists, PV-1701
shall also start opening and go to full open condition to relieve maximum fuel gas from
stabilizer reflux drum.
i)
Start admitting naphtha form crude column reflux drum into

Naphtha Stabilizer bottom with the help of stabilizer feed pumps.
Build up about 75% level in stabilizer bottom through FIC-1701. It
can be cascaded with LIC-1606 (reflux drum level controller) once
steady operating conditions are achieved in stabilizer section.
ii)
To commission stabilizer re-boiler divert some quantity of GO CR

slowly to raise the temp. gradually at the rate of 10-15 0 C/hr
through stabilizer re-boiler 05-EE-014 by adjusting FV-1704 this
shall increase stabilizer bottom temp. gradually. Do not exceed rise
in temp. beyond 20 C/hr.
iii)
Stabilizer pressure will tend to rise as the bottom stream gets

heated by GO CR. When normal stabilizer pressure (8/12 Kg/cm 2g
at PIC-1701) is reached, normal working of the column will be
established. During the process of heating up, stabilizer bottom
level will fall if rate of heating is too fast. Necessary make up
should be done through FIC-1701.
iv)
Raise gradually stabilizer trey temp. by adjusting TIC-1703/FIC1704. When tray temp. stabilizes at around 170 C put TIC-1703 on
auto. Sudden increase of temp. and pressure will destabilize the
column making heavy fraction to go to the top, requiring longer
time to stabilize. So increase or decrease of temp. or pressure of
stabilizer shall be done gradually.
v)
When level appears in stabilizer reflux drum, drain water from

boot and stabilizer reflux/LPG pumps suction. Start total refluxing
to the column keeping FIC-1703 on manual control. Maintain top
temp. at about 85 C.(Top Temperature to be maintained depending
on LPG weathering).Start diverting LPG when there is excess
accumulation in reflux drum to caustic wash system.
vi)
Divert stabilizer column bottom to storage/slops via stabilizer

feed/stabilizer bottom exchanger, Naphtha stabilizer cooler. Till
caustic and water circulation is established properly, Naphtha
stream from stabilizer bottom remains routed to slop or other
destinations bypassing the wash facilities.
vii)
Slowly divert naphtha to caustic wash and water wash vessels.

Complete filling of the vessel, without leave in any vapor space,
shall be indicated by LI-2004B followed by sharp rise in pressure.
Care should be taken to avoid popping of the PSV on the vessel.

Receive 10% solution caustic & water up to 25 to 30 % level in
respective wash vessel.. Quantity of caustic make up in the vessel
should be verified with flow indication FI-2001B on make up line.
viii)
Caustic circulation in the vessel is established by operating caustic

circulation pumps 05-PA-019A/B through FI-2001B. HV-2001 at
vessel inlet should be kept to full open position by operating HIC2001.
ix)
Similarly water circulation is established in water wash vessel 05VV-010.
x)
Naphtha stream from light naphtha cooler is routed to 05-VV-009

and 05-VV-010 by operating HIC-2001/HIC-2002. Specifications
of outgoing naphtha should be compared with specified stream
properties to establish efficiency of washing.
xi)
When caustic strength goes down to less than 1% spent caustic

should be drained to spent caustic drum VV-16 and fresh caustic
should be made up.
xii)
Water from water wash vessel shall also be drained to spent caustic
drum VV-16. However draining of wash water to this vessel shall
be indicated in inter-phase level LI-2008B on the water wash
vessel. Quantity of water drained should be made up by running
water make up pumps 05-PA-040A/B. Streams collected in the
degasser vessel after degassing shall be sent to ETP by spent
caustic pumps 05-PA-043A/B.
6.4
STEPS INVOLVED IN START UP FROM BOTTLED UP CONDITION
1.
Inform RSM/OMS/TPS & other units about start up.
2.
Check & line up for close crude circulation

PA-01 5HC5001 EE-01 EE-02 EE-03 EE-04EE-05EE-06 Desalter
EE-103A/B/C
5HC5002 --EE-102A/B
Desalter
EE-104A/B
Desalter
PA-025HC5005 EE-07A/B/CEE-08A/BEE-09A/B
EE10A/B/C/DFF-01CC-01
PA-025HC5006 EE-105A/B/C/D EE-108A/B

EE-106A/B/C/D
FF-01CC-01
EE-107A/B/C/D
PA-51 EE-10 A/B/C/D EE-07A/B/C EE-04 EE-21

PA-51EE-107A/B/C/DEE-105A/B/C/D/EEE-103A/B/C E111A/B
New & Old joins together FC1805 hot RCO R/D
E22A/B/C/D FC1806 cold LR R/D
Unit circulation
3. Establish circulation & maintain crude flow @ 6000mt/day
4. Maintain desalter pressure 8 9 kg/cm2 by operating PC 1206
5. Prepare/ top up chemical solution (NaOH, Ahuralan, Demulsifier, Ammonia)
6. Check & isolate all FO/FG/Pilot burner valve.
7. Establish IFO circulation.
8. Take low pass flow inter lock in line.
9. Check for any leak / abnormality in plant, fix it.
10. Deblind FG.
11. Fully open STD.
12. Purge heater box with steam & bring negative draft inside.
13. Start FD fan.
14. Light all pilot burner one by one. If the first one does not light in first shot, isolate
gas & purge box with steam again.
15. light gas & FO burner as per requirement & raise COT @ 40 0C/hr.
16. Raise temp. to 1200C. Hold for 2 hrs to strip off water to over head reflux drum.
17. Raise temperature to 2500C.
18. With the increase of temperature column top pressure will increase. Maintain top
pressure 1.5/2.14 Kg/cm2g by PIC-1504.
19. Switch on desalter, Drain out accumulated water fro desalter.
20. Adjust RCO cooler O/L temp to 50-600C
21. When level builds up in V02, Drain water & start reflux pump.
22. Maintain top temperature.
23. Check & get hot bolting done the leaky/smoky flanges.
24. Raise temperature to get 3000C C01 bottom.
25. Drain condensate & introduce stripping steam to C01/C03/C04.
26. Bring unit out of circulation by routing RCO to R/D. Adjust RCO cooler to get
required R/D temperature.
27. Rout V02 sour water to SRU.
28. Start CR pumps when level appears in stripper & adjust column condition.
29. Start product pump & rout initially to off spec. tank. Adjust draw temperature.
30. Diver V2 gasoline to stabilizer.
31. Introduce slowly heat to Stabilizer & HN stripper Reboiler.
32. Adjust column condition.
33. Commission Amine wash system.
34. Commission LPG / Naphtha & SKO naphtha caustic wash system.
35. Rout LPG through amine & caustic wash system to Horton sphere.
36. Rout LN / SKO through caustic wash system.
37. Send product sample to laboratory. When certified rout to on grade R/D tank.
38. Take all inter locks in line.
39. Slowly increase TPut as per requirement.
40. Start Stripped sour water injection to desalter.
41. Start all chemical injection. Maintain PH
42. Start ID fan. When its suction exceeds 1600C, close STD as required.
6.5
CHECK LIST FOR UNIT NORMAL START UP FROM BOTTLED UP

CONDITION
Sl.No
Description
Action by
InformRSM/OMS/TPS/Water
Block/Laboratory about Start up
Check & rectify all furnace igniter
Check & commission all utilities, if
decommissioned.
Check all FG and FO burner valves. These
should tight shut.
Bypass IFO low pressure inter lock &
establish IFO circulation through furnace by
opening IFO C/V & return BPC.
Adjust to obtain IFO required temperature.
Establish IFO circulation, first with RCO
then switch over to VR.
Prepare / top up chemical solution
Ahuralan
Ammonia
Ammonical caustic
Demulsifier
Check all motors for power supply
S/I
2
3
4
5
6
7
8
9.
10.
11
12
Establish cold circulation with BH/NIG

crude at 50% Tput
Purge F01 with steam for 20 minutes.
Check / confirm about negative draft inside
furnace
Deblind furnace FG line.
Stop purging steam & start FD fan
Field Opr
Panel/Field
Opr.
Field Opr
Panel/Field
Opr
Panel/Field
Opr
Field Opr
Pump/Field
Opr.
Panel/Field
Opr
Panel/Field
Opr.
S/I
Panel/Field
Done
YES/
NO
Remarks
13
14
15
16
17
18
19
Sl.No
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Light up all pilot burners with the help of

igniter
Bypass low FG pressure inter lock & Light
gas burner & heat up to 120 deg C @ 30 to
40 deg C / Hrs
Switch on desalter
Take low pass flow inter lock in line
Drain water from all stagnant line LPDs.
Have a round in the unit to check for any
leakage & fix it, if any.
Raise temperature to 250 deg C @ 40 deg
C/Hrs.
Description
Opr
Field Opr
Panel/Field
Opr.
Field Opr
Panel Opr.
Field Opr
S/I/Field
Opr.
Panel/ Field
Opr
Action by
Get hot bolting done on Smoky / Leaky

S/I
flanges, if any
Maintain RCO cooler O/L temp. @ 50 60 0 Panel/Field
C
Opr.
Take oil burner in line as per requirement
Field Opr.
Raise Coil Outlet Temp. to 300 deg C @ 40 0 Panel/Field
C /hrs
Opr.
Introduce stripping steam & take the unit out Panel/Field
of circulation
Opr.
Raise COT, as per requirement to normalize Panel/Field
the unit.
Opr.
Flush circulation line
Field Opr.
Start Chemical injection
Field Opr.
Start DM water injection to desalter and
Field Opr.
demulsifier dosing I
When level build up in V2 Drain water Pump/Field
completely.
Opr.
Start sour water pump. Divert it to SRU. Pump/Field
Commission inter-phase level controller
Opr
Start reflux pump / Maintain top temperature Pump/Panel
Opr
Start product & CR pump when level
Pump Opr
appears in stripper
Establish column condition
Panel Opr.
inform to GRE S/I and route all products to
S/I/
off grade tank to GRE Slop tanks
Field Opr.
Divert V2 gasoline to C5. Build up level in Panel/Pump
C5. Introduce Heating media to bottom
Opr.
reboiler & bring up slowly bottom
Done
YES/
NO
Remarks
36
37
38
temperature up to required one. Adjust

Stabilizer operating condition.
When level builds up in V03, drain out water
completely.
Start reflux pump & establish stabilizer
condition
Commission LPG caustic wash system &
route LPG to Horton sphere.
Field Opr.
Pump/Panel
Opr
Panel
/Field /Pump
Opr.
39
Commission Naptha caustic wash system &

route Naptha to R/D ( GN tank)
Panel
/Field /Pump
Opr.
40
Commission Amine ( C6) system, cocoordinating with SRU shift In charge.

Start ID fan & bring furnace on balanced
draft mode.
S/I/Panel/Fie
ld Opr.
Panel /Field
Opr.
Adjust TPut as per requirement

Sent all product samples to Laboratory. If
certified, route as per RSM
Take all inter locks in line
Panel Opr.
Panel/Pump
Opr.
Panel Opr.
41
42
43
44
NORMAL SHUT DOWN PROCEDURE
CHAPTER-7
NORMAL SHUTDOWN PROCEDURE
NORMAL SHUTDOWN PROCEDURE

7.1
GENERAL
In this section, procedure for planned shut down is discussed. While shutting down all
process units simultaneously or any section of the process unit, care should be taken not
to admit air into the system until all hydrocarbon vapors have been removed.
It is important that process unit operates involved in shut down understand the purpose
and effect of each activity. In particular, operators should make sure that their actions will
not result in creation of hazardous conditions either because actions taken were wrong or
these were taken at wrong time.
Rate of temperature drop in process unit equipment should not be very sharp to induce
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 plan. It is to be ensured that
a slop tank and one crude tank having sufficient space is available to receive the slops/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. Adequate ullage should be ensured
in off sites slop tank.
7.2
BRIEF SHUT DOWN PROCEDURE
The throughout to CDU will be gradually reduced to about 50% of normal capacity or
turn down capacity of the unit and all other flow rates shall be reduced on pro data basis
wherever applicable to be suitable for operation of the unit on reduced capacity.
Necessary adjustment will be done in reflux rates withdrawal rates in all the sections of
the unit to keep the product on specification.
Number of burners will be reduced in the CDU, furnaces if necessary. Chemical injection
will be discontinued.
Adjustment will be done in stabilizer column operation to stop production of LPG, which
will be released to fuel gas system. All caustic wash sections will be bypassed. Desalter
will be taken out of service.
COT of atmospheric section will be gradually reduced to 300 C . Divert product to slop
when they become off spec. Cut off column bottom stripping steam. Re-circulate LR
along with other product through slop header. Back up FG when pressure tends to
become low. Cut off fire in atmospheric heater and allow to cool down while on
circulation. When system is sufficiently cooled, empty out all equipment to slop. Flush
out fuel oil system.
Steam out columns exchangers etc. to remove hydrocarbon vapours etc. if opening of the
equipment in hydrocarbon service is planned.
7.3
DETAILED SHUT DOWN PROCEDURE
The procedure indicated below will ensure a safe and smooth shut down of the units but
is not mandatory.
Plan chemical solution preparation in advance so that very little solution is drained after
unit is shut down for M&I.
The important steps in the shutdown procedure are summarized as below:
Reduction of feed rate to all units.
Discontinue chemical Injection
Shutdown stabilizer
Decommissioning of desalters
Putting the CDU on circulation
Shut down atmospheric section
Emptying out of the units and purging/isolation

All above steps are elaborated below:7.3.1
THROUGHPUT REDUCTION
Reduce crude throughout gradually to 50% of normal feed rate step by step. Manipulate
all atmospheric heater pass flow controllers for this purpose, bypass low pass flow / low
FO / FG pressure inter lock.
Make adjustment on all operating variables in each step so that normal operating pressure
and temp. conditions are maintained.
7.3.2
DISCONTINUATION OF CHEMICAL INJECTION
Stop caustic injection pumps 05-PA-031A/B and isolate the following:

caustic injection to desalted crude
caustic injection to crude inlet line to CDU from storage.
Stop Demulsifier injection pump 05-PA-027A/B and isolate the valve near crude
inlet to CDU from storage.
Stop ammonia solution injection and isolate the following injection lines:
Ammonia solution injection to crude column overhead vapour lines.
Stop corrosion inhibitor injection after stopping the ammonia injection.
Isolate the vessels including cylinders and drums, which contain chemicals.
Depressurize and drain pumps and lines including calibration pots.
7.3.3
SHUTDOWN OF NAPHTHA STABILISER
Control system of stabilizer column shall be changed from total condensation to partial
condensation operation. LPG down stream unit will be informed about discontinuing
LPG production.
Inform DHDS and LAB to stop wild naphtha to AU5 unit. Also inform CRU to stop drag
stream to AU5.
Reduce feed to stabilizer. De-cascade atmospheric column reflux drum level controller
from stabilizer feed flow controller. LPG-to-LPG vaporizer should remain isolated at
HIC-1901 and to Amine regeneration unit.
De-cascade stabilizer column top temp. controller TIC-1703 from reflux flow controller
FIC-1703. increase top reflux to stabilizer and cut off LPG withdrawal from reflux drum.
De-cascade stabilizer reflux drum level controller LIC-1704 from LPG product flow
controller FIC-2503. Bring the column to total reflux operation, by maintaining pressure
such that only sufficient vapor condenses to maintain reflux flow.
Reduce the column top pressure very gradually by operating PIC-1701. 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 condense afterwards
in FG system.
Reducing heating medium flow (GO CR) to stabilizer re-boiler. Operate TIC-1704 first to
lower the temp. Throttling of FV-1704 by manual mode can be done for this operation.
Pump out stabilizer top reflux drum liquid to stabilizer till reflux pump looses suction.
Keep receiving feed to stabilizer till atmospheric column starts operating on total reflux
in source of shut down and then cut off feed to the stabilizer. Close the isolation valve in
the stabilizer feed line.
By utilizing the available pressure, empty out the stabilizer bottom to slops storage tank
and maintain stabilizer bottom level. Keep a watch on rundown stream, as it may contain
lighter components, which may create problem in slop tank.
To facilitate emptying out, top pressure control valve of the column may be closed.
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.
Bypassing the caustic wash system should be done prior to shut down of the system. As
soon as caustic wash system is bypassed both the caustic circulation pump and water
circulation pump to be stopped.
Reduction in stabilizer column pressure, naphtha flow and stabilizer bottom level will
all indicate completion of the 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 depressurizing, residual liquid in column, piping exchanger will be drained to CBD
or OWS. LPG should not be drained to CBD or OWS in large quantity, as it may flash in
the way.
7.3.4
DECOMMISSIONING OF DESALTERS
Switch off power to both desalters and then stop desalting water to both the units.
However crude flow through desalters can be maintained.
Shut off desalter effluent water (brine) lines after ensuring the water level is lowered to
minimum.
Wide open the mixing valves at desalter inlet by manual operating MV-1201 & MV-1202
the pressure control system of the desalters should to work so that steady desalted crude
pump suction pressure is ensured.
When CDU is on hot circulation, as elaborated ahead, desalter can be bypassed after
opening PV-1206 at desalter inlet fully in manual mode. Drain desalter content into close
blow down (CBD) system. Desalter can be kept filled with gas oil and be isolated after
draining. Keep desalter pressure around 0.3 Kg/cm2g when it is idle.
7.3.5
NORMAL SHUTDOWN
CDU is still running with around 50% of normal capacity with LR routed to slop and the
side draw off products from atmospheric column are going to respective product tanks.
Start reducing atmospheric furnace COT by TIC-1416 at 30 C per hour.
As temp. of crude oil drops, there will be less of distillate product and column pressure
will tend to fall. Admit fuel gas into the reflux drum through pressure controlled PV1504B if fuel gas is available from else where.
As column temperature start dropping, quantity of products will go off spec. Divert the
off spec distillate products to slop at the battery limit. Inform related units about the
rerouting.
At a column bottom temperature of around 300 C cut off stripping steam to column
bottom. Keep striping steam to side strippers also to be discontinues as and when side
draw off products are diverted to slop. Also GO CR to HN reboiler to be stopped.
With a drop in column top temperature, the overhead product yield will gradually come
down. Stop withdrawing naphtha product and resort to total top refluxing. Liquid in
reflux drum will be emptied out into crude column slowly.
Gradually stop product withdrawal and stop product pumps, when they give unsteady
performance on continuous operation.
Reduce CR rates. Stop all CR pumps one by one, starting from HN CR pump as and
when they loose suction.
With lowering of heater COT, LR yield will increase and its viscosity will come down.
Line up LR R/D to pre-desalter crude pump suction and establish close circulation of LR,
as was done during hot circulation at the time of start up.
Isolate the crude feed line from the unit battery limit.
Hot circulation circuit:
PA-1 -->Crude Preheat Train Circuit Before Desalter (including both New and Old
Preheat Train) ----> Desalter ----> Crude Preheat Train Circuit After Desalter (including
both New and Old Preheat Train) -----> Furnace -----> Column -----> PA-51 ------>RCO
circuit. ----> P1 suction.
When heater box temperature drops to about 200 C, cut off all furnace fire. Purge out
burners and firebox and get FG line blinded. Continue IFO circulation.
Continue crude circulation till system gets cooler down sufficiently to about 100 C at
the column bottom. After this, stop all crude pumps. Discontinue RCO pump discharge
from crude tanks and line up LR pump discharge to slop tank. Stop LR pumps also when
they loose suction. Stop ID / FD fan
7.3.6
SHUTDOWN OF ATMOSPHERIC SECTION FOR M&I
Take flushing oil to the atmospheric column through RCO pump suction. Build up about
80% level at the bottom of the column.
Line up circuit again through LR circuit and crude charge pump and complete the
circulation block up to column.
PA-1 -->Crude Preheat Train Circuit Before Desalter (including both New and Old
Preheat Train) ----> Desalter ----> Crude Preheat Train Circuit After Desalter (including
both New and Old Preheat Train) -----> Furnace -----> Column----->PA-51------>RCO
circuit ------>PA-1
Flash out heavy stuff from all exchangers/control valve bypasses by operating
them one by one.
Continue circulation till entire circuit is flushed out check consistency of

circulating stream. When it is sufficiently thin, stop circulation and pump out the
material to slop tank. The flushing operation may have to be repeated more than
once.
Deblind & line up service water connection at P01 suction. Start P01 & push the
line material (Both new & old circuit) to column via desalter. When desalter interphase level raises to 100% bypass & drain desalter content to CBD &
subsequently pump out CBD content to slop tank. Continue water flushing to
C01& pump out C01 to slop header through RCO circuit.
After water flushing is over, isolate & bypass all RCO & Crude Heat Exchangers
& drain all the exchangers to CBD.
Slowly open steam to the discharger of crude charge pumps and flush the lines
and equipment into the C01 bypassing desalter. Steam crude preheat exchangers
and displace the material into the column. Open emergency steam to all the passes
of the furnace to expedite the displacement (this is suggested in view of large hold
up of hydrocarbon in piping which remain stagnated).
Pump out the material collected at crude column bottom to slop tank. Run LR
pump as and when necessary.
Depressurize crude column to flare. After depressurization, close all valves

releasing to flare. Close cooling water B/Vs at plant battery limit and drain out
water from condensers and product coolers.
Steam out discharge of RCO pump and route the material into slop header. Care
should be taken to avoid steaming beyond battery limit.
7.3.7
Isolate fuel gas header from all the reflux drums.

EMPTYING OUT OF THE UNITS AND PURGING/ISOLATION
After maximum quantity of hydrocarbon material has been removed from the unit, drain
all equipment and lines to CBD one by on. Drain Amine settler bottom to amine drain.
Reverse blinds on CBD lines from various equipment to open position. Drain all the oil in
the CBD. Ensure adequate ullage in CBD drum by pumping out CBD drum contents to
slop. Rise in CBD drum level should be watched periodically while draining.
Decommission FG header to flare header & purge with steam. Isolate flare header at
battery limit. Reverse the blind to close position of the fuel gas header in the plant battery
limit, if FG is not required by ARU. Decommission LPG vaporizer. Blind off fuel gas
line. Isolate all inlet and outlet lines at the battery limit.
Flush out fuel oil header by taking flushing oil at unit battery limit. Drain out oil to CBD.
Open vent at top of equipment, other high point vents and reflux drum vents etc. before
steaming. The step of steaming can be taken up only after shutdown of the rest of the unit
so that cooling water can be isolated for effective steaming. Steam out for a period of
about four hours, after which it will be discontinued. Allow the system to cool down with
vent valves full open. Stop steaming the equipment when steam enters CBD system.
Start steaming crude column, stabilizer column, desalter, furnace coils and exchanger
trains etc. as detailed under the section of start up procedures. Continue steaming till all
hydrocarbon vapours are removed from the system. Ensure that column vents are opened
to atmosphere to avoid vacuum formation. During steaming care should be taken so that
system pressure does not exceed operating pressure. Then stop steaming and let the
equipment to get cooled. Connect steam hoses to the utility connection point of all
equipment and start steaming.
Steam out the headers in hydrocarbon service till clear steam comes out from all high
point vents and all hydrocarbons are eliminated.
Shut off steam to the lines.
Carry out insertion of blinds as per the master blind list for isolating the unit for
maintenance.
After positive isolation is over start again steaming followed by hot water wash by
introducing water from top of the column by reflux pump. At least 4-hour hot water
wash to be done followed by cold-water wash to cool down the columns.
Blind steam out point & open column manholes.
During steam purging ensure that dry steam has come out from all LPDs & HPVs & no
trapped hydrocarbon is left inside.
7.3.8 CHECK LIST FOR UNIT NORMAL SHUTDOWN FOR BOTTLED UP
CONDITION
Sl.No
Description
InformRSM/OMS/TPS/Water
Block/Laboratory about S/D
2
Ensure flushing oil availability in GHC
3
Ensure slop tank at GRE has sufficient
ullage
4
Check CBD pump is in healthy condition
Sl.No
Description
5
6
7.
Inform RSM / P&C/OMS for availability

of LS crude tank
If the S/D is for longer period, stop VR
receiving in IFO drum & Receive RCO ex
EE4 to it at least 12 hours before the unit is
schedule to S/D. Accordingly reduce /
adjust IFO temperature.
Stop / divert CRU drag stream / DHDS &
LAB wild naphtha processing. Inform CRU
/ LAB plant / DHDS shift in-charge.
8.
Thru put reduction

a)
Switch over to total LS crude
processing (4 Hrs before TPut reduction)
b)
Reduce Tput to 8000 Mt/Day level.
c)
Bypass low FG pressure & low FO
pressure inter lock
9.
a)Route ATF / SKO to HSD pool
b)Route LN to GN pool
10. Stop water & demulsifier injection to
desalter
11
Reduce F1 COT @ 30deg C
12.
13.
14
Stop all chemical injection & desalter

desludging pump
At 250 deg C (Column bottom temp.) cut
off stripping steam to column / strippers &
put unit on hot circulation
Adjust RCO cooler to maintain 50-60 deg
Action by
Done
YES/NO
Remarks
Done
YES/NO
Remarks
S/I
S/I
S/I/Panel
Opr.
Pump.Opr
Action by
S/I
Panel/Field
Opr.
S/I/Field
Opr.
Panel Opr.
Panel/Field
Opr.
Field Opr.
Panel/Field
Opr.
Field Opr.
Panel/Field
Opr
Panel/Field
Opr
Panel/Field
Opr
20
21
cooler O/L temp.

Reduce temperature to 120 deg C @ 40 deg
C/Hrs by cutting off all oil burners one by
one & flush it with steam.
At 120 deg C cut off furnace by closing
main FG isolation valve & purge box with
purging steam.
Insert blind in FG line and stop furnace box
purging.
Switch off desalter.
Stop all product pump when stripper level
is low
Stop all reflux pumps
Stop ID / FD
Sl.No
Description
Action by
22
If the S/D is for longer period carry out

flushing
Bring down C1 level to lowest
possible level by diverting it to
RCO tank.
Receive FLO at Crude pump
suction. Build up C1 level to 80%.
Initially route C1 bottom product to
RCO tank for 20 minutes.. Than
establish close circulation
Check RCO sample at B/L. If it is
light Stop circulation pump, if not
repeat point a to d.
Flush all RCO R/D lines with FLO to
individual units / tanks
Isolate RCO to IFO drum I/L valve. Empty
out IFO drum to slop header to lowest
possible level. Take gas oil in the vessel.
Continue IFO circulation. Repeat this
sequence for 2 to 3 times. Check sample. If
it is light, stop circulation.
Decommission LPG caustic wash system if
not in use (for other units)
Decommission naphtha & ATF
caustic
wash system
Isolate all R/D battery limit valves.
Panel/Field
/Pump Opr.
15.
16
17
18
19
23
24
25
26
27
Field Opr
S/I
Field Opr
Panel/pum
p Opr
Pump Opr.
Panel/Field
Opr
Field Opr.
Panel/Field
Opr
Field Opr
Field Opr
Panel/Field
Opr
Done
YES/NO
Remarks
28
29
Keep C1 /C5 floating with FG system on Panel Opr

positive pressure.
Stop crude circulation when the column Panel/Field
(CC-01) bottom temp. comes down to 100 /Pump Opr.
deg C.
CHAPTER-8
8.1
GENERAL GUIDELINES
An emergency in the unit means a serious up set in the unit operating conditions resulting
in products going off, and damage to equipment (if proper actions are not taken promptly
and so warrants quick decision and quick actions.
Under emergency conditions, action is to be taken promptly as per the guidelines given
below:
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 coilpurging steam is opened.
If coil purging in F-1becomes necessary, no condensation of steam inside the coils

is permitted, since the last tubes are of stainless steel.
The passivation solution should be prepared at the earliest, since the same may be
needed for passivation of F-1 coils.
Steam flushing of individual oil burners, is required to keep the tips free for
subsequent light up.
Fuel oil BPC bypass valve is required to be opened in time, so that BPC pressure
does not exceed 10.0 kg/cm2.
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.
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.
Crude feed line battery limit isolation valve is to be closed before establishing
circulation.
While on hot circulation, 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)
While pumping out any material from the unit pump out temperature has to be
low enough.
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.
Crude oil circuit must be flushed with diesel at the earliest convenient time to
avoid congealing.
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
8.2
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
DCS failure
Fire in the plant
POWER FAILURE IN UNIT:
A power dip of eve 2/3 seconds is enough to trip a motor. If on the other hand, due to
malfunctioning of a transformer in the sub-station or some cable faults or power shedding
etc. there is a partial/total failure of power supply to the unit, then unit will have to be
shutdown depending on the resumption of power supply to the unit. The pumps will not
be transferring liquid from one place to other because the motors have stopped.
Power failure may be of 3 types
1) HT POWER FAILURE
2) LT POWER FAILURE
3) TOTAL POWER FAILURE
EFFECTS OF POWER FAILURE:
Following are the effects of power failure:
All the motors will stop.
No flows through heater coils.
No reflux to columns.
Exchangers will get a thermal shock.
Columns top temperature will start shooting up and pressure will also shoot up.
For sometimes the vapors will continue to come from column overheads and
condense in condensers and then go to vessels. So, vessels will become full. Since
there is no material going out of the vessels, vessel safety may pop.
No illumination in the plant and no alarm signals will work.
There are chances of fire in the plant due to thermal shocks and leaks.
Heater refractory may get a thermal shock. Hence there are chances of bricks
falling down.
1) HT POWER FAILURE
In case of HT power failure only Crude pump will trip. Furnace will cut off on Low pass
flow inter lock.
Sl.No
JOB DESCRIPTION
Action
Done
Inform RSM/TPS/OMS/SPNM
Furnace should trip on inter lock. Close FG
by
S/I
Panel
YES/NO
1
2
3
& FO C/V from panel.

Isolate individual oil & gas burners valves
Opr.
Field
and flush the burner oil guns with steam.

Isolate main FG line B/V.
Opr.
Field
Pilot burners should be in line, otherwise
Opr.
Field
isolate them & purge the heater with steam.

Close the discharge valves of the pumps,
Opr.
Pump
which were running.

Route ATF / SKO to HSD & Naptha to GN
Opr.
Panel/Fie
pool.
If power clearance is obtained from TPS
ld Opr.
Remarks
immediately
Start stand by pumps & establish flow
Panel/Pu
through heater coils.

Take low pass flow inter lock in line.
mp Opr.
Panel
Purge heater box with steam if pilot burners
Opr
Field
are off.
Start FD fan after bypassing its inter lock.
Opr.
Panel/Fie
Ensure negative draft.

Light all pilot burners. Take FG & FO
ld Opr.
Field opr.
burner in line.
Raise temperature @ 40 deg / hr.
Panel/Fie
Stabilize unit condition.
Take ID fan in line.
9
10
11
ld Opr.
Panel
Opr.
Panel/Fie
Take all inter locks in line.
ld Opr.
Panel
Check product colour.
Opr.
Pump
Send sample to Lab.

If power clearance is not obtained/power
Opr.
S/I
is not resumed within few minutes,

Inform RSM/SPNM/CPNM about
situation.
Start coil purging steam & displace the oil
Panel/Fie
contents of oil to column (while purging the
ld Opr.
the
S/I
coil with steam, care should be taken that

column operating pressures should not
3
exceed)
Cut off striping stream c/vs. of CC-01/CC-
Panel
03/CC-04 from the panel.

Close CC-001/3/4 stripping steam control
Opr.
Field
valve block valves and bypass valves.
Opr.
Bleeder of these c/vs. to be opened.
Put unit on close circulation.
Panel/Fie
Adjust RCO cooler O/L temperature to
ld Opr.
Panel/Fie
about 50-60 deg C.

Stop ID fan & switch over furnace to forced
ld Opr.
Panel/Fie
draft mode.
Run FD till Column cools down / Column
ld Opr.
Panel
pressure comes under control.

Route product to off grade tank.
Opr.
S/I/Panel
/Field
Opr.
Field
10
Stop all chemical injection pump.
11
12
Opr.
Stop dm water to desalter.
Field Opr
Stop all product & reflux pump when Panel/Pu
13
stripper / vessel level comes down.

mp Opr.
Decommission Naphtha / SKO caustic wash Field Opr
14
system.
Decommission LPG wash system, if other Field Opr
15
16
unit LPG is not washed here.

Field Opr
Inform OMS to line up crude tank for
S/I
17
gravity line up.

Isolate all product battery limit valve.
Field
Opr.
ON RESUMPTION OF HT POWER
Ensure coil-purging steam valves are closed
and establish cold circulation.

Opr.
Adjust RCO cooler CW flow to have 40 50 Panel/fiel
deg O/L temperature.

Purge heater box with steam & establish
d Opr.
Field
negative draft if pilot burners are not in line.

Start FD fan, if stopped.
Opr.
Panel/Fie
Light all pilot burners.
Field
ld Opr.
Field
Opr.
Light gas burner.
Increase temperature @ 40 deg. C/hr.
Ensure low feed pass flow in line.
Field
Opr.
Panel/Fie
ld Opr.
Panel
Check the unit for any leak. Fix it if so.
Opr
S/I/Field
10
11
Take oil burner.

At 300 Deg C cut off feed by introducing
Opr.
Field Opr
Panel/Fie
stripping steam in C01 & putting unit out of
ld Opr
circulation.
Introduce stripping steam to strippers.
Panel/Fie
13
Increase temp. as required.
ld Opr
Panel/Fie
14
ld Opr
Start top reflux pump when level appears. Pump/Fie
15
( Drain water completely).

Start sour water pump & rout to SRU.
12
ld Opr.
Pump/Fie
Maintain required top temp.
ld Opr
Panel
17
Start CR / Product pump, when level appears
Opr
Pump
18
in stripper.
Adjust column condition.
Opr
Panel
19
Heat up stabilizer bottom .
Opr
Panel
20
Opr
Drain water from V3 when level appears & Pump/Fie
21
start reflux pump& adjust column condition.

Route LPG & Naptha to R/D after
ld Opr
Panel/Fie
22
commissioning caustic wash system.

Route all products to off grade tank.
ld Opr
Pump/Fie
23
24
Sent sample to lab.

If certified, divert product to on grade tank.
ld Opr
S/I
Panel/Fie
16
ld Opr
25
Panel
Opr
2) LT POWER FAILURE:
Following are the effects of LT power failure:
EFFECTS:
All the motors except Crude pump and Desalted crude pump will stop.
ACTIONS TO BE TAKEN:
In case of LT power failure to the unit (but steam being available) following actions
should be taken:
Sl
JOB DESCRIPTION
No
1
2
Inform RSM/TPS/CGP/OMS/SPNM
With the LT power failure, fuel oil pumps will
Action by
YES/NO
S/I
also automatically stop but gas firing will

3
4
continue.
Shut FO C/V from panel.
Isolate all FO burners & flush with steam.
Panel Opr/
Field Opr.
Confirm if the failure is partial, and if power
Pump Opr.
is available in standby pumps, start all stand

by pumps one by one & stabilize the unit by
6
7
8
temporarily increasing FG firing.

Establish IFO circulation. Take oil burners in
line.
Stabilize unit condition.
Take IFO inter lock in line.
If the failure is total & does not resume in
short time
Inform
Panel/Fiel
d Opr.
Panel opr.
Panel Opr.
S/I
RSM/SPNM/CPNM/OMS/GRE/GRSPF/SR
2
Done
U
Cut-off gas firing in the heaters by closing
individual burner block valve. Isolate main
FG isolation valve also.
Field Opr.
Remarks
3
4
Purge the heater box with steam.

Cut off striping stream c/vs. of CC-01/CC-
Field Opr.
Panel Opr.
03/CC-04 from the panel.

Close CC-001/3/4 stripping steam control
Field Opr.
valve block valves and bypass valves.

6
Bleeder of these c/vs to be opened.

Isolate all pump discharges, which were
Pump Opr.
7
8
running.
Establish close circulation.
Field Opr.
Panel/Fiel
Keep watch on pressures of vessel / column
d Opr.
Panel Opr.
and release the same into flare by opening

10
PIC or PSV bypass if required.

Close all the R/D valves.
Panel/Fiel
d Opr.
On resumption of power start the unit as per

1
2
normal start-up procedure.

Inform RSM/SPNM/CPNM
Purge the heater box with steam. (15 to 20
S/I
Field Opr.
minutes).
Start FD fan.
Panel/Fiel
Check furnace draft. Ignite all pilot burner
d Opr.
Field Opr.
5
6
one by one.
Take FG & FO burner in line.
Raise COT @ 40 deg C /hrs.
Field Opr.
Panel/field
Feed cut at 300 deg c by introducing stripping
Opr.
Panel/Fiel
steam in the column & taking out of
d Opr.
circulation.
Increase COT as per requirement.
Panel/Fiel
Take frequent round around the plant. Fix any
d Opr.
S/I/Field
10
leak / smoky flange if observed.

Start reflux pump when level appears in O/H
Opr.
Pump Opr.
vessel & maintain top temperature. Divert
11
excess naphtha to stabilizer

Start CR & Product pumps when level
Pump Opr.
12
13
appears in strippers.
Adjust unit condition.
Initially route products to off grade product
Panel Opr.
Panel/Fiel
14
tank.
Slowly
bottom
d Opr.
Panel Opr.
15
temperature.
Drain water from V3 when level appears &
Field opr.
16
start reflux pump& adjust column condition.

Commission LPG / Naptha / SKO caustic
Field Opr.
17
18
wash system.
Send R/D sample to lab.
If certified divert R/D to on grade tank.
S/I
Panel/Fiel
Take all inter lock in line.
d Opr.
Panel Opr.
19
increase
stabilizer
3) TOTAL POWER FAILURE:

EFFECTS
Following are the effects of Total power failure:
There will be no power to run Ht / LT motors.
There will be no CW / Air / Steam / No illumination.
There are chances of fire in the plant due to thermal shocks and leaks.
In case of power failure to the unit, following actions should be taken:
Sl.N
JOB DESCRIPTION
Action by
o
1
Inform
TPS/CGP/RSM/SPNM/OMS
Cut off furnace from panel by
Panel Opr
closing FG & FO C/V.

Isolate individual oil & gas burners
Field Opr.
Done
YES/NO
valves and flush the burner oil guns

with steam if available.
S/I
Remarks
4
5
Sl.N

Purge the heater with steam, if
Field Opr.
Field Opr.
available.
JOB DESCRIPTION
Action by
o
6
Cut off striping stream c/vs of CC-
Panel Opr.
01/CC-03/CC-04 from the panel.

Close CC-001/3/4 stripping steam
Field Opr.
Done
Remarks
YES/NO
control valve block valves and

bypass valves. Bleeder of these c/v
8
s to be opened.
Close all discharge valves of the
Pump Opr.
pumps which were running.

Keep close watch on system /
Panel Opr.
vessels pressure. If it soots up

release to flare by opening PSV /
10
PIC bypass.
Take frequent round around of the
S/I/field opr.
plant. Fix any leak / smoky flange

11
if observed.
Isolate all steam battery limit valve.
On obtaining clearance for
Panel/Field Opr.
power / steam / CW / AIR start up

1
2
unit as follows:
Inform RSM/SPNM/CPNM/OMS
Commission steam: open all steam
header
condensate
drain
S/I
Panel/Field Opr.
trap
bypass. Slowly creak open battery

limit valve & drain out condensate.
When dry steam started coming out
of trap bypass, slowly open battery
3
Sl.N
o
limit valve. Close trap bypass.

Check instrument air pressure
JOB DESCRIPTION
Panel/Field Opr.
Action by
Done
YES/NO
Remarks
Check cooling water pressure /
Panel Opr.
flow
Physically check total unit for
S/I/Field Opr.
6
7
8
possible leakage. Attend it if any

Purge all FO burner with steam.
Purge heater box with steam.
Start IFO pump & establish
Field Opr.
Field Opr.
Panel/Field Opr.
circulation after bypassing inter

9
lock.
Line up for & establish crude close
Field Opr.
10
11
circulation.
Check furnace draft.
Start FD fan after bypassing inter
Field Opr
Panel/Field opr.
12
13
lock.
Light up all pilot burners.
Bypass FG low-pressure interlock
Field Opr.
Panel/Field Opr.
14
& take FG burners in line.

Raise temperature @ 40 deg C / hr.
Panel/Field Opr.
15
Take FO burner if required.

Feed cut in at 300 deg c by
Panel/Field Opr.
introducing stripping steam in the

16
17
column & taking out of circulation.

Increase COT as per requirement.
Take frequent round around the
Panel/Field Opr.
S/I/Field Opr.
plant. Fix any leak / smoky flange

18
if observed.
Start reflux pump when level
Panel/Pump Opr.
appears in O/H vessel & maintain

top temperature. Divert excess
19
naphtha to stabilizer.
Start CR & Product pumps when
Pump Opr
20
21
level appears in strippers.

Adjust unit condition.
Initially route products to off grade
Panel Opr.
Field Opr.
22
product tank.
Slowly increase stabilizer bottom
Panel Opr.
temperature.
23
Drain water from V3 when level
Panel/Field/Pum
appears & start reflux pump&
p Opr
24
adjust column condition.

Commission LPG / Naptha / SKO
Field Opr.
25
26
caustic wash system.

Send R/D sample to lab.
If certified divert R/D to on grade
S/I
Panel/Field Opr.
27
tank.
Take all inter lock in line.
8.3
Panel Opr.
STEAM FAILURE
STEAM FAILURE:Steam Failure may be of three types.

1. HP Steam
2. MP steam
3. LP Steam
1) MP STEAM FAILURE:
EFFECTS:
Following are the effects of MP steam failure:
Atomizing steam to oil burners will not be available. Hence no atomization, and
no proper combustion. Heaters will be sprayed with oil, later on burn on the
surface of tubes.
Stripping steam to CC-001/3/4 will not be available. Chances of product backing
up into steam line are more, if b/vs are not closed immediately. So it may be
observed that unit cannot run without steam and shutdown is a must.
Fire fighting steam will not be available.
ACTION TO BE TAKEN:
Following actions are required immediately in case of MP steam failure.
Sl
No
1
1
JOB DESCRIPTION
Action by
Done
YES/NO
Inform
TPS/CGP/RSM/SPNM/OMS
S/I
Panel Opr.
Remarks

Isolate individual oil
&
gas
Field Opr.
burners valves and flush the

burner oil guns with steam if
3
4
available.
Purge the heater with steam, if
Field Opr.
Field Opr.
available.
Cut off striping stream c/vs of
Panel Opr
CC-01/CC-03/CC-04
6
from
the
panel
Field Opr.

bypass valves. Bleeder of these c/v
7
s to be opened.
Adjust
temperature to about 50-60 deg C.

Cut off gas burners if gas is not
Sl
available.
JOB DESCRIPTION
No
10
11
12
13
Isolate FG main isolation valve.

Stop all product & reflux pump
Field Opr.
Panel/Field Opr.
Field Opr.
Panel/Field Opr.
14
when stripper / vessel level looses.

Decommission LPG / Naphtha /
Field Opr.
15
16
SKO caustic wash system.

Inform OMS to line up crude tank
Field Opr.
S/I/Panel Opr.
RCO
cooler
Panel/Field
O/L
Opr.
Panel/Field
Opr.
Field
Opr.
Action by
YES/NO
for gravity line up.

ON RESUMPTION OF STEAM
1
Done
Inform RSM/SPNM/CPNM/OMS
S/I
Remarks
2
3
4
5
6
7
8
9
Sl
No
10
11
12
13
14
15
16
17
Purge oil burners.

Purge heater box with steam &
establish negative draft.
Start FD fan.
Light gas burner.
Increase temperature @ 40 deg.
C/hr.
Ensure feed pass flow low in line.
Check the unit for any leak. Fix it
if so.
JOB DESCRIPTION
Field Opr.
Field Opr.
Panel/Field Opr.
Field Opr.
Field Opr.
Panel/Field Opr.
Panel Opr.
S/I/Field Opr.
Action by
Done
YES/NO
At 300 Deg C cut off feed and

introduce stripping steam in C01
& putting unit out of circulation.
Increase temperature as required.
Start top reflux pump when level
appears (Drain water completely).
Start sour water pump & route to
SRU.
Start CR / Product pump, when
level appears in stripper.
Heat up stabilizer bottom & adjust
Panel/Field Opr.
Panel/Field Opr.
Pump Opr.
Pump/Field Opr.
Panel Opr.
Panel/Pump Opr.
Panel Opr.
Panel Opr.
Remarks
18
19
column condition.
Panel/Field/Pum

Route LPG & Naphtha to R/D
Opr.
Field Opr.
after commissioning caustic wash

20
system.
Route all products to off grade
Panel/Field Opr.
21
22
tank.
Sent sample to lab.
If certified, divert product to on
S/I
Panel/Field Opr.
23
grade tank.
Take all interlocks in line.
Panel Opr.
2) HP STEAM FAILURE
i)
Only IFO / VR heating system will affect.
ii)
Monitor IFO temperature.
iii)
If HP Steam temperature is falling below 160 deg.C,

Stop VR receiving from GHP ( inform GHP) .
iv)
Take RCO from D/S of EE4 in VR drum.
v)
Adjust furnace firing.
3) LP STEAM FAILURE
i)
Utility steam will not be available. Care should be taken to

the smoky flanges where steam lancers are provided.
ii)
Hot pump seal quenching steam will not be available.
iii)
Fire fighting steam will not be available.
UNIT TO BE SHUT DOWN AS PER THE PROCEDURE MENTIONED FOR MP

STEAM FAILURE.
8.4 COOLING WATER FAILURE
EFFECTS:
No water to condensers and coolers. No water to pumps.
Hence in the absence of cooling medium, there will not be any condensation and
all columns pressure will shoot up very fast.
Pumps glands may be burnt and lube oil temp. will increase. Gland will start
leaking.
Pumps will have to be stopped.
If cooling water failure is only partial, it can be tackled by reducing throughput
and throttling water to coolers/condensers proportionally.
ACTION TO BE TAKEN:
Sl.N
JOB DESCRIPTION
Action by
o
1
Inform
tower/RSM/SPNM
Panel Opr.

Isolate individual oil & gas
Field Opr.
YES/NO
Cooling
S/I

4
5
burner oil guns with steam

Pilot burners should be in line,
Field Opr.
Field Opr.
otherwise isolate them & purge

6
Done
the heater with steam.

CC-01/CC-03/CC-04 from the
panel.
Panel Opr.
Remarks
Close
CC-001/3/4
stripping
Field Opr.
steam control valve block valves

and bypass valves. Bleeder of
these c/v s to be opened.
8
9

Adjust
RCO
cooler
O/L
Panel/Field Opr.
Panel/Field Opr.
temperature to about 50-60 deg

10
C.
Stop ID fan & switch over
Panel/Field Opr.
11
furnace to forced draft mode.

Run FD till Column cools
Panel/Field Opr.
down/Column pressure comes

12
13
under control.
Route products to off grade tank.
Stop all chemical injection
Panel/Field Opr.
Field Opr.
14
pump.
Panel/Pump Opr.
when stripper / vessel level

14
looses.
Decommission LPG / Naphtha /
Field Opr.
15
16
SKO caustic wash system.

Inform OMS to line up crude
Field Opr.
S/I/Panel Opr.
tank for gravity line up.

ON RESUMPTION OF CW
Inform
2
3
RSM/SPNM/CPNM/OMS
Check CW flow / pressure
Line up & establish cold
Panel/Field Opr.
Panel/Field Opr.
circulation.
Take low pass flow inter lock in
Panel Opr.
line.
Field Opr.
S/I
establish negative draft if pilot

6
burners are not in line.

Panel/Field Opr.
7
8
9
Light up all pilot burners.

Light up gas burner.
Field Opr.
Field Opr.
Panel/Field Opr.
10
C/hr.
Check the unit for any leak. Fix
S/I/Field Opr.
11
it if so.
At 300 Deg C cut off feed by
Panel/Field Opr
introducing stripping steam in

C01 & putting unit out of
12
circulation.
Introduce stripping steam to
Panel/Field Opr.
13
14
strippers.
Panel/Field Opr.
Panel/Pump Opr.
appears.(
Drain
water
15
completely).
Start sour water pump & rout to
Pump/Field Opr.
16
17
SRU.
Panel Opr.
Panel/Pump Opr.
18
19
20
level appears in stripper

Panel Opr.
Panel Opr.
Panel/Pump/Fiel
d Opr.

Field Opr.
21
after
commissioning
caustic
22
wash system.
Panel Opr.
23
24
tank.
Send sample to lab.
S/I
Panel/Field Opr.
25
grade tank.
Panel Opr.
8.5
INSTRUMENT AIR FAILURE
Instrument air is supplied to the unit at a pressure of about 6.7 Kg/cm 2g from the
compressor house. It is taken to an air receiver and from there it is taken to the unit. PC
on this line maintains the supply pressure at 3.0 Kg/cm2g in the header.
Air receiver in the unit can supply air for some time interval. If due to some reasons, air
supply cannot be restored within this period, then the supply lone header pressure will
fall below 3.0Kg/cm2g and will decline fast. The instruments will cease to function.
Control valves will remain fully open or close depending on whether the control valve is
air to close or air to open. Hence unit will have to be shutdown.
EFFECTS
Following are the effects of instrument air failure.
Instrument loops that are having pneumatic provision such as closed loop control
valves will stop functioning.
However open loop instruments involving electronic data transmission shall
remain.
On account of closure of FO / FG control valves, heater will trip.
Allow FD/ID fans to run as long as possible.
All the LCs will open fully.
The PCs of CC-001 and CC-005 will open fully leading to loss of pressure.
Atomizing control valve will go to full open position.
With the pumps running all the flows will go up. But since heater firing is
substantially reduced, temperature will fall down. Level in vessel will come
down. Reflux pumps will lose suction, and hence columns top temperature will
shoot up. So shutdown is imminent.
Sl.
No
1
JOB DESCRIPTION
Action by
Done
YES/NO
If Instrument air can't be

restored, Cut off furnace from
panel by closing FG & FO
Panel Opr.
Remarks
C/V.
Field Opr.

3
4
burner oil guns with steam.

Check pilot burner, if not in
Field Opr.
Field Opr.
line isolate them & purge the

5
heater with steam.

Panel Opr.

6
panel.
Close CC-001/3/4 stripping
Field Opr.
steam control valve block

valves and bypass valves.
Bleeder of these c/v s to be
7
8
opened.
Adjust RCO cooler O/L
Panel/Field Opr.
Panel/Field Opr.
temperature to about 50-60

9
deg C.
Panel/Field Opr.
10

Panel Opr.
down
Column
pressure
11
comes under control.

Route product to off grade
Panel/Field Opr.
12
tank.
Field Opr.
13
pump.
Stop all product & reflux Panel/Pump Opr.
pump when stripper / vessel
14
level comes down.

Decommission LPG / Naphtha
/ SKO caustic wash system.
Ensure LPG system is not used
Field Opr.
15
16
for other unit.

Field Opr.
S/I/Panel Opr.
17

Isolate all product battery limit
Field Opr.
valve.
ON RESUMPTION
INSTRUMENT AIR
1
2
OF
Check battery limit IA

pressure
Panel/Field Opr.
Field Opr.

3
4
5
6
burners are not in line

Light gas burner.
Increase temperature @ 40
Panel/Field Opr.
Field Opr
Field Opr
Panel/Field Opr.
deg. C/hr.
Ensure low feed pass flow in
Panel Opr.
line.
Check the unit for any leak.
S/I/Field Opr.
9
10
Fix it if so.
Take oil burner.
Field Opr.
Panel/Field Opr.

11
circulation.
Panel/Field Opr.
12
13
strippers.
Start top reflux pump when
Panel/Field Opr.
Pump/field Opr.
level appears.( Drain water

14
completely).
Start sour water pump & rout
15
to SRU
Pump/field Opr.
Panel Opr.
16
Start CR / Product pump,
Pump/field Opr.
17
18
when level appears in stripper.

Heat up stabilizer bottom &
Panel Opr.
Panel Opr.
19

Drain water from V3 when
Panel/Pump/fiel
level appears & start reflux
d Opr.
pump&
20
adjust
column
condition.
Field Opr.
after commissioning caustic
8.6
21
wash system.
Field Opr.
22
23
tank.
Send sample to lab.
If certified, divert product to
S/I
Panel/Field Opr.
24
on grade tank.
Panel Opr.
FEED FAILURE:
Crude oil is supplied to unit by booster pumps from crude control. Crude feed supply to
the unit could get interrupted due to many reasons viz. improper functioning of booster or
unit feed pumps, improper lining up and chocking of strainers & or power supply failure.
etc. Interruption in feed flow calls for immediate action.
EFFECTS
Feed pumps will lose suction
No flow to the furnace.
Rapid drop in CC-001 bottom level
JOB DESCRIPTION
Furnace will cut off on inter lock.
Isolate FO / FG burners & flush with steam and the purge heater box.
Duration and cause of crude failure should be found out.
If the feed supply cannot be restored immediately bring the unit to circulation,
cut off stripping steam to columns & route the products to off spec. Tanks.
If the interruption is for a longer period the unit should be shutdown as per the
normal procedure.
8.7
ALL UTILITIES FAILURE:
With the total power supply failure to the whole refinery, there will be no supply of
circulating water, industrial and instrument air, and steam i.e. supply of all the utilities
will stop. This is major emergency and unit is automatically shutdown. Following action
will have to be taken immediately:
JOB DESCRIPTION
Close the C/V block valves and bypass valve of stripping steam to CC-001/3/4
and open bleeder to prevent backing up of crude oil/products into steam line.
Open the bleeder on steam line to drain out the product, if any, which might
have backed-up into steam line from columns.
Release the pressure from the reflux vessels to flare gas as & when required.
Since condensation will not take place in condensers column pressure will
shoot up and so safety valves may pop.
Drain the flare gas knockout drum, as well as gas bullets immediately.
Since instrument air supply will also fail, no indication will be available in
control room. Hence checks for temperatures, pressures, levels etc. Will have to
be made locally.
Isolate individual FO/ FG burners. Flush with steam if steam pressure is

available.
Line up for close circulation.
Close all battery limit R/d valves.
Keep vigil of the unit for detection of possible leakage.
8.8
FAILURE OF HEATER TUBES
Whenever tube rupture takes place, bridge wall temperature will start shooting up. Smoke
will start coming from the top of the stack. It will become dense, as leak will increase.
Sharp rise in stack temperature may also be observed. Plant operating personnel and the
supervisor have to assess the extent of leak/rupture and take recourse either to normal
shutdown or emergency shutdown. Following steps are indicated to bring down the unit
quickly in the event of a failure of heater tube.
JOB DESCRIPTION
Put off all the fires in the heater. Stop ID/FD fans.
Feed to the heater to be stopped.
Snuffing steam will be opened in radiation and convection sections.
Emergency coil steam will be opened in all the passes of the heater.
Top and CR pumps will be stopped when they lose suction.
Top refluxing will continue as long as possible.
Columns pressure will be watched for any rise due to additional amount of
steam put into the heater coils.
Stripping steam to the column CC-001 and Stripper will be stopped.
LR circuit will be flushed by taking FLO.
Stabilizer/ caustic wash section is decommissioned as per normal procedure.
Shutdown rest of the equipment as per normal procedure.
8.9 110V DC SUPPLY FAILURE

110V supply is used for (i) Solenoid valves operation (ii) indication bulbs on panel (iii)
limit switches for open condition. In case of failure of 110V DC, fuel oil and fuel gas
shutdown valves will get closed.
Sl.No
JOB DESCRIPTION
Action by
Done
Remarks
YES/NO
1
2
3
Inform I/M,E/M,RSM,SPNM,OMS
Close FG & FO C/V from panel.
S/I
Panel/Field
Opr.
Field opr.

4
5
with steam.
Field Opr.
Field Opr.
otherwise isolate them & purge the

6
heater with steam.

Panel Opr.
01/CC-03/CC-04 from the panel.

Field Opr.

bypass valves. Bleeder of these c/v s
to be opened.
Panel/Field
Adjust RCO cooler O/L temperature
Opr.
Panel/Field
10
to about 50-60 deg C.

Stop ID fan & switch over furnace to
Opr.
Panel/Field
11
forced draft mode.

Run FD till Column cools down /
Opr.
Panel Opr.
Column
pressure
comes
under
control.
Panel/Field
13
14

Stop all product & reflux pump when
Opr.
Field Opr.
Panel/Field
15
stripper / vessel level comes down.

Decommission LPG / Naphtha / SKO
Opr
field Opr.
16
17
caustic wash system.

Inform OMS to line up crude tank for
Field Opr.
S/I/Panel
18
gravity line up.

Isolate all product battery limit valve.
Opr.
Field Opr.
12
19
Do not bypass FO / FG low pressure
Panel opr.
inter lock.
ON RESUMPTION OF 110V DC
1
2
POWER
Inform RSM/SPNM/CPNM
Check SOVs / shut down valves are
S/I
Panel Opr.
working.
Field Opr.

Panel/Field

Light gas burner.
Increase temperature @ 40 deg. C/hr.
Opr.
Field Opr.
Field Opr.
Panel/Field
8
9

Check the unit for any leak. Fix it if
Opr.
Panel Opr.
S/I/Field
10
11
so.
Take oil burner in line.
Opr.
Field Opr.
Panel/Field
introducing stripping steam in C01 &
Opr.
4
5
6
7
12
putting unit out of circulation.

Introduce
stripping
steam
13
strippers.
14
Opr.
Start top reflux pump when level Pump/Field
15
appears.( Drain water completely).

Opr.
Start sour water pump & route to Pump/Field
16
17
SRU.
Start CR / Product pump, when level
Opr.
Panel Opr.
Panel/Pum
18
19
20
appears in stripper
p Opr.
Panel Opr.
Panel Opr.
Panel/Field
to Panel/Field
Opr.
Panel/Field
appears & start reflux pump& adjust /Pump Opr.
column condition.
JOB DESCRIPTION
Sl.No
Action by
Done
Remarks
YES/NO
21
Route LPG & Naphtha to R/D after
Field Opr.
21

Panel/Field
22
23
Sent sample to lab.

Opr.
S/I
Panel/Field
24
grade tank.
Opr.
Panel Opr.
CAUTION:
If FO/FG SOVs, are on bypass mode, on resumption of 110V DC supply shut-off valves
will get automatically open. To avoid this, keep FO/FG shutdown valves on interlock
mode. Low fuel pressure trip will ensure that the S/D valves do not re-open automatically
on restoration of 110V DC powers.
8.10
To supply 24V DC, 2 nos. of keltron panel and battery back up is provided. 24V Dc
supplies is used for (i) Circuit relay/logic system for interlock (ii) Pressure switch signals
(iii) Control valve limit switches for close condition. With failure of one of Keltron panel,
Trouble in Keltron Panel will come and the other Keltron panel will take over. On
failure of both the panels Battery back-up on line signal will come. If 24V DC battery
back up also fails then FO & FG SOVs will get closed and furnace shall switch over to
natural draft. Take following actions to overcome the situation.
ACTION TO BE TAKEN
Sl .No
1
2
JOB DESCRIPTION
Close FG & FO C/V from panel
Action by
Panel Opr.
Field Opr.

3
with steam.
Field Opr.
Done
Remark
YES/No
Field Opr.
otherwise isolate them & purge the

5
heater with steam.

Panel opr.
01/CC-03/CC-04 from the panel

Field Opr.

bypass valves. Bleeder of these c/v s
to be opened.
Put unit on close circulation
Panel/Field
Adjust RCO cooler O/L temperature
Opr
Panel/Field
to about 50-60 deg C

Stop ID fan & switch over furnace
Opr.
Panel/Field
10
to forced draft mode

Run FD till Column cools down /
Opr.
Panel/Field
Column
pressure
comes
under
Opr.
control.
Field Opr.
Field Opr
Panel/Pum
when stripper / vessel level comes
p Opr.
14
down.
Decommission LPG / Naptha / SKO
Field Opr.
15
16
caustic wash system

Inform OMS to line up crude tank
Field Opr.
S/I/Panel
17
for gravity line up.

Isolate all product
battery limit
Opr.
Field Opr.
18
valve.
Do not bypass FO / FG low pressure
Panel Opr.
19
inter lock.
Inform Instrument
11
12
13
Electrical
people to attend the problem.

ON RESUMPTION OF 24 V
POWER SUPPLY
S/I
Field Opr.

2

Panel/Field
3
4
5
Light all pilot burners

Light gas burner.
Opr.
Field Opr.
Field Opr.
Panel/Field
6
7
C/hr.
Check the unit for any leak. Fix it if
Opr.
Panel Opr.
S/I/Field
8
9
so.
Take oil burner.
Opr.
Field Opr.
Panel/Field
introducing stripping steam in C01
Opr.
& putting unit out of circulation.

Sl .No
JOB DESCRIPTION
10
Introduce
stripping
steam
11
strippers.
Action by
to
Field Opr.
Panel/Field
Opr.
12
Panel/Pum
13
appears.( Drain water completely).

p Opr.
Pump/Field
14
15
SRU.
Start CR / Product pump, when level
Opr.
Panel Opr.
Panel/Field
16
17
appears in stripper.
Heat up stabilizer bottom & adjust
Opr.
Panel Opr.
Panel Opr
18
column condition.
Route LPG & Naptha to R/D after
Field Opr.
19

Panel/Field
Opr.
Done
Remark
YES/No
20
21
Sent sample to lab.

S/I
Panel/Field
22
grade tank.
Opr.
Panel Opr.
8.11 UPS FAILURE:

If UPS supply failure, UPS will run through battery back up system. If battery back up
system is failed, the following effects will be noticed.
US panel is to be blank.
All SOV will be closed.
Furnace will be cut off totally.
ACTION TO BE TAKEN:
Sl
.No
1
2
Call inst. People to energies UPS system as fast as possible.
Load US panel from HM.
Open FO & FG SOV from ladder monitor.
Light up burner in all furnaces.
Normalize the unit.
JOB DESCRIPTION
Action by
YES/NO
Close
FG & FO C/V from
Panel Opr.
panel.
Field Opr.

3
4
burner oil guns with steam.

Field Opr.
Field Opr.

5
Done
the heater with steam.

panel.
Panel Opr.
Remarks
Close
CC-001/3/4
steam
control
valves
and
stripping
valve
bypass
Field Opr.
block
valves.
Bleeder of these c/v s to be

7
8
opened.
Adjust RCO cooler O/L
Panel/Field Opr.
Panel/Field Opr.

9
C
Panel/Field Opr.
10

Panel Opr.
down / Column pressure comes

11
under control.
Route product to off grade
Field Opr.
12
tank.
Field Opr.
13
pump.
Panel/Pump. Opr

14
comes down.
Decommission
Naphtha / sko
LPG
Field Opr.
caustic wash
15
16
system
Field Opr.
S/I/Panel Opr.
17

Field opr.
18
valve.
Inform i/m & e/m people to
S/I
attend the problem.

ON RESUMPTION
Field Opr.

2

Panel/Field Opr.
Field Opr.
4
5
Light gas burner.

Increase temperature @ 40
Field Opr.
Panel/Field Opr.
deg. C/hr.
Panel opr.
line.
Check the unit for any leak.
S/I/Field Opr.
8
9
Fix it if so.
Take oil burner.
Field Opr.
Panel/Field opr.

10
circulation.
Panel/Field Opr.
11
12
strippers.
Start top reflux pump when
Panel/Field Opr.
Panel/Pump Opr.
level appears. (Drain water

13
completely.
Start sour water pump & rout
Pump/Field Opr.
14
15
to SRU.
Panel Opr.
Panel/Pump Opr.
16
17
level appears in stripper.

Heat up stabilizer bottom &
Panel opr.
Panel Opr.
Sl

JOB DESCRIPTION
Action by
.No
18
YES/NO
Drain water from V3 when
Field/Pump/Pane
level appears & start reflux
l opr.
pump&
19
Done
adjust
column
condition.
after commissioning caustic
wash system.
Field Opr.
Remarks
20
Field Opr.
21
22
tank.
Sent sample to lab.
If certified, divert product to
S/I
Panel/Field Opr.
23
on grade tank.
Take all inter locks in line
Panel Opr.
8.12 DCS CONSOLE FAILURE

If DDCS CONSOLE is failed, but UPS is running, the following effects will be seen:
All screens will be turned to blank.
Unit is running but there is no control on unit.
ACTION TO BE TAKEN
Call Inst. People to load it from History module as early as possible.
Normalize the unit if anything found wrong.
Unit cannot be run long time with this problem. It is to be shut down.
Sl
JOB DESCRIPTION
Action by
.No
1
Field Opr.
YES/NO
2
3
burner oil guns with steam

Isolate main FG line B/V
Field opr.
Field Opr.

4
the heater with steam

Close CC-001/3/4
stripping
Field Opr.
steam control valve block valves

and bypass valves. Bleeder of
5
these c/v s to be opened.

Open
Done
pass
flow
required.
Adjust
RCO
bypass
cooler
Field Opr.
if
O/L
Field Opr.
Remarks
C.
Monitor desalter pressure from
Field Opr.
field
Field Opr.
furnace to forced draft mode

Panel Opr.
down / Column pressure comes

10
under control.
Open Column / Vessel PIC
Field Opr
bypass to maintain pressure if

required. Pressure to be seen
11
12
13
from field.
Stop all chemical injection pump
Field Opr.
Field Opr.
Pump/Field Opr

comes down. Level to be seen
14
from the field.

Decommission LPG / Naptha /
Field Opr.
15
16
SKO caustic wash system

Field opr.
S/I
17

Field Opr.
18
valve.
Inform Instrument / Electrical
S/I
people to attend the problem
ON RESUMPTION OF 24 V
POWER SUPPLY
1
2
Establish crude circulation

Start FD fan, if stopped
Panel/Field Opr.
Field Opr.
Panel/Field Opr.
4
5
6

Light gas burner.
Field Opr.
Field Opr.
Panel/Field Opr
C/hr .
Panel opr.
line.
Check the unit for any leak. Fix
S/I/Field Opr.
9
10
it if so.
Take oil burner.
Field Opr.
Panel/Field Opr.

11
circulation.
Panel/Field Opr.
12
13
strippers.
Panel/Field Opr.
Field /Pump Opr.
appears.(
Drain
water
14
completely).
Pump/Field Opr.
15
16
SRU.
Panel Opr.
Pump/Panel Opr.
17
18
19
level appears in stripper

Heat up stabilizer bottom.
Panel Opr.
Panel Opr.
Field/Pump/Pane
l Opr.

Field opr.
20
after
commissioning
caustic
21
wash system.
Field Opr.
22
23
tank.
Sent sample to lab.
S/I
Panel/Field Opr.
grade tank.
24
Panel Opr.
8.13 FIRE IN THE PLANT

EFFECTS
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.
ACTION TO BE TAKEN:
In no way get panic as it may result in some inappropriate decisions.
Initial fire fighting is to be started by plant personnel with available fire

extinguisher & water hydrants.
Immediately call the fire people at 7333 or 6333 for help.
Isolate the equipment or hydrocarbon to the equipment if fire is not being

controlled.
Damage by the fire to be immediately observed & its effect to normal

running of plant.
If anything abnormal is observed, Tput reduction to be started so that unit

can be taken on circulation (Hot or cold) or shut down in short duration
depending on situation.
Product colour to be observed continuously
If fire gets extinguished immediately unit conditions to be normalized.
CHAPTER-9
PROCEDURES FOR EQUIPMENT
HAND OVER TO
MAINTENANCE/INSPECTION
EQUIPMENT HAND OVER TO MAINTANANCE/INSPECTION

PROCEDURES FOR PREPARATION OF EQUIPMENT HANDLING OVER
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.
9.1
PUMP
9.1.1
COLD PUMP
Sl.No
Description
1
2
Close first discharge valve then suction valve, (close

MOV & MOV bypass valve)
Pump casing liquid drain in to OWS. (For LPG & high
RVP product service pump casing liquid to be vent in to
flare and after de-pressuring the pump vent to flare
STATUS
Yes/No
Remarks
valve to be closed.
If pump service is for heavy product, take FLO and
drain in to OWS (for flushing the pump casing)
If pump service for Caustic, Amine, Anti-oxidant or

other chemical drain pump casing liquid in to chemical
drum and then flush with water two or three times.
If mech. Seal flush line is there, close seal flush line

valve
NOTE: - Ensure pump casing liquid free by checking
drain line and seeing pump pressure gauge
If mech. Seal and pump bearing cooling water line is

there, close cooling water line valve
Pump motor & its auxiliary motors power supply

isolate from sub-station
Ensure that "DON'T OPERATATE, MEN AT WORK"

board is to be kept at the site
HOT PUMP
9.1.2
Sl.No
Description
Close first discharge valve and warm-up valve then

suction valve, (close MOV & its bypass valve)
Cool pump below 200 deg. C.
Pump casing liquid drain in to ows
If mech. Seal flush line is there, close seal flush

line valve
If quench steam line is there, close quench steam

valve
If pump service is for heavy product, take FLO and

drain in to OWS (for flushing the pump casing)
If auxiliary oil pump is there, stop oil pump after

cooling the main pump below 70 deg. C
NOTE: - Ensure pump casing liquid free by
checking drain line and seeing pump pressure gauge
8
9
If mech. Seal and pump bearing cooling water line

is there, close cooling water line valve
Pump motor and its auxiliary motors power supply
STATUS
Yes/No
Remarks
isolate from sub-station.

NOTE:
Ensure pump casing liquid free by checking drain line and setting pump
pressure gauge.
If mech. Seal and pump bearing cooling water line is there, close cooling
water line value.
Isolate pump motor and its auxiliary power supply from sub-station.
Now pump is already for handing over to maintenance.
9.2 VESSELS
The vessels used in oil refineries are mainly for light/heavy hydrocarbons and some
chemicals. When the necessity arises for a person to enter into the vessel, the following
procedures should be followed:
Sl.
Description
No
1
Equipment is to be electrically isolated and tagged

wherever necessary. It should be ensured that electrical
switches are locked out and properly tagged duly signed
with date and time.
Equipment to be isolated/closed disconnected. Vessel
should be completely isolated from other equipments, in

order to ensure that there should be no change in the
work environment
Equipment is to be properly depressurized/drained.
Depressurise vessel content to CBD /OWS after
isolation
Depressurise vessel content to flare by opening
STATUS
Yes/No
Remarks
flare line b/v

Keep some pressure 0.5Kg/cm2, if vessel has
heavy hydrocarbon for proper draining
Note:
a) If vessel contains hot material (>200 C)
then drain to CBD after sufficient cooling
b) Watch the level and pressure of CBD
during draining
c) Vessel having sour water and hydrocarbon
the sour water to be drained O.W.S
To ensure the complete draining open OWS b/v
and check for liquid draining/gas may come
After complete draining, close CBD/OWS b/v
Vessels containing liquid/ light hydrocarbons
should be drained completely by opening all low
point drains (L.P.D) of connected pippins, level
gauges and stand pipes etc. by unplugging the
L.P.D
Vessel containing any chemical should be drained
4
in chemical Blow Down vessel (Ch.B.D) only

Vessel to be disconnected/blinded/wedge open
Ensure complete draining
Inlet/outlet any injection is there to be blinded/
Wedged opened and/or disconnected. Vent and
utility system lines to be de-blinded
1. Vessel to be properly steamed/purged
Open saturated steam drain B/V for condensate
draining.
Charge steam to the vessel minimum and watch
the pressure.
Open all high point vent and drain points.
Open steam B/V as per requirement.

Open drain (vessel) to O.W.S.
Check the condensate for oil containments
Ensure complete removal of hydrocarbon by
condensate checking.
If necessary stop steaming for sometime and recharge the steam.
Vessel containing only gas purging can be done
with inert gas, nitrogen.
Ensure venting/draining of steam from all H.P.V.
as L.P.D. of level gauges, stand pipes and other
pipes.
5
Vessel is to be water flushed:

Water flushing is an effective means of cleaning
and cooling.
Vessel containing liquid hydrocarbon, hot water
washing to be done.
Vessels metallurgy must be considered before
using water for washing.
Hot water washing to be done by using steam and
water.
Ensure proper draining of the vessel.
Observe
for
any
abnormal
sound
(steam
hammering) in the vessel

Reduce water and open drains sufficiently, if not
opened fully.
Stop the water drains the condensate and watch
for any oil or small of gas etc.
Start again water & steam and repeat 3/4 times
till the clear condensate is not coming.

Ensure complete hydrocarbon/chemical washed
out.
Stop the steam.
Stop water after sufficient cooling.
Open top and side man-ways.
Put exhaust fan on top/side man ways (if
required).
Utility steam line & N2 to be blinded.
6
Water hose to be disconnected.

Gas/Oxygen deficiency test to be done:
Check the vessel material, hydrocarbon or mud at
the bottom.
Do gas (hydrocarbons) test by explosive meter.
Oxygen deficiency by oxygen meter.
Toxic gases like hydrocarbon sulphite, carbon
monoxide, and chlorine etc. test to be done by
special techniques.
No hot work shall be permitted unless the
explosive meter reading is zero.
Vessel entry where no hot job is to be carried out
may be permitted if combustible gases are up to
5% of lower explosive limit (LEL)
Vessel entry with an air-supplied mask may be
permitted with LEL of 50%.
The oxygen level should be at least 19.5 vol%
and the concentration of toxic gases below the
threshold limit
Proper ventilation and lighting provisions:

Where natural (sufficient) ventilation is not
available, fans/ air eductor, air hose to be

provided.
Only approved reduced voltage extension (24
volts) lights are to be provided for work inside
vessels.
Flood light to be provided outside of the vessels.
8
Proper means of exit to be provided:

Proper means of exit to be provided if an
alternate route of escape not existing.

Precautionary tags/boards are to be provided:
To prevent any unwarranted entry in the work
area precautionary tags/boards are to be provided
such as No Entry or Caution-mean at the work
10
Inside on the manhole of the vessel.

Iron sulphide to be removed/Kept wet:
The vessel containing light hydrocarbon and sour
water may contain pyrophoric substance.
Vessel to be kept wet with water.
Sludge to be removed along with water and kept
wet until they are removed from the site, at safe
11
location.
Stand by person to be provided outside the vessel
(minimum-2) near the man way. All the above activities
to be competed and vessel are cleaned with proper
precautions then man entry can be given for inspection
and maintenance purposes.
9.3 COLUMNS
In petroleum refineries, this equipment is more prone to deposit pyrophoric substance.
Deposits of iron sulfide are formed from corrosion products that most readily accumulate
at the trays, pump around zones and structured packing. If these pyrophoric iron sulfide
(PIS) deposits are not removed properly before the columns are opened up, there is a
greater likelihood of PIS spontaneous ignition. The trapped combustible hydrocarbons,
coke, etc. that do not get adequately removed during steaming / washing often get
ignited, leading to fires and explosions inside the equipment. These fires not only result
in equipment damage but can also prove fatal for the personnel who are performing
inspection and maintenance work inside the columns. This is entirely avoidable if safe
procedures for column handover are followed.
The targets of these procedures should be two fold:
First, to remove all the combustibles Second, to remove or neutralize pyrophoric iron
sulfide deposits.
Column should be completely isolated from other equipments piping etc. in order to
ensure that there should be no change in the work environment.
1) Steps for column de-pressurization/draining:
1
Column to be isolated/closed/disconnected
Column should be completely isolated from other
equipments piping etc. in order to ensure that
there should be no change in the work
environment
Column to be properly depressurised/drained:
Column under pressure to be depressurised to
fuel gas and then to flare after isolation
Deblind the closed blow down (C.B.D) and OWS
connection/pipes of column and connected
pipings, such as pump suction headers and reflux
line.
De-cap the low point drain(L.P.D) and high point
vents (H.P.V) as pipelines, level gauges, stand
pipes and other tappings connected.
Drain the column material to C.B.D.
Drain the pumps suction headers of draw-off

products to C.B.D if provision is not there then in
O.W.S. and drain the other connected pipelines at
L.P.D. through hose connections to C.B.D or
O.W.S.
Ensure complete draining by opening O.W.S.

line. Close all drain B/V and watch the column
pressure and level, if any increase then again
draining to be done,
Columns containing chemicals like caustic amine
etc. to be drained in
chemical blow down (C. B.D.) vessel only.
3
Column to be disconnected/ blinded/ wedge open:

Ensure complete draining
De-blind top vent and utility steam
Blind/wedge open all the take off (draw off) and
return lines
Column to be properly steamed/purged:
Open saturated steams/utility steam to the column
Open vent and other High Point Vent of all
instruments and other connected piping
Open all L.P.D of level gauges and stand pipes
etc.,
Watch column pressure and level
If required wedge to be increased and/or increase
the steam
Check the condensate for oil in condensate
Ensure
complete
steaming/oil
removal
by
observing condensate
columns in which N2 purging is to be done
wedged opening not required
5
Ensure that all H.P.V & L.P.D are clear/dechoked

Column to be water flushed/Hot water washed:
Water flushing is an effective means of cleaning
gas freeing and cooling
Columns containing hydrocarbons-Hot water
flushing to be done
Columns metallurgy must be
considered before using water types (Cooling

water/DM water) for washing
Hot water washing to be done by using steam

from bottom and water from top
Ensure proper draining of column
Observe for any abnormal sound like steam
hammering in the column
Ensure complete washing by checking condensate
drains
Stop steaming and continue water washing for
sufficient cooling
Stop water washing
Open alternate man ways starting from top of the
column
6
Install exhaust fan/evacuator on top man way

Gas/Oxygen deficiency test is to be done:
Check inside through man ways e.g. safety torch
for any foreign material/hydrocarbon/coke etc.
Do gas (hydrocarbon) test by explosive meter.
Oxygen deficiency test by oxygen meter.
Toxic gases like hydrocarbon sulphide, carbon

monoxide, and chlorine etc. test to be done by
special techniques.
Column entry where no hot job is to be carried

out may be permitted if combustible gases are up
to 5% of lower explosive limit. (LEL).
Entry with an air mask may be permitted LEL of
50%
The oxygen level should be at least 1.5% by

volume and the concentration of toxic gases
below the threshold limit.
No hot job shall be permitted unless the explosive
meter reading is zero.
After man entry get open the trays man ways for
inspection.
Open all the man ways.
Make arrangement inside column of rope ladder
etc.
Proper ventilation and lighting to be provided:

Where natural (sufficient) ventilation is not
available fan/air ejector/air hose to be provided.

Proper means of exit to be provided:
To prevent any unwanted entry in the work area
precautionary tags/boards to be provided such as
No Entry or Caution- man at work inside on
the manhole of the column.

Stand by persons are to be provided outside the column
(minimum-2) near the man way.

Note: If all the above activities are completed, then
column may be handed over for inspection and
maintenance work.
9.4 EXCHANGERS/COOLERS/CONDENSERS/REBOILERS:
Sl.No
1
2
3
4
5
6
7
Description
Isolate
and
bypass
exchangers/coolers/condenser/reboiler
Drain the content in CBD
STATUS
Yes/No
Remarks
the
Flush the equipment handling heavy material

with FLO to CBD. Open the OWS valve to
ensure complete draining
Provide blinds towards the exchanger on both
the tube & shell side
Give steam connection to the top vent. Steam
flushing to OWS opening to be done till the
equipment is hydrocarbon free
Water flush the coolers and condensers, which
were handling light hydrocarbons
Clearance to be given to hand over for
cleaning/maintenance job
9.5 TANKS:
Sl.No
1
2
Description
Pump out tank material to OM&S respective tank till losses
suction
Get Water hose connection from drain or through dip hatch
STATUS
Yes/No
and build up level for pumping out more hydrocarbons. As

far as possible hydrocarbon to be pumped out.
3
4
5
6
7
8
9
9.6
Get tanks 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 mater. 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
FURNACE
Sl.No
1
2
3
4
5
6
7
8
Description
STATUS
Yes/No
Remarks
Shut down the furnace as per procedure and

blind fuel gas lines
Open the damper and air registers fully
Isolate and flush fuel oil circuit first with FLO
and then with
steam till it is hydrocarbon
free and blind fuel oil lines (I/L & O/L)
Open all manholes/ inspection holes of
furnace
Blind all steam as per blind list (box purging
steam, atomizing steam, emergency steam,
soot blowing steam & Decoking steam)
When the box cools down to around 50 Deg.
C, De-energize ID / FDs
Check for hydrocarbon & oxygen content
inside furnace
Give clearance for "MAN ENTRY" and
maintenance jobs
9.7 FLARE HEADER HANDOVER FOR MAINTENANCE:

Sl.No
1
2
Description
Ensure that all equipments connected with
flare system are depressurized after shut down
Provide steam connection if not there at the
furthest end of the system
STATUS
Yes/No
Remarks
3
4
5
6
7
8
9
10
11
12
13
Isolate all PSV/ lines connected to flare

header
Introduce steam & purge the system to flare
for 4-hrs.drain condensate from KOD drain
Reduce steaming to minimum & close battery
limit valve of flare header. Open U/S bleeder
of battery limit valve
Give clearance to provide blinds /wedge
opening at U/S
Open the drains and vents of all instruments
and of knockout drum
Increase steaming rate & continue for 8 hrs
Stop steaming
Check hydrocarbon content with explosimeter

Give clearance for maintenance jobs
If man entry in KOD is involved carry out
water washing after steaming. Blind its I/L &
O/L flange
The muck coming out from flare system
should be separately disposed off, as it is
likely to contain pyrophoric iron
9.8 CONTROL VALVES:

Sl.No
1
2
3
4
5
Description
STATUS
Yes/No
Remarks
STATUS
Yes/No
Remarks
Bypass the control valve

Close up-stream and down-stream b/vs
Drain c/v loop, Ensure isolation valves are
holding
Give clearance for removing the c/v
End blind the open flanges
9.9 SAFTEY VALVES

Sl.No
1
Description
Take spare safety valve in line if provided
2
3
4
5
Isolate the safety valve

Ensure that isolation valves are holding by
depressurizing the loop through LPD
Give clearance to open the safety valve
End blind the open flanges
CHAPTER-10
PROCEDURES FOR EQUIPMENT
TAKING OVER FROM MAINTENANCE
EQUIPMENT TAKING OVER FROM MAINTENANCE

If equipments are not properly checked while taking over from maintenance it may result
in accidents or give troubles during start-ups. Check the following items while taking
over any equipment from maintenance.
9.1 PUMPS/MOTORS:
Sl.No
1
2
3
4
5
6
7
Description
STATUS
Yes/No
Remarks
/ FIN
COOLERS
Check that electrical cable and earthing

connections are complete
Ensure mechanical completion. See that 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 lines are blinded / deblinded as
required for normal run
Check all vents / drains are closed and capped /
blinded
10.2 EXCHANGERS
/REBOILERS
/ CONDENSERS
/ COOLERS
Sl.No
Description
STATUS
Yes/No
Remarks
1
2
3
4
5
6
Tube and shell cleaning is proper

Leaky tubes are plugged / replaced
Shell is painted as per inspection
Exchanger is properly as per inspection
Check for short bolting
All flanges gasket that were opened during
maintenance are replaced by new gaskets
7
Bull plugs, thermo wells, pressure gauge
assemblies, PSV/TSV's are in position
8
Insulation is complete
9
Fan belts and covers are in position, in case of
Fin coolers
10
All flanges are deblinded
11
Electrical /earthing connections are complete
10.3 FURNACE
Sl.No
Description
1
2
3
Heater tubes are cleaned

All foreign material is removed from the fire box
Skin thermocouples / oxygen analyser and other
instrument are in position

All tubes ( convection / radiation) are properly
cleaned
Man ways, explosion doors, peep holes, header
box covers are boxed up

Stack damper operation is smooth and damper's
7
8
9
open / close position indicators are correct

Operation of all burner valves is satisfactory
Burner alignment is correct
Blinding / de-blinding is done as per the master
10
blind list
Steam and oil connections to the individual
11
burner gun are correct

Area around the furnace is cleaned.
9.4 VESSELS:
STATUS
Yes/No
Remarks
Sl.No
1
2
3
4
Description
STATUS
Yes/No
Remarks
STATUS
Yes/No
Remarks
Vessel is thoroughly cleaned

No foreign material is left inside
Drain points and instrument tap are clear
Vessel's internals including instrument are in their
respective
positions
and
properly
secured.
Demister pads are in position

Vessels is coated /painted as per inspection report.
Take clearance from inspection

If all the above things are satisfactory give
clearance to box up the manhole

Manhole should be boxed up on four bolts in
8
9
10
11
12
presence of production staff

Remove the blinds as per master blind list
Connect the blinds as per master blind list
Line-up all safety valves
Vessel is ready for service
Cap / blind drain / vents
10.5 COLUMNS:
Sl.No
Description
1
2
Inspect tray man-way box up and properly bolted

The tray decks below the manhole are clean and
3
4
free of foreign material

Temporary connections are removed
All instrument tapings drain points, distributors,
5
6
down-comers, inlet and outlet nozzles are clear

All internals as fitted properly
All inside fittings like distributors, thermo wells,
7
8
flats of level indicator, etc are in position

Tray man way covers are boxed up
Manholes are boxed up on 4 bolts while ensuring
that nobody is left inside

Tray man way and manholes should be
10
boxed up in presence of production staff

All man way covers are boxed up as above with
11
new gasket
Blinding /de-blinding is complete as per master
12
blind list
NRV's are installed in their proper direction
Column bottom drains are connected properly &
13
14
15
are clear
Safety valve are installed and lined up
The instruments are in their respective position
The column is ready for service
CHAPTER-11
SAFETY
SAFETY
11.1
FIRE PREVENTION ACTIVITIES:
Regulation for the prevention of fire:

1) Ban on carrying of a potential source of ignition, ban on lighting fires in battery area.
Ban on smoking, Ban on carrying lamps, use of spark arrestors.
2) General precautions:
Maintain good house keeping. Follow the laid down procedure strictly. Sampling and
draining of hydrocarbon should be done under strict supervision. Do not operate
equipment unauthorized. Use only approved type of tools, anticipate the hazards during
vessel cleaning and take preventive step in advance.
11.2 FIRE PREVENTION ACTIVITIES
Fire prevention can be best achieved with the application of:
11.2.1 SOUND ENGINEERING:
Design of the plant materials used for construction means of escape etc.
11.2.2 GOOD HOUSE KEEPING:
Cleanliness of the plant, methods of storage.

Good habits: observation of fire prevention rules etc.
Common sense: No smoking near inflammable material etc.
11.2.3 INSTRUCTION TO PERSONNEL
Knowledge of job.
Safe practices.
Action in case of fire.
Knowledge of fire extinguishers etc.
11.2.4 REGULAR TRAINING OF EMPLOYEES
Induction training program.

Refresh course.
Special listed training programmes.
11.2.5 SAFETY AUDITS
1) INTERNAL
2) EXTERNAL
VARIOUDS SAFETY STUDIES:

Ex. Risk analysis hazop, hazan, etc. prior to commissioning of any plant or equipments.
COMPLIANCE OF STAUTORY REQUIREMENTS:
INSPECTIONS:
To check for proper placement and operation of fire protection equipment and seek
correction of common fire causes, such as poor housekeeping improper storage of
flammable materials, smoking violations and excessive accumulation of dust of
flammable material.
11.2.6 FIRE EMERGENCY MOCK DRILLS
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 exits and 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.
11.3
FIRE PROTECTION SYSTEM IN REFINERY
FIRE STATION:
Our refinery has two fire stations. Equipped with all modern equipments & trained man
power.
COMMUNICATION:
Ex-telephones: Fire call numbers 7333 & 63333, Hot lines for communicating mutual aid
member, P.A., paging, walkie-talkie system fire alarm: By breaking the glass of any of
the alarm located in the refinery area: At GR-62 nos. & at GHS-53 nos. Sirens 11 nos. at
various locations.
FIRE PROTECTION:
Following fire protection facilities provided depending upon/risk of the installation:
FIRE WATER SYSTEM:
Fire water storage 22,400 M3.
Fire water pumps 8300 M3/hr.
Distribution piping network- approx. 50 Km.
Hydrants (around 1000)
Monitor around (400)
Water spray system (Oil tanks & hydrocarbon pump houses) LPG area as per OISD-116.
FOAM SYSTEM:
Semi fixed:
Provided an oil storage tanks. Railway gantry no.6
Mobile:
Foam tenders 5 Nos. & foam nurser:1
MOBILE FIRE FIGHTING EQUIPMENTS:

Foam tender:
DCP tender:
Emergency tender:
Foam nurser:
CARBONDIOXIDE PROTECTION SYSTEM:

Turbines and generators in power plants
FIRST AID FIRE FIGHTING EQUIPMENT:
First team comprising of operation/maintenance staff at site & any other refinery person
available at site this persons will handle the situation till the arrival of trained fire fighter
with the help of.
PORTABLE FIRE EXTINGUISHERS:
Dry chemical powder, foam, Water type, CO2, halon
10 Kg: 2000 Nos., 25 Kg Trolley mounted: 100 Nos. DCP Trolley mounted 75 Kg.
175 Nos. Foam type Trolley mounted 45 lts : 30 Nos.
FIRE FIGHTING TEAM:
First main team comprising of shift in-charger of fire stations, fire operators on duty with
fire fighting equipments and officers from fire and safety & CISF personnel.
Second main team: Fire operators (Re-enforcement), CISF staff(reserve as well as on

duty except for gate staff), fire fighting crew from external sources (like neighboring
industries , BMC etc.)
11.4
FIRE PROTECTION SYSTEM IN THE UNIT

A.
Fire extinguisher:
200 NOS.(10 kg DCP)
B.
Fire glass:
20 NOS.(25 kg DCP)
C.
Fire water monitors:
from all four sides.
and hydrants
D.
Tower platform monitors:
3 NOS.
E.
Water sprinkler system:
in pump house and at

Caustic/water vessels and on fin coolers.
F.
Hydrocarbons gas detector, near P-5A/B,P-6A/B, P-14A/B, P-50A/B,

PA- 07A/B
G.
Safety shower and eye washer:
2 No.
(Near caustic tank, near furnace)
H.
Riser hydrant:
A) at vessel platform
B) all columns.
11.5 WORK PERMIT SYSTEM

Work permit is a written document that categorically spells out
The task.
Equipment involved & its condition.
Its location.
Personnel involved.
Time limitation
Precautionary measure to be taken together with likely hazard to be encountered,

if any.
Act as a predetermined checklist for various safety precautions.
Serves as a media of information.
Instills a sense of security from accident.
Work permit system is required in the refinery as per, Sec.7(2a) SSW

OISD-105
Rule 172 of petroleum rules, 1976
OBJECTIVE:
To make the procedure of the work foolproof.
To guarantee against accidental starting of machinery or entry of
any hazardous liquid or gas into a vessel whose jobs are proposed.
11.5.1
11.5.1.A
TYPES OF WORK PERMITS:

HOT WORK PERMIT
Hot work permit is issued for an activity, which may produce enough heat to ignite a
flammable substance i.e. welding, gas, cutting etc.
11.5.1.B COLD WORK PERMIT
Cold work is an activity, which does not produce sufficient heat to ignite a flammable air
hydrocarbon mixture or a flammable substance.
11.5.1.C EXCAVATION PERMIT
For Excavation Permit clearance is required from other

departments i.e. electrical, Instrumentation & civil.
Every excavation shall have a safe access way.
No one is permitted to excavate if any equipment is working next
to the edge of expected excavated area.
If the depth of excavation is more than 1.5 meters, one ladder

shall be provided for every 20 meters of length.
Adequate number of persons should be made available outside the
pit for rescue purpose in case of any emergency.
No job is permitted in a pit after sun set.
11.5.1.D WORK AT HEIGHT PERMIT
Whenever any worker is engaged on work at a place from which he is liable to fall more
than 2 meters, he shall be provided with a safety belts equipped with life-lines, which are
secured with a minimum of stakes to a fixed structure of anyother effective means.
Helmet shall also be used.
11.5.1.D WORK AT DEPTHS
For entry into confined spaces permit is a must. The intent of an entry permit is that all
necessary measures are taken to protect entering personnel against such hazardous as
oxygen deficiency, hazardous gases, contamination, high temperatures, fire and difficulty
in escaping etc and also to make sure that all concerned are well informed of the job in
progress so that they can avoid hazardous operations connecting to the proposed work
site.
11.5.1.F ELECTRICAL WORK PERMIT
Before issuing any permit to the Maintenance or Engineering personnel for any
maintenance work on any equipment, the shift in charge of the production department
must ensure that electrical isolation has been obtained from the concerned electrical
supervisor. No permit for the work will be issued unless the electrical isolation has been
obtained.
11.5.1.G
VESSEL ENTRY PERMIT
No hot work shall be permitted unless the explosive meter shows

zero.
Vessel entry, where not 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 upto
50%.
The oxygen level should be at least 19.5 vol% and the
concentration of toxic gases below the threshold limit.
11.5.2
RESPONSIBILITIES OF THE PERMITTEE:
A permittee is a supervisor in charge for the particular maintenance of the equipment or a

system requiring such maintenance. He is required to ensure scruples compliance of the
instructions mentioned in the permit and make available to his persons, fire and safety
equipment etc. required for the job.
11.5.3
RENEWAL OF THE PERMIT:
Normally the permit is issued for seven days only. However, if the removal is required to
be taken if should be distinctly understood that renewal or revalidation has to be done by
the authority who is competent to issue of permit after ensuring all necessary checks as
for a fresh permit. The renewal is to be recorded on all the copies of the permit.
11.5.4
SURENDERING OF THE PERMIT:
After the maintenance job is over, the permittee should fill up the permit and handover
the same to the permit issuing authority (issuer) as taken of having completed the job and
surrender the permit. Permittee must also ensure that all the tools, tackles & safety and
fire fighting equipment are removed from the site and the area cleaned to avoid accidents.
11.5.5
SIGNATORIES FOR FIRE PERMITS:
For any Hot work / Vessel Entry or Excavation permit on any holiday / Sunday and
extended hours working, approval / clearance of HOD of that area along with clearance
from RSM in each shift is essential.
For any cold work on Holiday / Sunday and for extended hours working, approval /
clearance of Manger / Sectional head is essential.
For Tank Dyke cutting approval / clearance of HOD is essential.
11.5.6
COPIES OF PERMIT:
1) Following persons / department shall keep a copy of work permit.

a) Person doing the job and shall make the permit available at site.
b) Area in-charge
c) Fire Station.
2) After completion or stoppage of the job, the person to whom the permit was issued,
should throughout by check the area for clearing of debris, removal of temporary
electrical installations etc and then sign the work permit and return it to the issuer
who in turn will keep it stored for future reference.
11.5.7
POINTS TO BE ENSURED WHILE GIVING CLEARANCE:
1) Equipment / Area inspected.

2) Surrounding area checked / cleaned.
3) Sewers, Manholes, CBD etc and hot surfaces covered.
4) Consider & ensure no hazard from other routine / non-routine operation and alters
surrounding / concerned persons.
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 / depressurized, steamed / purged.
9) Firewater system checked for readiness.
10) Equipment water flushed.
11) Gas / oxygen deficiency test done and found OK.
12) Shield against sparks provided.
13) Proper ventilation and lighting provided.
14) Proper means of exit provided.
15) Precautionary tags / boards provided.
16) Portable equipment / Hose nozzles properly grounded.
17) Standby personnel provided for fire watch from process / maintenance /
contractor / fire and safety department.
18) Iron sulfide removal / kept wet.
19) Area cordoned off.
20) Precautions against public traffic taken.
21) Clearance obtained for excavation / road cutting from technical / fire / concerned
departments.
22) Clearance obtained for dyke cutting.
23) Checked spark arrestors on mobile equipment.

24) Checked for oil / gas trapped behind lining in equipment.
25) Check for hot tapping.
Note: For further details refer Refinery safety manual kept in Control room.
11.5.8 ACCIDENT REPORTING PROCEDURE:
With a view to timely transmission of the information or submission of the notice of the
accident to the inspector of Factories within the stipulated time prescribed under rule 103
of Gujarat Factories Rule, 1963 the following procedure has been followed by Gujarat
Refinery.
Any accident, however, small to an employee is reported to HOD supervisor/ shift-incharge. When the injured is not in a position to report himself, such reports are made by
anybody present at the site of the accident.
As soon as the supervisor gets the information, he arranges for the ambulance from the
hospital and also informs the following :
Fire station
Hospital
Sectional/department head
Refinery shift Manager.
The supervisor also fills the accident from no. A-1 in triplicate. The original copy of the
form is sent along with the injured to hospital. The medical officer on duty examines the
injured employee, if the nature of the injury is such that the injured person requires rest
for more then 48 hours. A lost time accident report is prepared by the medical officer in
the form A-II and sent the same to fire and safety department. The medical officer
indicated the probable days of rest required by the injured person.
On receipt of the Medical officer report, the personal department informs the factory
inspector as required under the provisions of factories act 1948 and Gujarat factory rules
1963. After receiving form A-II from the fire and safety section in form no.21. One copy
is sent to fire and safety section and third is retain by the personal department.
Medical Fitness Certificates : Form No. A-II

In a 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 will be allowed to resume the duty
accordingly.
In case the injured person is likely to become disabled for 24 hrs. or more he shall be
marked as on Accident leave and is allowed to join duty on production of fitness
certificates form A-III to Fire & Safety section, personal Department, Time office and the
concerned section. The medical officer concerned shall send the copies of form A-III to
the fire & safety department, personal department and the concerned department. In case
the employee has developed any permanent disability the medical office assess the
disablement of the injured person on the form A-IV and sends the report to Personal
Department, Fire & Safety Section, Accounts Department and the concerned section.
The Personal Department, on receipt of the joining report of the injured person the
recommendation of the Department Head and the report of the Medical Department of
form A-IV, shall take action for the payment of leave wages and compensation if due by
issuing necessary memos to the Account Department.
FATAL INJURIES:
In case of fatal injury, the statutory obligation says that the situation when the accident
occurred should remain as far as possible undisturbed till arrival of police. Therefore,
with the exemption of removing the casualty from the scene of accident this requirement
is strictly observed and following persons are immediately informed:
General Manager/Executive Director
Chief Medical Officer
Manager (Fire & Safety)
Chief Human Resources Manager
Personal department immediately informs them relatives of the injured. Police and
Inspector of factories:
INVESTIGATION REPORT:
In case of any accident, whether minor or of lost time nature, the supervisor will arrange
to send an investigation report to the fire and safety department and the concerned
department head on form number A-V within 48 hours of the accident.
11.5.9
CONTROL VALVE FAIL SAFE CONDITION
S.No.
TAG NO.
SERVICE
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
S.No.
5LV2602
5LV3104
5LV3106
5FV1807
5FV2502
5LV3202
5PV1701
5FV2501
5PV3111
5FV1508
5FV2011
5FV2503
5PV1415
5PV1504A
5PV1504B
5PV1912
5PV2011
5PV3203
5PV4406
5SDV1406
5SDV1701
5SDV1901
5SDV1902
5SDV1903
5SDV1904
5SDV2001
5SDV2002
5SDV2003
5SDV2201
5SDV2202
5SDV2203
5SDV2601
5SDV2602
5LV1201
5LV3103
5FV1201
5FV1409
5FV2501
5LV1602
TAG NO.
BOILER FEED WTR

RICH AMINE TO ARU
LPG BOOSTER PMP FLW
VENT FRM VV-003
LPG SURGE DRM
FO TO VV-026(BPC)
LPG FRM PA-014A/B
FO TO HTR
FG TO VV-002
LPG PRODUCT R/D
FG SUPPLY(PILOT)
DRAIN FRM VV-003
WASH WTR EX VV-007
WTR EX VV-008
CASTIC EX VV-009
WASH WTR EX VV-010
WTR FRM VV-025
CAUSTIC EX VV-013
WASH WTR EX-VV-014
WASH WTR EX VV-015
AMINE SETTLER BTM
FO TO VV-026
SOUR WTR TO VV-005
SERVICE
ACTION/ FAIL
SAFE CONDITION
A/C (FO)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/C (FO)
A/O (FC)
A/O (FC)
A/C (FO)
A/C (FO)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/O (FC)
A/C (FO)
A/O (FC)
A/O (FC)
ACTION/ FAIL
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
68
69
70
71
72
73
74
75
76
5PV3202
5SDV1401
5LV1202
5TV1702
5FV1401
5FV1402
5FV1403
5FV1404
5FV1804
5FV2206
5FV3102
5HV1701
5PDV1420
5SDV1402
5SDV1601
5SDV2501
5PV1423
5FV1410
5FV1412
5FV1413
5FV1414
5FV1505
5FV1805
5FV1806
5HV2001
5HV2002
5HV2201
5HV2202
5SDV1801
5FV1501
5LV1508
5LV1510
5SDV1403
5LV1206
5FV1502
5TV1116
SAFE CONDITION
A/O (FC)
FO RETURN
A/O (FC)
A/O (FC)
LOCK (FC)
CRUDE TO HTR PASS-1
A/C (FO)
CRUDE I/L PASS-2
A/C (FO)
CRUDE I/L PASS-3
A/C (FO)
CRUDE I/L PASS-4
A/C (FO)
HSD R/D
A/O (FC)
A/O (FC)
A/O (FC)
STABISER O/H VAPOUR
A/O (FC)
ATM STM TO HTR
A/C (FO)
FO SUPPLY
A/O (FC)
SOUR WTR TO SRU
A/O (FC)
A/O (FC)
FG TO HTR
A/O (FC)
A/C (FO)
A/C (FO)
A/C (FO)
A/C (FO)
TOP RFLX TO CC-001
A/C (FO)
LR TO BL(FPU)
A/O (FC)
LR TO BL STORAGE
A/O (FC)
A/C (FO)
LN WTR TO VV-010
A/C (FO)
A/C (FO)
KERO+ATF+WASH WTR TO VV-014
A/C (FO)
LN TO CAUSTIC WASH
A/O (FC)
A/C (FO)
KERO STRIPPER FEED
A/O (FC)
A/O (FC)
FG SUPPLY
A/O (FC)
A/C (FO)
ATF/KERO CR RETURNED TO CC-001
A/C (FO)
A/C (FO)
Note: a) A/O stands for AIR TO CLOSE

b) A/C stands for AIR TO OPEN
c) FC stands for FAIL TO CLOSE
d) FO stands for FAIL TO OPEN
11.5.10
CORRECTIVE ACTION TO BE TAKEN TO PREVENT HAZADOUS
SITUATION FROM ESCALATING

HAZARDOUS SITUATION
Severe hydrocarbon leakage
Furnace Coil Rupture
Severe Exchanger Leakage
Pump Seal Leakage
ACTION
Cut off all furnace
Take unit on circulation. If required
shutdown totally.
Block adjacent roads
Inform F&S
Isolate leaky section using PPEs &
depressurize to flare.
Inform RSM/CPNM
Open STD
Cut off fuel to furnace
Cut off feed
Put coil purging steam.
Take emergency S/D of entire
plant
Inform RSM / CPNM
Bypass exchanger-using PPE &
isolate it.
Depressurize
Keep steam Lancer
Inform RSM / CPNM
Cut off furnace if H/C vapor travels
towards furnace
Start stand by pump
Isolate the leaky pump
Depressurize
Keep fire Engine standby.
Inform RSM / CPNM
11.5.11 SAFETY SYSTEM AND THEIR FUNCTIONS

Following safety systems are available in our unit
1. PSVs
2. Interlocks
3. Hydro-carbon leak detectors
4. Fire water sprinkler system
5. PPEs
1. PSVs
Purpose: PSVs are provided to protect the equipments like columns, vessels, pipe line
etc by relieving excess pressure to flare / atmosphere when there is abnormal
pressurization due to CW failure or fire etc.
Where Situated: Normally it is situated at column top vessel top, compressor discharge
and positive displacement pump discharge.
Relieve Where: Normally to flare system.
Flare Knock Out Drum: All PSV discharge is routed to flare connected to a header
which is routed to flare KOD located at AU5 battery limit. Liquid which is carried along
with gas is settled in this vessel are drained out to CBD. Only gas from its top is send to
flare. It is provided with a level indication (with alarm). Level indication is transmitted to
DCS CR. In normal condition once in a shift draining is done.
2. Interlocks
Purpose: Meant for protecting of equipment in case of extreme deviation in parameter
from operating limit, before it reaches the equipment design limit.
Location: Furnaces
What all interlocks: (Furnace fuel will cut off if there is)
Low Combined pass flow
Low FG pressure
Low Fuel Oil pressure.
FD fan failure
ID fan failure (STD does not open with in 30 sec)
3. Hydrocarbon Leak detectors:
Facility: The unit is provided with 05 numbers of hydrocarbon detectors located at

vulnerable points where chances for leak is more. It senses the leak & if concentration is
more than the specified limit, will give signal to DCS control room through alarm. After
getting the alarm, Panel operator instructs the field operator to check physically the area,
for any leakage.
4. Fire water Sprinkler:
Firewater Sprinkler is provided on all black hot hydrocarbon pump for cooling purpose.
During pump seal leak & subsequent fire, sprinkler system is activated to cool the pump
to avoid damage to piping & structure. This system will be provided to all hot pump in
near future.
5. PPEs:
Safety helmet, safety shoe, rubber / canvas hand gloves, apron, Breathing apparatus, gas
mask/ canister for use in different gas atmosphere etc are provided for safe operation and
emergency handling in case of abnormal condition. BA set is kept in DCS control room.
Safety helmet & safety shoes have been provided to all operating personnel. Other PPEs
are available in Check & Change room of operators.
6. HVLR.
High Velocity Long Range monitor has been provided for spraying water jet at top of
high column during fire fighting
CHAPTER-12
MATERIAL SAFTETY DATA SHEET
MATERIAL SAFETY DATA SHEET (MSDS)
12.1 AHURALAN
AHURALAN ESK 50
1) CHEMICAL IDENTITY
Chemical Name
Corrosion Inhibitor
Synonyms
Corrosion Inhibitor
Formula
R1NHR2NHR3RH
Chemical
Classification
Trade Name
Long chain fatty

amine derivative
Ahuralan ESK 50
C.A.S. NO.
5285-60-9
UN NO.
Regulated
Identification
Shipping Name: Codes/Label

Hazardous waste: I.D. No. Hazchem Code
Ahuralan ESK 50
Hazardous
ingredients
C.a.s. No.
C.a.s. No.
Ahuralan
50
Hazardous
ingredients
ESK 5285-60-9
2) PHYSICAL AND CHEMICAL DATA

Boiling
Point/ 150 - Physical State
Liquid
Appearance
o
Range C
300
Melting/
Vapour pressure < 1 mmHg Odour
Freezing Point <10
@ 35 oC, mm @ 68oF
o
C
Hg
Vapour Density
(Air = 1)
Specific Gravity
(Water = 1)
Solubility
in Insoluble
o
water @ 30 C
0.83
pH
3) FIRE AND EXPLOSION HAZARD DATA
Solubility in
others
Not applicable
Viscous,
Yellowish brown
Pungent
Flammability
Moderate
LEL (%V)
TDG
3
UEL (%V)
Flammability
Auto ignition Temperature oC
228
Explosion Sensitivity to Impact
Explosion Sensitivity to Static
Electricity
Hazardous Combustion products CO, CO2
Hazardous Polymerization
Combustible
Yes
Explosive
Liquid
Material
Flammable
Yes
Oxidiser
Material
Pyrophoric
No
Organic Peroxide
Material
0.7
Flash Point (OC) oC
5.0
Flash Point, (CC) oC
No
Corrosive Material
No
Others
No
4) REACTIVITY DATA
Chemical Stability
Stable
Incompatibility
with
other None
material
Reactivity
Hazardous Reaction Products
5) HEALTH HAZARD DATA
Routes of Entry
Effects of Exposure/ Inhalation
Symptoms
Ingestion
Contact
Emergency Treatment
Inhalation, ingestion, contact
Obtain immediate medical attention.
37 66
No
Inhalation
Ingestion
Contact
LD50
mg/kg
(Oral-Rat),
Permissible
Exposure Limit
TLV
ppm
Remove affected person to fresh air. If respiratory

problems develop.
Do not induce vomiting.
Skin Contact : 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,
rinsing with warm water.
Eye Contact: Flush with water for at least 15 mins. If
irritation occurs.
LD50 ,
mg/kg
mg/kg
ppm
Odor Threshold, ppm

mg/kg
(ACGIH)
STEL,
ppm
mg/kg
mg/kg
NFPA Hazard Signals
Health
Flammability
Reactivity/Stabilit
y
Special
6) PREVENTIVE MEASURES
Personal
Equipment
Protective Gloves, footwear, coveralls, and/or apron as necessary to prevent

repeated or prolonged skin contact. 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
contact.
Handling and Storage Store in tightly closed, properly labeled containers in a cool, well
Precautions
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.
7) EMERGENCY AND FIRST AID MEASURES
FIRE
Fire
Extinguishing
Media
Special
Use water fog, foam, dry chemical powder, CO2

Use water to cool fire exposed components.
EXPOSUR
E
Procedure
Unusual Hazards
First
Aid Obtain immediate medical attention.
Measures
Inhalation : Remove affected person to fresh air. If
respiratory problems develop.
Antidotes/
Dosage
SPILLS
Steps to be taken
Ingestion : Do not induce vomiting.

Skin Contact : 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 Contact : Flush with water for at least 15 mins. If
irritation occurs.
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
Waste Disposal
or sewer. To prevent further losses, reposition, plug or
Method
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.
12.2
AMMONIA
AMMONIA
1) CHEMICAL IDENTITY
Chemical Name:
AMMONIA
Chemical Classification : Inorganic Compound
Synonyms: Liquid Ammonia, Ammonia Gas,

Ammonia Anhydrous.
Trade Name: Ammonia
Formula:
NH3
UN NO. 1005
Regulated
Identification
C.A.S.NO: 7664-41-7
Shipping Name : Ammonia
Codes/Label: Non Flammable Gas, Class 2

Hazardous waste I.D. No: 17
Hazchem Code : 2 PE
HAZARDOUS INGREDIENTS
C.A.S.NO.
C.A.S.NO.
1. Ammonia
7664-41-7
2.
2.PHYSICAL AND CHEMICAL DATA

Boiling Point/Range
-33.4oC
Physical State : Liquefied Compr.Gas
Appearance
o
o
: Colourless
Vapour pressure @ 35 C
7600 mm Hg at 25.7 C
Odour :
Strong Pungent Odour
Melting / Freezing
-77.77oC
Point
___________________________________________
Vapour Density
0.60 Solubility in water @ 30oC
Others
(Air = 1)
Very soluble
Moderately soluble in Alcohol
Specific Gravity
(Water = 1)
0.771
@ 0oC
pH: I N aq. Sol. 11.6
3.FIRE AND EXPLOSION HAZARD DATA

Flammability
No
LEL
TDG Flammability
NA UEL
Electricity
Hazardous Combustion products
16.0 % Flash Point oC

25.0 % Flash Point oC
651.0
Stable
Not available
Not Pertinent (OC)

Not Pertinent (CC)
Emits toxic fumes of NH3 & NOx

Does not occur.
eactivity
azardous Reaction
Combustible Liquid
Yes
Flammable Material
Pyrophoric Material
No
No
Explosive Material
Oxidiser
Organic Peroxide
No
Corrosive Material
No
No
No
Others
4.REACTIVITY DATA
Chemical Stability
Stable
Incompatibility with Strong Oxidisers, Calcium hypochlorite, Gold, Mercury, Silver,

Halogens,
Other material
Acetaldehyde, Acrolein.
Reacts with Silver chloride, Silver nitrate, Silver azide, chlorine, bromine, iodine,
heavy metals and their compounds, Incandescent reaction when heated with Calcium.
Reacts with Silver chloride, Silver nitrate, Silver Azide and Silver Oxide
Products
form explosive silver nitride.
5.HEALTH HAZARD DATA
Routes of Entry
Inhalation, Skin or Eyes
Effects of Exposure/ Symptoms: - 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.
Contact of the liquid with skin
freezes the tissues and causes the caustic burns.
Emergency Treatment Inhalation:- Remove the victim to fresh air and provide artificial
respiration or oxygen, if needed. Skin and Eyes : Wash the affected area with plenty of
water for 15 mins. Seek Medical Aid.
Permissible Exposure Limit 25 ppm 18 mg/m3 Odour Threshold 46.8 ppm
32.53 mg3
L.D50 (Oral-Rat)
350 mg/kg
3
TLV (ACGIH) 25 ppm 18 mg/m
STEL
35 ppm
27 mg/m3
NFPA Hazard Signals
Health
Flammability
Reactivity
Special
2
1
0
6.PREVENTIVE MEASURES
Personal Protective Equipment: - Avoid contact with liquid or vapors Provide rubber boots,
safety goggles, self-contained breathing apparatus, gas mask and protective clothing in case
of liquid ammonia.
Handling and Storage Precautions: -Avoid storing along with oxidizing materials and away
from all possible sources of ignition. Store in well ventilated flame resistant locations.
7.EMERGENCY AND FIRST AID MEASURES

FIRE
Fire Extinguishing Media
Special Procedure
Unusual Hazards
Stop flow of gas. Use water spray or fog.

Keep the containers cool
if exposed to heat or flame.
by
spraying
water
Gas is suffocating.
EXPOSURE
First
Aid
Measures
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.
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 vapors with plenty of water.
Waste Disposal Method :- Put into a large vessel containing water, neutralize with HCl
And discharge into sewer with sufficient water.
8.ADDITIONAL INFORMATION/REFERENCES
A human poison by an unspecified route. Difficult to ignite. NH3 and air in a fire, can
detonate. Potentially violent or explosive reactions on contact with interhalogens. Forms
sensitive explosive mixture with air and hydrocarbons. Those affected with eye and
pulmonary diseases should avoid exposure to Ammonia.
12..3
CAUSTIC SODA
CAUSTIC SODA
1. CHEMICAL IDENTITY
Chemical Name: SODIUM HYDROXIDE

Inorganic Compound
Chemical Classification : Alkaline
Synonyms: Caustic Soda, Soda Lye, Lye, Sodium Hydrate

Formula
1824
NaOH
Regulated
Identification
Trade Name : Caustic soda
C.A.S.NO. 1310-73-2
UN. No. 1823 /
Shipping Name : Sodium Hydroxide, Solid / Solution

Codes/Label
: Corrosive, Class-8
Hazardous Waste I.D. No: 16

Hazchem Code : 2 R
INGREDIENTS
C.A.S.NO.
1.
Sodium Hydroxide
C.A.S.NO.
HAZARDOUS
1310-73-2

Boiling Point/Range
White Flakes / Pellets
Melting / Freezing
Odourless
Point
C 1390 - 1557 Physical State : Solid

o
C 318.4 - 322
Odour:
@ 35oC 1 mm Hg at 730 oC
Solubility in water @ 30 oC
Vapour Density
Not Pertinent
Soluble in Alcohol, Methanol
(Air = 1)
Glycerol.
Specific Gravity
(Water = 1)
Vapour pressure
Appearance :
2.12
at 24oC/4 oC
Soluble
pH
3.FIRE AND EXPLOSION HAZARD DATA
13 - 14
Others:
and
Flammability
(OC)
TDG Flammability
(CC)
No
LEL
N.A.
UEL

Electricity
Combustible Liquid
No
Material
Yes
Flammable Material
No
Pyrophoric Material
No
4.REACTIVITY DATA
Chemical Stability
Incompatibility with
A1, Sn, Zn, Nitromethane
other material.
Reactivity
Compounds.
Hazardous Reaction
Products
Flash Point oC
Not pertinent
Flash Point oC
Not pertinent
Not Pertinent
Stable
Stable
Emits toxic fumes of Na2O.
Will not occur
Explosive Material
No
Oxidiser
Organic Peroxide
No
No
Corrosive
Others
Stable
Water, Acids, Flammable Liquids, Organic halides, metals,
and Nitro Compounds.
Vigorous reaction with Organic Halides, Metals, Nitro
Not available.

Routes of Entry
Effects of Exposure/
& lungs, mild nose
Symptoms
Inhalation, Skin, Ingestion & Eyes.

Inhalation : Causes small burns to upper respiratory tract
irritation.
Ingestion : Causes severe damage to mucous membrane,
Severe
Emergency Treatment
respiration,
scaring or perforation may occur.

Eyes: Severe damage. Skin: Causes severe burns.
Inhalation: Remove the victim from exposure. Support
give oxygen, If necessary.
Ingestion: Give water or milk followed by dilute vinegar or
fruit juice.
L.D50 (Oral-Rat)
Permissible
3
ppm Odourless mg/m
Exposure Limit
TLV (ACGIH)
ppm Not listed mg/m3
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.D50
ppm 2 (Ceiling) mg/m 3 Odour Threshold Odourless
ppm 2 (Ceiling) mg/m3
NFPA Hazard Signals

Reactivity/Stability Special
Health
3
STEL
Not listed
Flammability
0
Personal Protective
Avoid contact with solid or liquid.
Equipment.
Provide side covered safety goggles, face shield, filter
or
dust-, type respirator, rubber shoes and rubber hand gloves.
Handling and Storage
Precautions
7.
Keep in a cool, dry and well ventilated place.
EMERGENCY AND FIRST AID MEASURES

FIRE
Fire Extinguishing Media
Not Flammable
Special Procedure Keep the containers cool by spraying water if exposed to heat or flame,
Unusual
Hazards
Toxic
gases
are
produced
.
.
EXPOSURE
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. Support 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.
Waste Disposal Method
: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.
12.4
DIETHANOL AMINE
DIETHANOL AMINE
1.CHEMICAL IDENTITY
Chemical Name
Di-ethanol amine
Synonyms
DEA, 2,2-Iminodiethanol
Formula
H(NCH2 CH2 OH)2
Regulated
Identification
Chemical
Classificatio
n
Trade Name
C.A.S. NO.
Shipping Name
Organic compound, amine
111-42-2
DEA
UN
NO.
Di-ethanol amine
Codes/Label
Hazardous waste
I.D. No.
17
Hazchem Code
2T
HAZARDOUS
INGREDIENTS
C.A.S. NO.
1. Diethanolamine
111-42-2
HAZARDOUS
INGREDIENTS
C.A.S. NO.

Boiling
269.1(dec
Point/ Range omposes)
o
C
28
Melting/
Freezing
Point oC
Physical State
Liquid
Appearance
Fainlty
coloured
Odour
Vapour pressure
@ 35 oC, mm Hg
Ammonia
Vapour
Density
(Air = 1)
1.
3.65
Solubility
in
water @ 30 oC
Solubility in
others
Specific
1.0919
pH
Gravity
(Water = 1)
FIRE AND EXPLOSION HAZARD DATA
LEL (%V)
Flash Point (OC) oC
148.89
TDG
UEL (%V)
Flammability
662
151.6
Flammability
Slight

Electricity
Combustible
Yes
Liquid
Flammable
Yes
Material
Pyrophoric
No
Material
2.
Does not occur.

Explosive
No
Material
Oxidiser
No
Organic Peroxide
Corrrosive
Material
Others
No
No
REACTIVITY DATA
Chemical Stability
Stable
Incompatibility
with
other Oxidising materials
material
Reactivity
Routes of Entry
Effects of Exposure/ Symptoms
Inhalation/ingestion/contac
Diethanol amine has been characterized as being of low
toxicity.
Acute toxicity shows that direct contact may
impair vision and denature skin. DEA is an irritant to the

Emergency Treatment
eyes and has caused liver and kidney damages in animals.

(IMMEDIATE MEDICAL ATTENTION REQUIRED)
CONTACT : Remove victim to fresh air. Remove
contaminated clothing Wash affected part with plenty of

water for at least 30 mins.
INGESTION : Give plenty of water to conscious victim to
drink and induce vomiting.
(Oral-Rat), 2.83
LD50 ,
mg/kg
LD50
mg/kg
Permissible
Exposure Limit
mg/kg
ppm
TLV (ACGIH) ppm

mg/kg
NFPA Hazard Signals
Odor Threshold, ppm

mg/kg
3
Health
1
Personal Protective
Handling and Storage Precautions
STEL,
Flammability
1
ppm
mg/kg
Reactivity/Stabilit
y
0
Special
Splash proof goggles, rubber gloves and rubber boots.

FIRE
Fire
Extinguishing Foam, CO2, DCP, Water spray
Media
Special Procedure
EXPOSUR
E
SPILLS
Unusual Hazards
First Aid Measures
Antidotes/ Dosage
Steps to be taken
Waste
Method
Disposal
Use water spray, dry chemical, foam or carbondioxide. Water or foam may cause frothing. Use water
to keep fire exposed containers cool. Water spray may
be used to flush spills away from exposure.
IMMEDIATE MEDICAL ATTENTION REQUIRED.
Remove victim to fresh air. Remove contaminated
clothing Wash affected part with plenty of water for
atleast 30 mins.
Give plenty of water to conscious victim to drink and
induce vomiting
12.5
DEMULSIFIER
DEMULSIFIER
1.CHEMICAL IDENTITY
Chemical Name
Synonyms
Demulsifier
Chemical
Classificatio
n
Mixture
compounds
Blend of Ethoxylated Block Co-Polymer, Trade Name

Resin, Wetting Agent and Surfactant in
Aromatic Solvent
Formula
Regulated
Identification
C.A.S. NO.
Shipping Name
Codes/Label
Hazardous waste
I.D. No.
Hazchem Code
HAZARDOUS
INGREDIENTS
1.
Petroleum solvent
2.
Aromatics
C.A.S. NO.
of
organic
Demulsifier
UN
NO.
Demulsifier
HAZARDOUS
INGREDIENTS
C.A.S. NO.

Boiling
Point/ Range
o
C
Melting/
Freezing
Point oC
Vapour
Density
(Air = 1)
Physical State
Liquid
Appearance
Dark Brown
Vapour pressure
@ 35 oC, mm Hg
Odour
Solubility in water Dispersible

@ 30 oC
Solubility in Aromatic
others
solvent,
kerosene
Specific
Gravity
(Water = 1)
0.92 0.02 at 25oC
pH
6.0 to 7.0
3. FIRE AND EXPLOSION HAZARD DATA

Flammability
Yes
TDG
3
Flammability
LEL (%V)
Flash Point (OC) oC
UEL (%V)

Electricity
Combustible
Yes
Liquid
Flammable
Yes
Material
Pyrophoric
No
Material
Does not occur.

Explosive
No
Material
Oxidiser
No
Organic Peroxide
4.REACTIVITY DATA
Chemical Stability
Incompatibility
material
Reactivity
with
CO, CO2
Stable
other
No
Corrosive
Material
Others
No
>93

Routes of Entry
Effects of Exposure/
Symptoms
Ingestion
Inhalation
Inhalation, contact
May cause headache and nausea.
Nausea, vomiting. If retained leads to symptoms of
central nervous system depression.
Contact
Skin : Dermatitis,
Eyes : Irritation
Emergency Treatment
Medical attention is required.
Inhalation
Move to fresh air. If breathing is difficult give oxygen and

call for physician.
Ingestion
Contact
LD50
mg/kg
Permissible
Exposure Limit
TLV
ppm
(Oral-Rat),
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 ,
mg/kg
mg/kg 50 mg/m3
ppm 10
Odor Threshold, ppm

mg/kg
(ACGIH)
STEL,
ppm
mg/kg
15
75 mg/m3
mg/kg
NFPA Hazard Signals
Health
Flammability
Reactivity/Stabilit
y
Special
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

FIRE
Fire
Extinguishing DCP, CO2
Media
Special Procedure
Fire fighters must use SCBA.
Unusual Hazards
EXPOSUR
E
First Aid Measures
Antidotes/ Dosage
SPILLS
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
Steps to be taken
Waste
Disposal
vermiculite.
Method
8. 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.
CHAPTER-13
PROCESS UPSET & CORRECTIVE
ACTIONS
PROCESS UPSET & CORRECTIVE ACTIONS

Sl.No
1
Equpt No
Column
Measured parameter
Top Pressure
Deviation
High
Reflux drum level
High
Action to be taken
Check top pressure C/V
Reduce bottom firing /COT
if required
Check the reflux pump
Check R/D flow for any

blockage
Differential pressure
High
Maintain
required
top
temperature
Check withdrawal temp. of

side stream
Vessel
Level
High
Draw more product
Check over flash & pull
more HSD
Increase R/D flow
Optimize
inflow-keeping
specification on grade.
Check
for
any
R/D
blockage
Pressure
High
Check PCV opening
Check for any blockage
Maintain vessel level as

required
Maintain
temperature as required
vessel
Temperature
High
Increase
CW
flow
in
Cooler / Condenser
Reduce
CW
supply
temperature
Maintain
product
draw
temperature as required.
3
Furnace
COT of any pass
Skin temperature
High
Increase pass flow
Reduce furnace firing
Increase pass flow to that
High
pass
Adjust furnace firing to
check any impingement on that

pass
Arch temperature
High
Adjust furnace firing
Adjust excess air
Open STD a little
Stack temperature
High
Adjust furnace firing
Adjust excess air
Do shoot blowing.
If above does not solve,

decommission APH & do water
wash.
VV-02
Boot water PH
High
Increase ammonia / caustic
injection
VV02
Low
Reduce ammonia / caustic
injection
VV-02
CL content
High
Increase caustic injection
Check
caustic
solution
strength
Fe content
High
Reduce ammonia as per

PH requirement
Check
operation
Corrosion inhibitor pump
increase dozing
of
&
LPG
& H2S slippage by Pb- +ve
Naphtha
acetate test
caustic /
water
wash
Replenish
with
10%
spent
strength
caustic
fresh
caustic
Replace water of water

wash vessel
13.1 CRITICAL OPERATING PROCESS PARAMETER OF AU5

(10000 MT / DAY HS CRUDE IS CONSIDERED)
Pre heat
Desalter I/L temp.
Desalter Pressure
DM water flow
C01 top temp.
C01 bottom temp
C01 top pressure
C01 bottom pressure
C1 Reflux Temp.
F01 COT
Over Flash
HN Draw Temp
SKO Draw Temp
2800 C-2900 C
1200 C - 1250 C
12.0 13.5 kg/cm2
25- 30 M3
1090 C --1120 C
3450 C -3550 C
2.2 - 2.4 kg/cm2
2.3 2.5 kg/cm2
300 C - 400 C
3730 C - 3780 C
8- 12 M3
1500 C -1650 C
2000 C --2100 C
C2 Reboil temp.
S/steam in C3
S/steam in C4
S/steam in C1
C05 Feed temp.
C05 tray 13 temp.
C05 bottom temp
C05 top pressure
C05 bottom pressure
C5 Reflux Temp.
V-9 Caustic flow
V-10 water flow
C-6 top pressure
1850 C -1950 C
9001000 Kg/hr
190-210 Kg/hr
45005000 Kg / hr
1200 C --1300 C
850 C --950 C
1800 C --1900 C
10-11 kg/cm2
11-12 kg/cm2
400 C --500 C
812 M3
8-12 M3
11-12 kg/cm2
HSD Draw Temp

Top CR Flow
Top CR ( ret) Temp
KERO CR flow
KERO CR Temp (Ret
HSD CR Flow
HSD CR Temp (Ret)
3000 C --3100 C
140155 M3
1100 C -- 1200 C
200 - 250 M3
1300 C --1400 C
380420 M3
2100 C --2300 C
L. amine flow
V6 caustic flow
V7 water flow
Furnace Arch
Skin
Box
5-7 M3
8-12 M3
8-12 M3
8700C Max
550 0C Max
1100 0C Max
13.2 CRITICAL INSTRUMENTS / CRITICAL OPERATING PARAMETERS & AND its

IMPLICATION OF OPERATING OUTSIDE ALLOWABLE LIMITS. (AU5: 10000 MT HS
CRUDE)
Sl.N
o
1
Equipment
Furnace
Pass flow
Critical
Parameter
110 - 125
m3/hr
Instrumen
t Provided
FRC
Furnace
COT
373 3770C
TC
cascaded
IMPLICATION
If pass flow decreases, its skin &
COT will increase.
If pass flow increases, its skin &
COT will decrease.
Ensure flow above low alarm limit
Ensure equal pass flow through all
passes
Ensure steady oil temp.
with PC
on oil or
PC on gas
Furnace O2
02-03%
O2
analyzer
Furnace
arch
pressure
-5 to +2
mmwc
PI
Sl.N
o
5
Equipment
Furnace arch
temperature
Critical
Parameter
8700C
Max
Instrumen
t Provided
TI
Furnace stack
temperature
160
1800 C
TI
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.
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.
Implication:
Adjust burner flame height.
Adjust air requirement
If required reduce Tput
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.
C1 Column
top Pressure
2.2-2.5
Kg/Cm2
PC split
range
between
FG &
Flare
Column top
Temperature
109-1120C
TC
cascaded
with top
reflux
Over Flash
08-12
m3/hr
FI
10
Column
Bottom Level
40-50%
LI / LCV
cascaded
with
bottom
R/D flow
11
Desalter Interphase Level
30 to 40%
LDIC
12
Desalter
Amps
< 20 amps
Ammeter
13
Desalter
Pressure
11.5 to
13.5
PG / PC
on pre
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
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 carry 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.
desalter
crude
pump
discharge
line.
14
De-salter
temperature
120-130
15
Reflux drum
boot level
40 to 50%
LCV
16
Caustic /
water wash
vessels inter
phase level
10 to 20%
LCV
17
Boot Water
Chloride
content
High
Fe
content
57
m3/hr
High
18
L. Amine flow
in C6
FCV
Ensure that pressure is well below

PSV set point
Ensure furnace pass flows are
steady.
High pressure: PSV may pop,
resulting product coloration.
Low pressure: Water carry over to
column & non achievement of
required tput.
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 may
occur.
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
Ensure 30-40% level
>At low-level objective will not solve.
Feed H2S may not remove
At high-level caustic solution will
be carried over to storage tank &
will result in failure of Cu-corrosion
test.
Increase caustic dozing & adjust
ammonia to maintain boot water
PH of 6-6.5 & Cl_ of < 3 ppm
For control Fe content < 2 ppm
increase corrosion inhibitor dozing
Low concentration of L. Amine or

Low flow: LPG will fail in sulfur
and Caustic make up will rise.
CHAPTER-14
HANDING & TAKING OVER OF
INFORMATION DURING SHIFT CHANGE
HANDING & TAKING OVER OF INFORMATION DURING SHIFT

CHANGE
1.Shift PNE:
Out going PNE Should inform Incoming PNE
About any equipment problem existing
Any quality deviation & corrective action taken

Any hazardous condition existing in plant
Any instruction yet to be implemented
About any follow-up action to be taken for equipment under maintenance.
About any additional manpower requirement if any
About any Interlocks bypassed & reason.
2. Panel Operator:
Out going Panel Operator Should inform Incoming Panel Operator
About any prevailing instrument problem
About Any instruction yet to be followed
About Deviations from normal operating parameter
Corrective actions taken for deviation of quality.
About Inter lock remaining bypassed if any.
About Critical alarm if any.
About Follow-up actions for quality deviation to be taken
About Any instrument under maintenance.

3. Field Operator
Out going Field Operator Should inform incoming Field Operator
About any equipment under maintenance.
About any unsafe condition
About any instruction yet to be implemented.
About any equipment problem, yet to be given to maintenance.
About follow up action for maintenance, H/O or T/O.
About change of product routing
About health of burners.
4. Pump Operator:
Out going Pump Operator Should inform Incoming Pump Operator

About any pump running in unsafe condition
About any problem which needs immediate attention.
About equipment under maintenance
About equipment run in the shift & observation
About any equipment ready for trial run.
About follow up action with maintenance.
About instruction yet to be implemented.
CHAPTER-15
CONTROL OF HAZARDOUS CHEMICAL
INVENTORY LEVEL
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
un-neutralized 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
NaOH
Ammoni
AU1
AU2
AU5
AU1
Average
AU5
Inventory level
consumption
for 15 days
715 Kg
189 Kg
280 Kg
5 Kg
10 Mt
2.5 Mt
4 Mt
75 Kg
8 kg
cylinder
120
/
2 4 Cylinders
10
cylinder
150
/
4 5 cylinders
a
AU2
daily Requirement
Cylinder
(requirement+
10%)
12 Mt
2.75 MT
4.4 Mt
2 3 cylinders
CHAPTER-16

14.1 FOR SHORT SHUTDOWN:
EQUIPMENT
Atmospheric
column
stabilizer column
ACTION
Float with Fuel gas
Atmospheric column reflux
drum (VV-02)
Stabilizer column reflux

drum (VV-03)
Desalter
Water wash vessel

Caustic wash vessel
Pumps
Heat Exchanger
Maintain positive pressure

Float with FG
Float with FG
Float with FG
Float with Flare

Switch off transformer
Stop water & demulsifier injection
Drain brine to low level & block the valve.

Drain water to lowest level & block the valve
Drain caustic to sour water system to lowest
level & block the valve
Isolate discharge valve
Close warm-up valve
Close quenching steam

Line up TSVs
on
Battery Limit valves

product lines
Tracing steam / Electric
tracers for RCO line

Steam
IFO
Pinch CW out let valve to cooler / condenser

Isolate
To be kept on
Keep it charged within Unit
Maintain circulation through ring
14.2 FOR LONG IDLING:

Make unit hydrocarbon free and follow Preservation procedure as per OISD-STD-171.
CHAPTER-17
TASK PERFORMED BY OPERATORS
17.1 Panel Operator:

Desalter operation
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 from tank.
Desalter pressure low,

high crude flow &
pretopping column
level going down
(AU1/AU2)
Desalter effluent is not
clear
Voltage Is low &

amperage is high
Desalter temperature
too high
Desalter temperature
too low
High salt content in
desalter outlet
Desalter tripped
Brine water PH is high
Brine water PH is low
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 passing.
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 TPut after consulting PNE.
Check / close post desalter. Close all bypass if it is opened.
Inform PNE.
If it is by particular crude, open post desalter heat exchanger bypass.
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 cant identify the problem, inform 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
High water content in
Reduce water injection rate, if it is high.
desalted crude
Ask PNE to reduce Dp across mixing valve.
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
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 Tput by reducing J/O opening / pass flow.(For K1
of AU1/AU2)
If crude flow is more then requirement, check desalter PSV
for passing.
Normalize Tput after stabilization.
Column level high
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 Tput 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 passes. If not, cut off the furnace.
Check coking up of passes.
Inform shift in charge for corrective action
Column bottom temperature high
Reduce reboiler / furnace COT.
Column bottom temperature low
Column bottom pressure high

Column bottom pressure low
Column top temperature high
Column top temperature low
Column top pressure high
Optimize furnace pass flow

Increase column bottom level.
Increase reboiler / furnace COT.
Optimize furnace pass 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 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) 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 TPut 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.
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 bypass.
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
tput or increasing bottom product flow.
Increase top temperature.
Product draw temperature high or

low
Main fractionators column flash

zone temperature high / low
Stabilizer feed temperature low /

high
AU1 K8 feed temperature Low /

High
RCO yield
LPG recovery
Furnace soot blowing
Adjust Kero / HSD pump around flow / temperature.

Adjust furnace COT if required.
Check desalter PSV (for fractionating columns)
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
Adjust temperature by adjusting HM 2 steam flow.
Maintain stripping steam flow/raise in reboiler temp.

maximum possible with respect to Tput.
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
ID /FD fan start up/stop

Unit start up & shut down
Emergency
Drum level low / high
VR not getting received
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.
VR temperature high / low

Drum pressure low / high
Steam flash drum pressure high

Steam flash drum level high
LPG vaporizer
FG header pressure low
LPG reflux drum/LPG-amine

settler boot water draining
LPG Surge drum draining
LPG/Light Naphtha wash

system
L Amine flow low (AU5)
Amine absorber level high
LPG extractor level high / low

(AU1/AU2)
Caustic / water circulation flow
high / low
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 about its line up in AU1 DM water tank.
Commission LP steam to LPG vaporizer
Open level C/v and adjust the vessel pressure, as per
requirement
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.
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.
Take level controller in manual mode
Observe level
After completion of job (ensured by field operator), take
level controller in cascade with flow controller
Drain water from LPG vessel to a min. level to CETP by
operating HIC.
After draining, close HIC
Asked field operator, to top up DM water in LPG wash
system to a required level.
Ask field operator to check controller malfunctioning
Inform ARU to check L Amine pump performance
Inform PNE for corrective action
Inform ARU to check at their end
Check battery limit valve position.
Inform field operator to adjust isolation valve.
If line restriction observed, inform GRE for checking
Adjust circulation rate.
If circulation flow is low, check the pump performance
Spent caustic strength low

Caustic strength in wash water
high
Quality Control
LPG weathering high / low
Check the suction strainer choke condition.

If required, start stand by pump
Ask field operator to replenish it with a 10% caustic solution
Ask field operator to replenish it with a fresh DM water
Decrease / increase stabilizer top temperature after

consulting PNE
Check reflux ratio. If it not optimum, adjust stabilizer bottom
temperature.
Inform PNE
Ask to increase L Amine strength from ARU (AU5)
Replenish spent caustic. Fresh caustic strength @ 12 to 14 %
Immediately, replenish water in wash water system
Increase / decrease K8 top temperature, after consulting PNE

Increase K9 top temperature
Decrease K9 top temperature
Increase / decrease K9 top temperature
Increase / decrease IPCL with drawl rate.
Increase stripping steam to ATF stripper

Decrease stripping steam to ATF stripper
Consult PNE
Reduce Fractionators top temp. if ATF flash point is >42
Otherwise reduce ATF draw
If flash point is ok, increase draw rate
Adjust ASA dozing rate (From GHC / AU2)
Check ATF caustic / water wash facility. Replenish if
necessary
Adjust Kero stripping steam (AU5)
Adjust main fractionators top temperature as applicable.
(AU1/2)
Adjust top CR flow (AU5)
Increase ATF draw if permissible after consulting PNE
(AU1/2)/increase/decrease HN draw (AU-5), if permissible.
Adjust H.Naphtha draw (AU5)
Adjust Kero CR flow
Adjust ATF draw (AU1/2)
Increase / decrease SKO draw
Adjust HSD stripping steam (AU5)
Adjust main fractionators top temperature as applicable.
LPG Cu-corrosion worse than 1b

(H2S +ve)
LPG Cu-corrosion worse than 1b
(Caustic +ve)
LCS IBP low / high < or > 72 deg
LCS dry point low ( < 90 deg)
LCS dry point high ( > 94 deg)
IPCL naphtha IBP / 5% low / high
IPCL naphtha FBP low / high
(1450)
ATF flash point low ( <380C)
ATF flash point high ( >420C)
ATF freezing point high (> -47)
ATF freezing point low (< - 50)

Conductivity low / high
ATF Cu-corrosion worse than 1
(AU5)
SKO/LABFS flash point low/
high
SKO/LABFS IBP low/ high
SKO/LABFS FBP low/ high

HSD flash point low / high
HSD pour point low / high

HSD 95% recovery low / high
Sour water PH is high/low
RCO Recovery is high (15-25%)
Product colored
Other job
(AU1/2)
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 Tput), 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 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.
As & when asked by shift in-charge.
17.2
Furnace Operation:
Sl. Observation
No
1 Furnace hazy, smoky burner.
COT is low
Flame impingement
Skin temperature high at particular point
5
6
COT & Skin temperature are high

Dripping of oil from burner
FO return line is cold/congealed
8
9
Convection zone / stack temperature high.

Soot blower not running/stuck up
10
11
12
13
Oil / gas burner not getting lit

Local temperature, Feed inlet / outlet PGs &
draft gauges are not functioning
Hot spot in the tube or hanger broken
Leak from flanges / valve gland
14
15
Furnace-refractory bricks are falling down

PSV of soot blowing steam passing
16
Stack damper / air register is not getting

operated
Action
If total furnace is hazy, ask to

increase combustion airflow from
panel.
If 1 or 2 burners are smoky, adjust
the burners by adjusting air registers,
atomizing steam or by stack damper.
Take more burners by consulting panel
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 panel. Inform S/I to
attend by Maintenance
Inform S/I to attend by Maintenance
Inform S/I
Keep steam lancer on it. Inform S/I to
attend by Maintenance
Inform to S/I
Ask to reduce steam pressure, if it is
high. Isolate the passing PSV & Take
spare one in line.
17
Any hydrocarbon leaks in the plant
18
VR not getting received
19
VR temperature high / low
20
Soot blowing of furnaces
21
Raise in furnace arch temperature
22
Check burner flame pattern
23
Check / record furnace draft gauges
24
Check / record furnace pass inlet & outlet

pressure.
IFO tank
25
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 panel 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 register
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 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
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
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/Panel
operator and take other FD fan in
line. Incase of ID fan, inform to
PNE/Panel operator and asked panel
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/Panel
Operator and take other FD fan in
stop the ID fan
If it is severe, inform to PNE/Panel
Operator and take other FD fan in
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
flow/Arrange for external cooling
If stand by FD fan is available, take
it in line by coordinating with panel
34
ID/FD fan lube oil cooler gasket leak
35
ID/FD fan lube oil contamination in fluid

coupling chamber
36
Other un expected job
operator
Incase of ID fan, stop ID fan by
coordinating with panel operator
Report to PNE to attend it by
maintenance
Report to PNE/Panel 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 panel 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
As per guidance of shift in-charge
17.3 Field Operator

Sl. Observation
No
1 Check all unit rundown position
2 Any change in product rundown to be
informed to panel operator before and after
C/O
3 Check product colour
4 Chemical dozing tank level becomes low
Chemical dosing tank level is steady
Chemical dosing tank level is raising
Preparation of Ahuralan solution:
Action
Log in log book / display in board
Up date log book and display board
Inform Panel 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
maintenance
Check whether the pump is
developing a required pressure or not
If it is not developing, check discharge
b/v NRV passing
Start the stand by pump, as per
procedure and observe tank level
maintenance
Inform S/I to arrange to connect CI
drum.
Transfer required amount of CI to tank
Dilute with K9 bottom / H. Naphtha
(1:4 ratio)
Circulate solution for 3-4 hr.
Adjust dozing to respective column
top as per requirement.
Preparation of Ammonia solution.
Preparation of caustic solution:
10
Ammonia-cal caustic solution preparation:
11
12
Check PH of sour water.

Failure of naphtha R/D test (Pb- acetate
soln.) for sulphur carry over
Log in chemical register.

Take required quantity of DM water in
the tank.
Dissolve cylinder of (20kg)
Ammonia (for AU-1/AU-2)/1 cylinder
(40Kg) of ammonia (for AU-V) in it.
Sprinkle water on ammonia cylinder
for fast condensation.
When cylinder exhausted, mark it &
inform S/I to replace with
maintenance help.
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.
Circulate the solution for 4 hrs.
Collect the sample & inform S/I for
strength checking.
Adjust dozing or replace spent caustic
as per requirement
Transfer 10% caustic solution in the
preparation tank.
Dissolve ammonia in it as per
procedure.
Circulate it for 4 hr
Transfer to the tank from where
dozing is done
Adjust dozing as per E1 boot water
PH
Adjust chemical dozing, if PH deviated
Replenish caustic after consulting with S/I
13
14
15
16
17
18
19
20
21
22
23
Failure of naphtha R/D test

(Phenolphthalein soln.) for caustic carry
over
Failure of LPG R/D test (Pb-acetate soln.)
for sulphur carry over
Failure of LPG R/D test (Phenolphthalein
soln.) for caustic carry over
Replenish water after consulting with S/I
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 bypass valves are
open
Heat exchanger and coolers
commissioning/decommissioning
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
Leak from floating head cover / flanges /

block valve flange/gland
Excessive leak in heat exchanger
24
25
Abnormal change in HE inlet / outlet

temperature
Abnormal change in HE pressure drop.
Over head reflux drum pressure high
26
27
Any leak vessel & its piping, valves

PSV passing
28
Desalter desludging
29
Desalter taking high amp- low voltage
30
Check brine color / oil in brine
Replenish caustic after consulting with S/I

Replenish water after consulting with S/I
Close the bypass 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 bypass/isolate
the heat exchanger.
Inform to S/I
Inform to S/I.
Divert PCV outlet to flare by coordinating
with panel operator.
Inform S/I to attend it by maintenance
Take stand by PSV inline. Isolate the passing
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 panel 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 panel to
increase level
Increase demulsifier dozing rate.
Reduce mixing valve delta P.
Inform PNE
31
32
Desalter brine is clear & demulsifier dosing

rate is high
Desalter brine PH is high
Reduce dosing rate.
Check the variation in stripper water

PH
Reduce caustic dosing to pre-desalter
Inform to PNE/Panel operator about
the variation in stripper water PH
Inform to panel 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.
33
Liquid level in Flare / FG KOD
34
35
Defective pressure/temperature gauge

Check proper tracing steam flow in Prefractionators & main fractionators level
instrument
LPG weathering measurement
36
37
Air fin cooler motor starting/stopping
38
Abnormal sound/Vibrations from air fin

cooler motor/fan
39
Unit Start up/Shut down
40
Emergency Handling
41
Any hydrocarbon leaks in the plant
42
Fuel gas header pressure low
Ensure that LPG weathering

thermometer is working or not.
After measurement, inform to panel
operator for any corrections.
As per panel operator, start/stop the air
fin cooler depending on column top
pressure/reflux temperature.
If abnormal sound/vibration is severe,
inform to panel operator/PNE and stop
the same.
If not, report to PNE to attend it by
maintenance
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 panel operator / shift
in-charge
Inform to S/I
Keep a steam lancer at the location, if
required
Increase oil firing by coordinating
with panel operator, if any margin
exists.
Adjust circulating refluxes to raise the
preheat
If fuel oil consumption is maximum,
then line up LPG to vaporizer & steam
43
44
45
17.4
Other un specified job

Product / feed / gas sampling
Other job
to vaporizer after taking permission

from superiors.
As per guidance of shift in-charge
As per procedure
As & when asked by shift in-charge.
Pump Operator
Check healthiness of running pump like the following:

Sl. Observation
No
1 Low LO level on oil cup
2 LO color / contaminated with water /
product
3 LO leak from cup / bearing housing
4
Vibration / high bearing temperature
5
6
Suction/discharge PGs not functioning

Suction pressure low& pump load not
increasing
Bearing CW flow low
High amperage of pump
7
8
9
11
Uneven amperage of pumps running in

parallel
Seal flush cooler of hot pump leaking / CW
line chocked
Seal flush cooler-pherulle leak
12
Leakage from pump gland / seal
10
Action
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
Throttle discharge after consulting panel
operator
Adjust load by adjusting discharge valve
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
13
Heavy leakage from pump gland / seal
14
16
17
18
19
20
21
Seal quenching steam for hot pump is low /

high
Leak from suction and discharge flanges /
valve gland etc
Coupling guard is not properly fixed
Abnormal sound from pump/motor
Poor illumination in pump house
Earthing of motor is not proper
Seal quenching steam b/v gland leak
Unit Start up/Shut down
22
Emergency Handling
23
Damaged / leaky hot water pot & water

hose to clean pump house
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.
Periodically drain out water from stand by pump for cold service.
Schedule change over of pumps.
Collection of routine & non-routine samples.
Checking of any hydrocarbon leaks in the plant
Checking of run down products colour during normal, start up and shutdown of plant.
Other job as & when asked by shift in-charge.
15
24
25
26
27
28
29
30
31
32
33
Immediately C/O the pump & isolate the

leaky one. Inform S/I & take the help of
others.
Adjust the quenching steam flow rate
Keep steam lancer & inform PNE for
attending it by maintenance
Inform S/I for attending it by maintenance
operating manual
operating manual
Release of Pumps/Motors to maintenance as per the following standard procedure
Logging of pumps data and pump running hours in each shift
CHAPTER-18
DCS INFORMATION
DCS INFORMATION
1.Refinery name and location
Gujarat Refinery
2. Plant data
AU- 5 Ver.10.20
3. DCS
3.1 MAKE
YOKOGAWA BLUE STAR
3.2 MODEL CENTUM-VP
4. DCS OPERATING SYSTEM
4.1 SOFTWARE TYPE/ VERSION
FCS: CENTUM VP HP UNIX

Ver.10.20
ICS: AT&T UNIX
HICS: HP UNIX
4.2HARDWARE PLATFORM
HICS:HP 9000WORKSTATION
FCS & ICS: YBL PROPRIETARY STATIONS
5.PLC (FOR SHUTDOWN SYSTEM)
5.1 MAKE
5.2 MODEL
5.3 ARCHITECTURE
6.CONTROLLER SUB SYSTEM
6.1MULTI LOOP
ABB-AUGUST SYSTEMS
CS 300E
TMR
6.1.1 MODEL NO
6.1.2 SCAN TIME
6.2 SINGLE LOOP
6.2.1 MODEL NO
6.2.2 SCAN TIME
CP 334D
1 ms to 500 ms (configurable)
N/A
7.HIGHWAY DATA COMMUNICATION SYSTEM

7.1 BUS/ HIGHWAY TYPE
7.2 SPEED OF COMMUNICATION
MULTIDROP/TOKEN
PASSING
10 MBPS (V- NET)
8. DATABASE ARCHITECTURE (viz. CENTRAL/DISTRIBUTED ETC)

DISTRIBUTED DATABASE
9.APPROX. NO OF LOOPS
9.1 CLOSED
9.1.2 OPEN
9.1.3 DIGITAL
91
421
239
10.INTERFACE WITH ADVANCE CONTROL

10.1 DMC
10.2 SET POINT
10.3 OTHERS (PLEASE SPECIFY)
NOT IMPLIMENTED
11. CONNECTIVITY/ NETWORK TO OTHER EQUIPMENT/ SYSTEM

11.1 FIELD BUS
11.1.2 LAN
11.1.3 IEE802.3
ETHERNET (IEEE802.3)
11.1.4 OTHERS (PLEASE SPECIFY)
12.DCS ARCHITECTURE (DRG. TO BE ENCLOSED)
CHAPTER-19
ADVANCE PROCESS CONTROL SYSTEM
1.ADVANCED PROCESS CONTROL SYSTEM

Inferred property based advanced control has been implemented. The inferred
properties of all critical streams has been developed by building a model based on
process and laboratory data along with rigorous chemical engineering calculation,
statistical analysis and validated with the laboratory results. User graphics are also
created for display of this property.
Installed inferred property are given bellow:
1.
2.
3.
4.
5.
LIGHT NAPHTHA endpoint

HEAVY NAPHTHA endpoint.
KERO 95% point, end point, and flash point.
SK/LABFS ASTM IBP, 95% point, end point and flash point.
HSD ASTM 95% point, recovery, flash point and pour point.
2. MVC OPERATOR REFERENCE MANUAL

What is Multi-Variable Control (MVC)?
Normal PID controllers in plant are called Single Input Single Output
Controller. They receive one input signal (such as temperature from a
thermocouple) and return one output signal (such as open or close

instruction to a fuel gas inlet valve).
Multi-Variable control is responsible for more than one control loop or parameters.
i.e one single controller controls many PID controllers to maintain various
parameters within the given range.
Why Multi-Variable Control (MVC) is required?
MVC is required for controlling processes that are interactive.
For example consider a Crude distillation column. In the column various draw
temperatures such as ATF, SKO, HSD etc are maintained in order to achieve a
particular quality of the above products. Any change in ATF flow in order to maintain
a given quality affects SKO and HSD qualities i.e. there is interaction among various
streams. So any change in Heavy naphtha flow has to be compensated by changing
the flows of SKO and HSD in order to maintain the quality of those streams constant.
It can be seen that 2 or more PID controllers needs to be adjusted simultaneously
because of interactions between various streams.
Therefore MVC is required for controlling processes, which are interactive.
Initiative by Gujarat Refinery:
Gujarat Refinery is the pioneer amongst Indian Oil Refineries in implementing
Multi-Variable Control (MVC) way back in 1999 in our Hydro-Cracker Unit
jointly with M/S Tata Honeywell. The MVC technology has been licensed from
M/S Honeywell and the trade name of the controller is Robust Multivariable
Predictive Controller Technology (RMPCT). Gujarat Refinery has further gone
ahead to implement the same MVC in FCC wherein the potential benefits is much
higher. The said job was again done jointly with M/S Tata Honeywell in the year
2001.
Refinery in-house team then decided to go ahead in implementation of MVC in
all the major process units keeping in view the profit margin potential
independently backed by the experience gained. This effort of the in-house team
resulted in implementing MVCs in units viz. CRU, FPU-1, AU-1, AU-4, AU-5
& AU-2.
MVC VARIABLES
Three types of variables are input to MVC
A) Controlled Variables (CVs)
These are the Plant parameters, i.e. the plant parameters operators' watch
and try to keep at pre-decided values. They are either measured values (Eg. SKO
draw Temperature) or inferred values (Eg. SKO FBP)
MVC attempts to keep the CVs at operator specified set points or within the range
(i.e. between high and low Limits)
B) Manipulated Variables (MVs )

These are the plant parameters operators change or manipulate in order to
maintain the CVs" within given range or set point.
Example ATF Rundown flow is manipulated to maintain ATF draw
temperature. Here ATF R/D flow is the Manipulated variable and ATF draw
temperature is the controlled variable.
C) Disturbance Variables (DVs )
These are the measured variables not under direct control of the controller
but can cause the CVs to deviate from the desired value. Operators generally do
not have any control on DV i.e. operators are not in a position to pro-actively
think the impact of DVs on plant operation which MVC does by its intelligent
algorithm.
Example Fluctuation of COT on account of sudden Gas pressure
fluctuation can cause SKO draw temperature to fluctuate. In this case the sudden
gas pressure fluctuation is not under the direct control of the operator.
Thus MVC predicts the effect of disturbance variable on CV assuming it

to be constant for the duration of prediction. It then tries to adjust the manipulated
variables in such a way so that the effect of disturbance is minimized.
Multivariable Control
Multivariable control means simultaneous control of more than one CV
by coordinated adjustment of more than one MV. Controllers consider additional
DV effect on the CVs for feed forward disturbance rejection and control action. .
MVC models between MV and CV obtained during plant step testing and it uses
this model for doing plant control.
Example Adjustment of Gas oil Flow (MV) affects Gas Oil Draw
Temperature (CV) as well as Overflash flow (CV). Therefore the value of Gas oil
flow-rate should be adjusted in such a way that both Gas oil draw temperature and
Overflash flow are within the acceptable limits. MVC tries to maintain both the
CVs within limits by adjusting the MV.
Also any change in COT (which is not under control of MVC) affects
Overflash flow. Therefore if there is any change in COT, say due to Fuel Gas
pressure disturbance, MVC predicts that Overflash flow will get affected after
some time due to disturbance in COT and takes advance action to minimize the
effect of disturbance on process.
Benefits of MVC :
The benefits of MVC are
Tighter Control
Plant pushed towards Constraints.
Economic (Operational) Optimization.
The incentive for MVC is reduction in plant parameter variations leading
to profitable plant operation. MVC is much useful, when process is interactive i.e.
when one MV affects Multiple CVs. (For Eg. Varying GO CR flow affects draw
tray temperatures as well as top reflux flow)
Implementation Platform for MVC Controller:
MVC controller runs in server (Windows based Computer), it is positioned
in IS building.
PHD (Real Time database) server acts as a communication
medium between MVC and DCS making to and fro (bi-directional) dataflow
between DCS and Computer. Software called RDI (Real Time data Interface) runs
in the Real Time database server.
PHD Server Computer
RMPCT
Computer
(MIS Building)
(MIS
Building)
RMPCT (AU-5)
PHD
PHD
PHD-PHD
RDI
RDI-CM50S
RefineryLAN
PLNM
(AU-5 Control Room)
Physical Network.
------------------------- Software Connection..
AU-5 DCS
TYPICAL MVC MVs & CVs FOR ATMOSPHERIC CRUDE UNITS:

A) Variables identification:
The first step in implementing MVC is identification of MVs, CVs and
DVs. Identification of the variables is a joint effort of Production, Process and
Advanced controls section. The crucial variables, which have an impact on
product quality or economics, are selected. The primary controllers of the MVs
are tuned so as to achieve the desired response before start of the step test. As
MVC is a slow controller (calculation is done every 1 minute) as compared to a
normal DCS controller (calculation is done every 1-2 seconds), it may not be a
good idea to select controllers, which should act very fast during plant
disturbances as MVs in MVC.
B) MVs and CVs of AU-1 MVC Controller:
Manipulated Variable
TOP CR Flow
LN R/D Flow
HN R/D Flow
SKO Rundown Flow
HSD R/D Flow
SKO CR Flow
HSD CR Flow
Furnace COT
Controlled Variables
Top Pressure Control valve to flare opening, Top Reflux Flow
Gas oil to EE-14 (Stabiliser Reboiler)
Top Pressure Control valve to flare opening, SKO flash, SKO
R/D flow
HN R/D Flow, SKO, HSD draw temperatures, Overflash flow
HSD draw temperature, Overflash flow
SKO draw Temperature, Top Reflux flow, Top Pressure
Control valve to flare opening.
HSD draw Temperature, Top Reflux flow, Top Pressure
Control valve to flare opening
Top Reflux Flow, Flare valve opening, Overflash flow, Top
Pressure Control valve to flare opening, Bottom Temperature
DCS OPERATOR INTERFACE OF MVC (MVC DCS GRAPHICS):

MVC graphics are provided on the DCS operator console through which
the Panel operator can operate the MVC controller. From the screen, the operator
can take any of the Manipulated variable from MVC or the entire controller.
Operator can also change the High / Low limits associated with each CV and MV.
In addition, the current move (i.e. the change in set point of each MV), the
future and steady state values of both MV and CVs are displayed. These
parameters give an instantaneous picture of the prediction and control actions the
controller is taking.
START-UP AND SHUTDOWN OF MVC:
A) Turning the Controller ON:
A graphic has been created in DCS. Pressing the requisite Button in
Operator keyboard results in accessing this graphic. This schematic is the operator
interface for MVC. It contains MV, CV description, current set point of MV and
process value of CV, current and future MV & CV moves, Low and high limits of
MV & CV.
In the right hand corner of the graphics there is a watchdog timer. This watch dog
timer a check for connectivity between the computers in IS building and DCS. If
the connection breaks due to some problem, the watchdog timer becomes 0.
This causes all the MVs to go to AUTO/MANUAL mode as per their individual
configuration. The controller can be started only when the value of watchdog
timer is greater than 0.
Following is the start-up sequence of MVC controller from the operator

console:
1)
2)
3)
4)
Select the MVC schematic and touch ON and press enter.

Check the CV high and low limits and modify if necessary.
Check the MV high and low values and modify if necessary.
For MVC to control the MVs, the respective PID controllers should be in
CASCADE mode. This is done by taking the individual MV and putting it on
CASCADE. Before putting it on CASCADE please verify whether in MV
CONTROL column, the value is RMPC. If it is in OPR, touch and select RMPC.
5) See the MODE column and confirm whether the desired MVs are in
CASCADE.
B) Turning the entire Controller OFF:

1) Select the MVC schematic.
2) Touch OFF and press enter,
Around one minute time all the MVs will shed to their normal control
modes.
D) Taking out One or More MVs from MVC Control:
If for any reason (say due to Flow meter checking) any of the MV needs to
be taken from MVC control, CLICK on the CONTROL column of the
corresponding MV and change from RMPC to OPR button. This will cause that
particular MV to go out of MVC control to Operator Control. (The MV will come
from CASCADE mode to AUTO mode).
Important Note:
Wait for at least one minute after changing the MODE from CASCADE to
AUTO before changing the set point or Valve opening values (Unless there is an
immediate need to do so). Immediately changing the set point or opening after
taking the mode from CASCADE to AUTO or MANUAL (within one minute)
may sometimes cause the entire controller to shed control fully. Watchdog timer
becoming 0 indicates this in the DCS. The controller then has to be reset by
advanced control group before RMPCT controller can again be started.
E) Taking out One or More CVs from RMPCT Control:
Touch the STATUS column for the corresponding CV. GOOD/DROP
option will appear at the bottom. By selecting DROP, the respective CV can be
dropped from MVC control. Once DROP for a particular CV has been selected,
after about one minute, the corresponding GOOD value in STATUS column will
change to DROP. By dropping a CV, MVC will not consider the CV value while
doing the calculation and it will not try to maintain a dropped CV within limits.
TIPS FOR GETTING MAXIMUM BENEFITS FROM MVC

1) See if the MV values have reached either the high - low limit or very near to
them for that MV. In that case if possible widen the limit. This will cause the
controller to optimise the values of all MVs, as the process is interactive.
2) The main objective of the MVC implemented in Atmospheric units is
minimization of RCO yield subject to meeting ATF, SKO, HSD draw temperature
and limits.
3) Sometimes it can be seen that MVC is not moving the MV in a desired way to
control a CV even though the present set point is well within the limits.
For e.g. Let us say SKO Run down flow is 25 M3/Hr and low and high
limits are 24 and 26 m3/hr. The present SKO draw temperature is 235 Deg C and
the low and high limits set by the operator are 231 and 233 deg C respectively. In
this case, the operator may expect that RMPCT will Decrease SKO Run down
flow to bring the draw temperature within limit, but it is not doing it.
The most likely reason for the same is that some other parameters say
HSD draw temperature is 294 Deg C whereas the low and high limits are 296 and
298 Deg C respectively and HSD TC controller has is at the highest limit. So the
controller feels that decreasing the SKO rundown flow from 25 M3/HR will cause
the HSD draw temperature to still go down from 294 Deg C and it cannot increase
the HSD TC opening to increase HSD draw temperature because it is already hit
the higher limit.
In this case, the operator can either widen the limits of least important CV
(either SKO or HSD draw temperature) or drop that CV altogether so that
controller takes action based only on most important CV. If possible the upper
limit of the MV can be increased so that both the targets can be achieved.
4) The main benefit of MVC is optimisation of the parameters, which have an impact
on quality, economics within the given constraints. Thus MVC helps in improving
the Refinery operation. However while MVC is in line, monitoring whether the
operational targets are being achieved by MVC or not is the responsibility of
operating group, because there may be some peculiar condition in the plant due to
which MVC may be taking the plant slowly towards the target or may not be
taking towards it at all. Such situations are most likely to happen when there is a
conflict in upper and lower limits among interacting parameters. Relaxing a less
important parameter (i.e. widening the limits) will most likely make MVC achieve
the operational target and if still such problem persists, Advance control group
may be informed of the same for corrective action.
STEPS FOR TAKING MVC ON LINE
1)
Check whether the Watch Dog Timer is not in Zero. If it is in Zero, MVC will
not start and the undersigned needs to be contacted for starting MVC program in
computer.
2)
If watchdog is on, check whether the low & high limits for Manipulated
Variables and Controlled Variables are ok. If any of the actual values are outside
the low or high limits, it will be indicated by Red colour.
3)
Once Watch dog is on, Touch ON button on MVC screen and press Enter. ON
button starts blinking.
4)
Check whether the status of the desired MVs (right hand corner of each
MV) to be taken in CASCADE mode is in RMPC. If the status of the MV to
be taken in MVC is in OPR, touch the STATUS column of the particular MV (3rd
Column from Left). Two options will come in the bottom viz. OPR, RMPC.
Touch RMPC. Now the status of that MV changes from OPR to RMPC in the
right hand corner. The same procedure needs to be repeated for other MVs
which are to be taken in cascade and is in OPR.
5)
Once the right hand corner of desired MV is in RMPC and the MVC has been
switched to ON position, Check whether the MVs have gone to CASCADE
MODE or not. If the other MVs have not gone to CASCADE mode, select those
MVs and change mode from AUTO to CASCADE.
6)
Once all the desired MVs have come to CASCADE mode after one minute the
STATUS column (3rd column from left) changes from FFWD to ON for the
MVs in CASCADE mode. The MVs for which the status is indicated ON are
under MVC control.
STEPS FOR TAKING OUT MVC FROM CONTROL
1)
Completely Switching MVC OFF : Select OFF button on MVC screen and
press enter. MVC will be switched off and all the controllers will go their earlier
mode (i.e. AUTO / MANUAL /BCAS) depending on the configuration.
2)
Taking out Single Controller from MVC control :

Change the Mode of the particular controller directly from CAS to
AUTO / MANUAL as desired. The change can be done from any screen and
only requires calling the desired controller for which mode change needs to be
done.
CHAPTER-16
CHAPTER-20

S.N0.
STREAM
1.
LPG
2.
LIGHT
NAPHTHA
3.
4.
HEAVY
NAPHTHA
SKO
5.
GASOIL
TEST
FREQUENCY
COPPER CORROSION
H2S &CAUSTIC WASH
DENSITY
DISTILATION
RVP
COPPER CORROSION
1/D
1/D
2/D
1/D
2/D
Once in an
alternate day
2/D
1/D
2/D
2/D
2/D
2/D
2/D
2/D
DENSITY
DISTILATION
DENSITY
FLASH
DISTILATION
DENSITY,FLASH
POURPOINT,
DISTILATION
TEST
PERFORMED
SHIFT
SHIFT
SHIFT
SHIFT
SHIFT
SHIFT
6.
7.
8.
9.
10.
11.
12.
13.
14.
SOUR
WATER
EX.V2
V-6/9/13
CAUSTIC
DESALTER
CRUDE
I/L,O/L
DESALTER
BRINE
WATER
V-7/10/14
WATER
FLUE GAS
CAUSTIC/
AMMONIA
RCO
TK-2A/B &
TK-6A/B
PH
CHLORIDE
FE
STRENGTH
1/D
1/D
1/D
1/D
SHIFT
DENSITY
SALT
BS&W
PH
OIL CONTENT
1/W
1/W
1/W
1/W
1/W
SHIFT- SUN
% OF CAUSTIC
1/W
G/S -WED
ORSAT
STRENGTH
ON REQ
ON REQ
SHIFT
SHIFT
RECOVERY AT 360C
CAUSTIC SOLUTION
STRENGTH
1/W
ON REQ
G/S
SHIFT
CHAPTER-21
MASTER BLIND LIST
SHIFT
SHIFT- SUN
BLIND LIST
BLIND LIST
S. No
1.
1
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
DESCRIPTION
SIZE
S/D
TYPE
24
RUNNI
NG
Out
CW inlet
In
Tail
Rich Amine To SRU

Lean Amine from SRU
LPG fron AU5
Crude to Unit
LR to Storage
HSD to FCC
LP steam to unit
MP steam to Unit
HP steam to Unit
Amine Ex Sump to CRU
HSD to DHDS
HSD to OMS
SOUR water to SRU
Stripped ex SRU
2
2
2
14
10
6
14
12
6
2
6
6
4
4
Out
Out
out
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
In
In
In
In
In
In
In
In
In
In
In
In
In
In
Spect
Spect
Spect
Tail
Tail
Spect
Tail
Spect
Spect
Tail
Spect
Spect
Spect
Spect
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Spent caustic to ETP

BFW to Unit
FLO
Instrument Air
Plant Air
Service Water
DM water
LPG Rundown
Light Naphtha to OMS
Caustic Ex OMS to Unit
LPG ex AU3
ATF R/D
SKO R/D
FG to DHDS
Slop to GRE/OMS
FG ex GHC
Hot RCO to GHC
IFO ex GHC
Wild Naphtha ex OMS/UNIT
Light Naphtha from Unit
Light Naphtha new line
CW return
Flare KOD to Flare line
SrN
o
1.
1
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
DESCRIPTION
2
3
4
4
4
4
4
4
4
3
4
6
6
8
10
12
10
8
2
3
6
24
24
CC01- COLUMN
SIZE
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
out
Out
Out
In
Out
Out
Out
Out
Out
Out
In
Out
Out
In
In
In
In
In
In
In
In
In
In
In
In
In
In
In
In
In
In
In
In
In
In
In
S/D
TYPE
In
Tail
In
In
In
In
In
In
In
In
In
In
In
In
In
In
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Feed Entry
30
RUNNI
NG
Out
Desalter PSV-1
Desalter PSV-1
Bottom O/L
Top O/L
Gas Oil CR Return
Kero CR Return
Top CR return
Top Reflux
Top CR Draw Off
Side Draw Off
Kero (to Stripper) Draw Off
Kero CR Draw Off
Gas Oil draw Off
Gas Oil CR Draw Off
10
10
14
30
14
14
12
8
16
8
16
16
16
16
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
Spect
Spect
Spect
Tail
Spect
Spect
Spect
Spect
Spect
Spect
Spect
Spect
Spect
Spect
Tail
Tail
Tail
Spect
Spect
Tail
Tail
Tail
Tail
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Vapour Return from HN Stripper

Vapour Return from Kero Stripper
Vapour Return from Gas OIL Stripper
Stripping Steam to Column
Column Top Vent
2 Nos of Over Flash Draw Off
Over Flash Return
Steam Out (Utility) to Column
Ahuralan Injection
Ammonia Injection
C2-Collumn
26.
Vapour Outlet
27.
Top Vent
28.
Pump Minimum circulation Return
29.
Reboiler Feed
30.
Reboiler Return
31.
Bottom Outlet
32.
Steam Out point
SrN
o
1
2
3
4
5
6
7
DESCRIPTION
1
2
3
4
5
6
Vapour Outlet
Top Vent
Stripping Steam I/L
Reboiler Feed
Reboiler Return
Bottom Outlet
Vapour Outlet
Top Vent
Stripping Steam I/L
Reboiler Feed
Reboiler Return
Bottom Outlet
Steam Out point
10
12
14
10
3
8
8
1
1
Out
Out
Out
Out
In
Out
Out
In
Out
Out
In
In
In
In
Out
In
In
In
In
In
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
10
2
2
6
10
6
2
Out
In
Out
Out
Out
Out
In
In
Out
In
In
In
In
Out
Tail
Tail
Tail
Tail
Tail
Tail
Tail
RUNNI
NG
Out
In
Out
Out
Out
Out
In
S/D
TYPE
In
Out
In
In
In
In
Out
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Out
In
Out
Out
Out
Out
In
Out
In
In
In
In
Tail
Tail
Tail
Tail
Tail
Tail
CC03- COLLUMN
SIZE
12
2
8
12
12
2
CC04-COLUMN
12
3
10
14
12
Steam Out point
1
2
3
4
5
6
7
8
9
Vapour Outlet
Top Vent
Reflux Nozzle
Reboiler Feed
Reboiler Return
Bottom Outlet
Steam Out Point
2 Nos Feed Inlet
PSVs
3
CC05- COLUMN
14
2
4
14
18
10
2
8
6
CC06- COLUMN
1
Vapour Outlet
2
Top Vent
3
Sour LPG Feed Inlet
4
Lean Amine Feed Inlet
5
Rich Amine outlet
6
Utility Connection
7
PSVs
4
2
4
2
2
2
4
In
out
Tail
Out
In
Out
Out
Out
Out
In
Out
Out
In
Out
In
In
In
In
Out
In
In
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Tail
Out
In
Out
Out
Out
In
Out
In
Out
In
In
In
Out
In
Tail
Tail
Tail
Tail
Tail
Tail
Tail
CHAPTER-22
CONTROL VALVES DATA
CONTROL VALVES DATA

S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
TAG NO.
5F
5LV2602
5LV3104
5LV3106
5FV1807
5FV2502
5LV3202
5PV1701
5FV2501
5PV3111
5FV1508
5FV2011
5FV2503
5PV1415
5PV1504A
5PV1504B
5PV1912
SERVICE
BOILER FEED WTR
RICH AMINE TO ARU
LPG BOOSTER PMP FLW
VENT FRM VV-003
LPG SURGE DRM
FO TO VV-026(BPC)
LPG FRM PA-014A/B
FO TO HTR
FG TO VV-002
LPG PRODUCT R/D
SIZE(in.) RATING
1
300
1
300
1
600
1
150
1.5
300
1.5
300
1.5
300
1.5
300
2
300
2
300
2
300
2
300
2
300
2
300
2
150
2
150
2
300
CV
3.8
7.5
6
7.5
22
7.5
22
12
45.63
60
27
22
22
12
49
49
49
MAKE
MIL
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
ARCA
MOTOYAMA
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
S.No.
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
5PV2011
5PV3203
5PV4406
5SDV1406
5SDV1701
5SDV1901
5SDV1902
5SDV1903
5SDV1904
5SDV2001
5SDV2002
5SDV2003
5SDV2201
5SDV2202
5SDV2203
5SDV2601
5SDV2602
5LV1201
5LV3103
5FV1201
5FV1409
5FV2501
5LV1602
5PV3202
5SDV1401
TAG NO.
5LV1202
5TV1702
5FV1401
5FV1402
5FV1403
5FV1404
5FV1804
5FV2206
5FV3102
5HV1701
5PDV1420
5SDV1402
5SDV1601
5SDV2501
5PV1423
5FV1410
5FV1412
5FV1413
5FV1414
5FV1505

2
300
2
300
2
600
FG SUPPLY(PILOT)
2
150
DRAIN FRM VV-003
2
300
2
300
WASH WTR EX VV-007
2
300
WTR EX VV-008
2
300
2
150
CASTIC EX VV-009
2
150
WASH WTR EX VV-010
2
150
WTR FRM VV-025
2
150
CAUSTIC EX VV-013
2
300
WASH WTR EX-VV-014
2
300
WASH WTR EX VV-015
2
300
AMINE SETTLER BTM
2
300
2
300
2
300
FO TO VV-026
3
300
3
300
3
150
3
300
SOUR WTR TO VV-005
3
150
3
150
FO RETURN
3
300
SERVICE
SIZE(in.) RATING
3
300
4
300
CRUDE TO HTR PASS-1
4
600
CRUDE I/L PASS-2
4
600
CRUDE I/L PASS-3
4
600
CRUDE I/L PASS-4
4
600
HSD R/D
4
300
4
300
4
600
STABISER O/H VAPOUR
4
300
ATM STM TO HTR
4
300
FO SUPPLY
4
300
SOUR WTR TO SRU
4
150
4
300
FG TO HTR
6
150
6
300
6
300
6
300
6
300
TOP RFLX TO CC-001
6
150
22
43
43
49
49
49
49
49
49
49
49
49
49
49
49
49
49
43
150
88
49
49
49
88
108
CV
88
117
140
140
140
140
195
95
115
195
195
195
195
195
444.6
359
359
359
359
250
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
UCH PIG.
MOTOYAMA
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
MAKE
UCH PIG.
ARCA
MIL
MIL
MIL
MIL
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
ARCA
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
63
64
65
66
67
68
69
70
71
72
73
74
75
76
5FV1805
LR TO BL(FPU)
5FV1806
LR TO BL STORAGE
5HV2001
5HV2002
LN WTR TO VV-010
5HV2201
5HV2202 KERO+ATF+WASH WTR TO VV-014
5SDV1801
LN TO CAUSTIC WASH
5FV1501
5LV1508
KERO STRIPPER FEED
5LV1510
5SDV1403
FG SUPPLY
5LV1206
5FV1502 ATF/KERO CR RETURNED TO CC-001
5TV1116
6
6
6
6
6
6
6
8
8
8
8
8
10
12
CHAPTER-23
LIST OF INTERLOCKS
300
300
300
300
300
300
300
150
150
150
150
300
300
300
440
440
250
250
359
359
341
475
475
475
680
475
900
1521
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
PIGNONE
UCH PIG.
ARCA
ARCA
LIST OF ALARMS & INTER LOCKS

In AU-V two types of alarms are in service. In first category, alarms are associated with
independent switches mounted on various circuits. Second category of alarms consists of
those, which are associated with various controllers/indicators.
Alarms emanating from independent switches can be brought either to DCS panel (CR to
or on panel of control room. Alarm setting can be provided to all DCS open loop or
closed loop measurements and can be taken to DCS panel, or control panel through a
converter. The alarms appearing on DCS are called software alarms while alarms on
panel of control room (console panel) are called Hard Wired alarms. The alarms
emanating from switches, but appearing on DCS only are also called software alarms.
Settings of software alarms can be wired to any value if the output from field is coming
through a transmitter, while hardwired alarms originating from switches have more or
less prefixed settings and are normally not varied
AU-5 TRIP SETTINGS (Warning vs: action alarm)
TAG NO
DESCRIPTION
TRIP
RANGE
Alarm
ACTION
VALUE
High 35 Kg/cm2
warning
Level
31 Kg/Cm2
05PSHH1130
P01A/B/Cv.
05PSHH2607
Dis. Pressure
CC-06 Top Pressure 18.9 Kg/cm2
0 25 Kg/cm2
17 Kg/Cm2
05PSL3102
V. High
P45A/B
0 -- 15
8.7 Kg/Cm2
05PSH1810
05FSL1401B
05FSL1402B
05FSL1403B
05FSL1404B
05PSLL1427
Discharge pressure
LR to SLOP
Low Flow in pass 1
Low Flow in pass 2
Low Flow in pass 3
Low Flow in pass 4
Very low pressure
0-215M3/hr
0-215M3/hr
0-215M3/hr
0-215M3/hr
0 10 Kg/cm2
120 M3/hr
120 M3/hr
120 M3/hr
120 M3/hr
4.0 Kg/Cm2
05PSLL1424
in fuel oil
Very low pressure 0.5 Kg/cm2
0 7 Kg/cm2
1.5 Kg/Cm2
05PSL1435
TAG NO
in fuel gas
Fuel gas to FF-01
DESCRIPTION
0 7 Kg/cm2
RANGE
1.5 Kg/Cm2
05FSLL1453
VALUE
Very low flow in 30000NM3/hr
0-164KNM3/hr
32000
05PSHH1452
combustion Air
High pressure in 10 mm WC
NM3/hr
-20,+20mm WC 05 mmWC
A
Furnace Arch
05PSHH1452B V. High pressure in 10 mm WC
Furnace Arch
05PSHH1452C V. High pressure in 10 mm WC
05SSLL1483
low 7.8 Kg/cm2

20 Kg/cm2
53.75 m3/hr
53.75 m3/hr
53.75 m3/hr
53.75 m3/hr
3 Kg/cm2
0.8 Kg/cm2
TRIP
Furnace Arch
Very low speed of 200 rpm
0 40 Kg/cm
1000 rpm
700 rpm
05SSLL1484
FD fan A
05FSL1455
FD fan B
Low flow in FD 15000 NM3/hr 82000 NM3/hr
18000
05FSL1454
Fan A suction
Low flow in FD 15000 NM3/hr 82000 NM3/hr
NM3/hr
18000
05SSLL1485
Fan B suction
1000rpm
NM3/hr
700 rpm
05TSHH1497
ID
Very high temp in 245 C
0 300 0C
2200C
05FSLL1460
CAPH
V. low flow cir. 60 lts/min
0 120 lts/min
100 lts/min
05FSLL1463
Oil in FD fan A
0 120 lts/min
100lts/min
05FSLL1457
Oil in FD fan B
0 120 lts/min
80 lts/min
PSLL-1427
Oil in ID fan A
Fuel Oil Pressure
0 8 Kg/cm2
4.0 Kg/Cm2
BPS -1407
PSLL-1424
Low
Fuel gas Pressure 0.8 Kg/Cm2
0-3
1.5 Kg/Cm2
BPS -1404
LALL-2502
LALL_2605
Low
V-20 level low
C-06 level low
0 -- 100
0 100
30%
22%
2.5 Kg/Cm2
5%
10%
1000 rpm
700 rpm
PROCESS INTERLOCK LOGIC:

A
05-FC-1401-PASS FLOW LOW-
F-01 cut off IFO SDV 1402
FAL 1401
05-FC-1402-PASS FLOW LOW
close
IFO Return SDV 1401 close
---FAL1402
BPS 1405
FG supply SDV 1403 close
---FAL1403
B
---FAL1404
FUEL OIL PRESS LOW
PSLL-14271407
BPS FUEL OIL SDV CLOSE
FUEL GAS PRESS LOW
PSLL-1424 -- BPS FUEL GAS SDV CLOSE
ARCH PRESS. HIGH
1407
PAHH-1452--- BPS STACK DAMPER OPEN
1410
NOTE: - If stack Damper does not open within 30 sec, Furnace will CUT-OFF.
VERY LOW COMBUSTION AIR FALL-1453 -- BPS FUEL OIL SDV CLOSE
FLOW
1409
FUEL GAS SDV CLOSE
STD OPEN.
05-KA-01B CIRCUL OF OIL FSLL-1463 ---BPS- - FD 1B TRIP
FLOW LOW
05-KA-01A CIRCUL.
FLOW LOW
LOW SPEED ID FAN
1417
OF OIL FSLL-1460 -- BPS- -- FD 1A TRIP
CAST APH O/L TEMP. HIGH
1416
BPS 1415
ID TRIP STACK DAMPER
TSHH-1497
OPEN
STACK DAMPER OPEN
NOTE: In case stack damper will not open automatically, ID fan will trip and furnace
J
will cut off

I.D.FAN CIRCULATING
FLOW LOW
FD FAN 1A SPEED LOW
1418
BPS 1412
FD FAN 1A TRIP
FD FAN 1B SPEED LOW
BPS 1413
FD FAN 1B TRIP
05-PM-01A/B/C DISCH. PRESS
HIGH
05-VV-20 LEVEL HIGH
OIL FSLL-1457 --- BPS I.D. WILL TRIP
05-VV-20 LEVEL LOW
05 PM-01A/B/C TRIP
LAHH-2501
SDV-2501
CLOSE
(LPG
LALL-2502
INLET TO VV-20)
TRIP 05-PM-50A/B (LPG
BOSTER PUMPS)
05-CC-06 HIGH PRESSURES
PAHH-2607
CLOSE FC-2601 (AMINE
TO C-06)
NOTE: - In case of high pressure in C- 06, FC-2601 will shut off. After attaining normal
condition FC-2601 will work as normal flow controller.
05-CC-06
BOTTOM
LOW
CLOSE SDV 2602
LEVEL LALL-2605
05-PM-45A
CLOSE SDV 2602

05-PM-45B
If pump (B) is running then selection switch [SS 3110] should be on (A), so that in case
at pressure low [PAL 3102B] pump (A) will start.
NOTE: - OFF push button of stand by pump must not be in lock condition.
CHAPTER-24
SKO/ATF SALT DRYER
SKO/ATF SALT DRYER

A Salt dryer is additionally provided in the SKO/ATF run down after coalescer to reduce
haziness in SKO/ATF due to fine mist of moisture, which slips through coalescer. The
salt dryer is loaded with 50MT of rock salt. It is provided with inlet at the bottom and
outlet at the top. Wet ATF/SKO enters the vessel through a Johnson Screen. A bypass
valve is also provided between inlet & outlet lines to bypass the dryer. A drain line is
provided at the bottom, which is connected with OWS & CBD. Two numbers of PSV are
installed at the top of the vessel, which is release to CBD & OWS. PGs provided at the
inlet and outlet to enable monitoring the pressure drop across the salt bed. As feed enters
at the bottom, the salt absorbs water droplets and its density increases. The dense brine
droplets settle at the bottom, which are drain out easily. Field operator drain out water
twice in a shift.
Design data: Salt to load: 61 Mt.
Inlet moisture: 1300-1500 ppm.
Outlet moisture: <200 ppm
Start up:
Ensure PSV are lined up
Line up outlet valve
Line up inlet valve slowly
Check that vessel top pressure is healthy.
Check that delta P across drier bed is healthy.
Shut down:
Bypass drier
Close inlet valve
Close outlet valve
Check that top pressure is below PSV set value
Drain out residual water at the bottom
Trouble shooting:
High-pressure drop. Johnson screen is chocked
Above calls for unloading of salts and inspection of Johnson screen
Moisture Slippage
Bed channeling due to high flow/partial chockage of Johnson screen.
High moisture in the bed due to unsatisfactory coalescer performance
Insufficient salt in the drier
High pressure in the vessel
Outlet valve partially closed
Rundown line restriction
Correct the problem by opening the valve
CHAPTER-25
HSD COALESCER
HSD COALESCER
OPERATION AND MANTENANCE M ANNUAL:

CLIENT
M/S INDIAN OIL CORPORATION LIMITED
PROJECT
IOCL GUJARAT REFINERY (UNIT-AU3)
INSPECTION :
M/S LRIS
ITEM
DIESEL COALESCER
TAG NO
05-VV-301 / ONE
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 despatched in wellpacked installation. It should be unpacked just before installation only and the whole
coalescer may be checked for any damage.
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: 1st stage: Coalescer element to coalesce fine mist of water and to retain dust particle
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 fibers 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 their 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 joint causing spillage and
wastage of service fluid, the coalescer should be put to the operation as follows :
Supply of stream (at required temperature) should be started before putting the coalescer
into operating
Provide all instrument / isolation valves at per drawing P&ID
Close all valves including inlet, outlet and drain plug. Open air vent.
Open inlet valves slowly so that coalescer is in operation.
Open drain plug and flush out any debris.
Close drain plug.
Allow coalescer to fill in with liquid and when the liquid starts coming out of the
air vent, close the air vent again.
Open coalescer outlet valve.
If there is a by-pass valve, close it slowly.
The fluid enters through the inlet to the coalescer. In the process of passing through the
elements, the entrained particles (Liquid+Dust) are caught through the depth of the
element and clean fluid passes 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.
CHAPTER-26
CHECKLISTS FOR TASK
OBSERVATION
EQUIPMENT HANDLING PROCEDURE :

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.
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
1. 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.
Energize 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/Vent if necessary.
Press/start button and check direction of rotation.
Check the discharge pressure and wait till amperage comes down
Open discharge valve gradually.
Check the amperage of the motor. Adjust the load, if required in consultation with
Panel Operator.
Check for any abnormal conditions like vibrations, abnormal sound, leakage, bearing
temperature etc.
2. HOT PUMP
The procedure is same as that for cold pump except for the following additional
points.
Ensure that pump is in warm-up condition
Close the warm-up valve (across NRV of discharge line).
(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 of
running pump and keep a watch on the discharge pressure gauge/flow-meter.
Switch off the originally running pump.
Consult the Panel Operator for any variation in flow
Open warm up b/v of hot pump to keep it warm up.
1.B RECIPROCATING PUMP

This is positive displacement pump; hence an outlet must be available for the liquid displaced
otherwise the system will get over-pressurized and leads to equipment damage.
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 valve.
(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 in line.
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.
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
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.
Energize 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.
Line up air duct/flue gas duct.
Bypass 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, as per requirement.
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.
26.1 TASK: HANDING OVER PUMP FOR MAINTENANCE

SR.
NO.
1
2
3
4
5
6
7
8
9
DESCRIPTION
STATUS
Yes/No
Remarks
Inform shift in-charge

De-blind pump casing drain to CBD/OWS
De-energize the pump-motor from substation.
Isolate pump suction / discharge / warm up valves
Slowly drain out pump casing content to
CBD/OWS. Open vent and drain it to CBD/OWS
Ensure that pump suction / discharge / warm up
valves are holding
If flushing oil provision is there, flush pump
casing with FLO.
Blind - pump suction / discharge valves
Hand over pump to maintenance
26.2 TASK: TAKING OVER PUMP FROM MAINTENANCE

SR.
NO.
1
2
3
4
5
6
7
DESCRIPTION
Inform panel operator / shift in-charge
Check all casing unwanted holes are plugged
Check suction / discharge are de-blinded and
there is no short / long bolts
Check coupling is properly fixed & covered
Check bearing cooling water are proper
Check motor connection is proper & earthing is
normal
Close casing drain & open pump suction valve 2
STATUS
Yes/No
Remarks
8
9
10
11
12
thread
Slowly open vent & allow air + liquid to vent
Check seal for any leakage
Vent liquid till all water etc are removed
If hot pump, open warm up valve & allow for
proper warming up
Check freeness of shaft.
26.3 TASK:
SR.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION
2
3
STATUS
Yes/No
Remarks
Isolate the vessel.

De-blind & drain to CBD
Ensure isolation valves are holding / total
draining by opening vessel drain to OWS
Isolate PSV and PIC
De-blind steam out point / provide steam
connection to the vessel
De-blind vessel vent.
Open vent & do steaming for 4 hrs
Blind all inlet, outlets and wedge opening, as per
blind list
Secondary steaming for 4 hrs.
Open manhole. Do- thorough water wash.
Check O2 and HC gas by O2 meter /
explosimeter.
If ok, provide air hose inside & give clearance for
man entry
26.4 TASK:
SR.
NO.
1
HANDING OVER OF OIL VESSEL
COMMISSIONING OF VESSEL
DESCRIPTION
Ensure cleaning of vessel inside & instrument
tapping before manhole boxing up
Check all blinds are removed as per blind list &
are boxed up with new / proper gasket
Check there is no long / short bolts.
STATUS
Yes/No
Remarks
4
5
6
7
8
9
Provide steam connection.

Do steaming for 3 4 hr. allow steam to vent
through vent & drain condensate to OWS.
Pressurize the vessel with steam to 2 3 kg & do
leak test for all disturbed flanges.
If there is no leakage, reduce steaming & slowly
open inlet valve. Close vent / drain & steam
valves.
Slowly open the outlet valve.
Blind vent/drain/steam out points
26.5 TASK: HEATEXCHANGER COMMISSIONING (CRITICAL)

SR.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DESCRIPTION
Check all inlet / outlet blinds are removed. All bull
plugs are fixed
Check all disturbed flanges are boxed up with new
gasket & check for short / long bolting.
Provide air connection at both shell & tube side
vent. Blow air from top & drain out water to OWS.
Provide hose connection at tube & shell side vent.
Fill tube & shell side with flushing oil. Vent air
from both shell & tube high point vent.
After filling is over, hold for hr. Drain out settled
water from both sides.
Refill both side with flushing oil. Close & end
blind the vents.
Close FLO isolation valve. Replace

soaked insulation if any.
Inform panel operator before opening
Open 2-3 thread cold side outlet valve. Drain at a
slow rate through inlet drain to CBD
Similarly open 2-3 thread hot side outlet valve.
Drain at a slow rate through inlet drain to CBD
Drain both sides till inlet sides are sufficiently hot.
Close both side drain valves & open cold side inlet
valves followed by hot side inlet valve slowly. Take
sufficient time.
When inlet / outlet valves are fully opened, slowly
close both bypass valves. Take sufficient time to
close bypass valves.
STATUS
Yes/No
Remarks
15
16
Blind FLO/CBD lines.

Check for any leakages and do hot bolting, if
required. (Steam lancers should be kept at the
leakage point)
26.6 TASK:
SR.
NO.
1
2
3
4
5
6
7
8
9
10
HEATEXCHANGER DE-COMMISSIONING
DESCRIPTION
De-blind both side CBD & FLO
Inform panel operator
Gradually open hot side by pass valve followed by
cold side bypass valve.
Isolate both side inlet & outlet valves. Drain both
sides to CBD at slow rate. Ensure both CBD lines
are hot during draining.
Check CBD level. Pump out, whenever required.
After sufficient time of draining, charge flushing oil
to both side & push out line content to CBD. Check
drain sample. If it is like HSD, stop flushing.
Check / ensure all 4 valves are holding by opening
drain valve to OWS.
Open vent valves of both side. Provide steam
connection & do steaming for 8 hrs.(Initially drain
into CBD & after that to OWS)
Give clearance for blinding both side inlet & outlet
valves.
After blinding is over H/O exchanger to
maintenance.
STATUS
Yes/No
Remarks
26.7 TASK:
SR.
NO.
1.
2.
3.
4.
HANDING OVER OF TANK
DESCRIPTION
Pump out material till pump looses suction
Water hose connection done from drain point and
level build up done up to 100 cms above
hydrocarbon level.
Pumping of hydrocarbon done
5.
Inlet/outlet and other inter connected lines except

drains are blinded.
Drain tank material to OWS.
6.
Open Man holes and sky light cover
7.
Taking water inside the tank through siphon drain

and overflowing from Manhole to continue till all
hydrocarbons are removed.
In case heavy oil tank, charge coil steam for hot
water wash.
Checking of hydrocarbons existing by explosive
meter.
If OK, then drain water
8.
9.
10.
11.
12
Air circulation and gas test by explosive meter

done.
If explosive meter is not OK then repeat the over
flowing by more water.
Blind steam coil inlet / condensate outlet
STATUS
Yes/No
Remarks
13.
14
15
Clearance given to Maintenance for tank

cleaning/inspection
In case of floating roof tank- check all pontoon
boxes for leak. If hydro-carbon is there, over flow
the box with water & drain through roof drain.
Check all pontoon boxes with explosimeter, before
giving hot job clearance.
26.8 TASK:
SR.
NO.
1.
TAKING OVER OF TANK
DESCRIPTION
Ensure maintenance job is over
2.
Ensure instrument maintenance job is over
Check cleanliness of tank inside. Ask to

mop. Check siphon drain line not chocked.
Box up side man holes.
4
5
De-blind inlet / outlet / steam coil inlet &

outlet
Check pontoon box are covered in case of
floating roof tank
Check roof drain is not chocked
Keep dip hatch open
Open tank inlet at slow rate. Inflow should

not be more than 100 kl / hr for floating
roof tank till the roof starts floating
Check for any leakage in manhole /
disturbed flanges after receiving liquid
level.
10
STATUS
Yes/No
Remarks
26.9 TASK:
SR.
NO.
1.
2
3
4
5
6
7
CONTROL VALVE HANDING OVER
DESCRIPTION
STATUS
Yes/No
Remarks
STATUS
Yes/No
Remarks
Inform panel operator about bypassing control valve

Take control valve on manual mode. Open its bypass
and close one isolation valve simultaneously. Ensure
the required flow by coordinating with panel
operator.
Isolate its both isolation valves. Open the control
valve fully.
Provide a hose at its drain point.
Slowly open drain valve & drain out total line
content.
After ensuring that the valves are holding, h/o the
control valve for maintenance
If control valve is required to shift to work shop, ask
to provide blind in D/S of inlet & U/S of outlet valve.
26.10 TASK: CONTROL VALVE TAKING OVER

SR.
NO.
1.
2
DESCRIPTION
Ensure instrument maintenance job is over
Close drain valve & plug.
Inform panel operator to open C/V
Slowly open inlet valve & check for any leakage
Open outlet valve & simultaneously close the bypass

valve with monitoring the required flow.
When bypass valve is totally closed, inform panel to
open C/v to have required flow.
26.11 TASK: HANDING OVER OF OIL GUN FOR CLEANING

SR.
NO.
1.
DESCRIPTION
Flush the gun with purging steam & than isolate.
Ensure that all three valves are not passing
Allow maintenance to remove the gun
26.12 TASK:
TAKING OVER OF OIL GUN FROM M/M
DESCRIPTION
Ensure that oil & steam flexible hoses are properly

fixed with gasket
Slowly open purging & atomizing steam valve.
Check for any leakage.
Isolate atomizing steam & take oil burner in line
Check any leaks, if any
26.13 TASK:
SR.
Remarks
Isolate oil & atomizing steam valve
SR.
NO.
1.
STATUS
Yes/No
STATUS
Yes/No
Remarks
HANDING OVER OF APH FOR CLEANING
DESCRIPTION
STATUS
Remarks
NO.
1.
2
3
4
5
Yes/No
Inform panel operator to open main stack damper
Stop ID fan & allow running furnace in forced draft
mode.
Allow maintenance to open inlet & outlet APH
manholes.
Allow for water wash. Man entry should not be
allowed.
Inform PNE to inform water block for additional
water consumption
26.14 TASK: LPG VESSEL WATER DRAINING (CRITICAL)

SR.
NO.
1.
2.
3.
4.
5.
6.
DESCRIPTION
Field operator informs the panel operator
before starting the job.
Panel operator constantly observes the vessel
level and takes the level controller in manual
mode, where ever applicable.
Field operator, first fully open U/S drain valve
and then slowly open the D/S valve and start
draining the water at a controlled rate.
Field operator stands continuously (without
leaving the place) and observes the drainage
material.
When LPG fumes start coming out along with
water, immediately close the U/S drain valve
and then D/S drain valve.
Field operator inform panel operator and
leave the place before ensuring that no
material is coming out from drain point
STATUS
Yes/No
Remarks
26.15 TASK:
SR.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
FURNACE LIGHT UP -DURING START UP (CRITICAL)
DESCRIPTION
Check all oil / gas / pilot gas burner valves are
closed.
Check all oil / gas / pilot gas line drain / vent valves
are closed and capped/ end blinded.
Inform panel operator to bypass IFO security &
establish IFO circulation through coil.
Purge furnace box with steam. Allow steam to come
out from stack. Confirm negative draft inside the
furnace.
De-blind fuel gas and pilot gas line.
Inform panel operator to bypass FG & PG inter lock
Open FG/PG SDV from panel/field.
Inform panel to open FG/PG PRC. Check line
pressure from Pressure gauge.
Light up pilot gas burners by electrical igniter &
simultaneously light up main fuel gas burner
Start FD fan for combustion air supply to furnace
Light up other gas burners, as per requirement.
Inform panel operator to maintain atomizing steam
pressure.
Flush oil burner with steam & light up fuel oil burner
as per requirement.
Start ID fan after observing high stack temp.
Check the furnace for any flame impingement on
tubes, excess air, incomplete combustion for all
burners (after closing the stack damper)
STATUS
Yes/No
Remarks
26.16 TASK: OIL BURNER LIGHT UP DURING NORMAL OPERATION

(CRITICAL)
SR.
NO.
DESCRIPTION
Inform panel operator and ask him to open main

stack damper
Ensure oil burner is properly boxed up.
Check primary / secondary air registers position.
Open them as required
Keeping fuel oil isolation valve closed, flush oil
gun with flushing steam. Check any leakage during
steaming.
If ok, close flushing steam valve & open atomizing
steam valve
Slowly open fuel oil valve & light up the burner
Observe the flame pattern and adjust the steam/oil /
air flow as per requirement
Observe the furnace condition. No flame
impingement should be there.
Inform panel operator about the furnace condition.
Ask him to close the stack damper.
2
3
4
5
6
7
8
9
26.17 TASK:
SR.
NO.
1
2
3
4
5
STATUS
Yes/No
Remarks
WARMING UP OF PUMP (CRITICAL)
DESCRIPTION
Check mechanical / Electrical completion of job.
Check lube oil quality and lube oil level in the lube
oil cup/ bearing. If required, top-up the lube oil.
Check the shaft movement & ensure that it is free
Check coupling / coupling guard
Check / commission bearing CW system
STATUS
Yes/No
Remarks
6
7
8
9
10
11
12
Adjust quenching steam to seal

Check casing inlet / outlet line drain / vent. Ensure
that these are closed & capped.
Commission casing vent cooler.
Slowly open 2-3 thread suction valve & vent out air /
liquid through vent cooler.
Check for any leakage & hotness of casing. If ok,
open fully suction valve.
Slowly open warm-up valve.
26.18 TASK:
SR.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PUMP CHANGE OVER (HOT PUMP) (CRITICAL)
DESCRIPTION
Check lube oil quality & lube oil in lube oil cup /
bearing. If required, top-up.
Check the shaft movement & ensure that it is free.
Check hotness of pump. It should be sufficiently hot.
Isolate warm up valve
Slightly open the discharge valve
Switch on the motor and wait till it attains the full RPM
Gradually open discharge valve.
Check Amp (Load). If the Amperage increased,
gradually close the discharge valve of former
(Running) pump. Repeat this operation till the pump
attains a full load.
Stop the previous pump.
Inform panel operator & confirm required discharge
flow
Check for any abnormality such as Vibration/ abnormal
sound / abnormal temperature etc. Report to shift incharge.
Slowly open warm up valve of the stand by pump,
pinch the cooling water valve to bearings and kept
pump as a stand by
STATUS
Yes/No
Remarks
26.19 TASK:
SR.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
PUMP CHANGE OVER (COLD PUMP)
DESCRIPTION
Check lube oil quality & lube oil level in lube oil cup /
bearing. If required, top-up lube oil.
Check the shaft movement & ensure that it is free
Slightly open discharge valve
Switch on the motor and wait till it attains full RPM
Gradually open discharge valve.
Check up Amp (Load). If the Amps are increased,
gradually close discharge valve of former (Running)
pump. Repeat this operation till the pump attains a full
load.
Stop the previous pump.
Inform panel operator & confirm required discharge
flow is obtained.
Check for any abnormality such as vibration/ abnormal
sound / abnormal temperature etc. Report shift incharge.
STATUS
Yes/No
Remarks
26.20 TASK: EMERGENCY HANDLING DUE TO POWER FAILURE

SR.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
DESCRIPTION
Remarks
Take clearance from CGP, whether the equipments

can be restarted
If clearance is obtained, quickly identify the tripped
rotary equipments. Start the standby pumps and
stabilize the unit condition
Inform the sub-station to reset the pump, which was
tripped.
Incase, stand by pump is not available, ask for
urgent help from substation
If clearance is not obtained, go for safe unit shut
down
Cut-off stripping steam
Cut-off furnace firing completely by closing
individual fuel oil, fuel gas and pilot gas isolation
valves.
Start box purging steam in the furnace
Route products to off grade tank / slop.
Stop DM water injection to de-salter
Stop all chemical dosing pumps
Keep watch of pressurized vessels. Release the
same to flare whenever needed.
Check all columns, heat exchangers and coolers for
any possible leaks or fire.
26.21 TASK:
SR.
NO.
1
2
STATUS
Yes/No
TANK WATER DRAINING
DESCRIPTION
Inform shift in-charge & ETP
Slowly open tank siphon drain valve. Watch
STATUS
Yes/No
Remarks
3
4
5
6
draining. Do not allow to drain hydrocarbon

Do not leave the place. Continuously monitor
draining operation.
When water draining is over, close the drain valve.
Observe that the drain valve is not passing.
Inform S/I about completion of job.
26.22 TASK:
SR.
NO.
1
2
3
4
5
DESCRIPTION
2
3
4
5
6
7
8
STATUS
Yes/No
Remarks
Inform shift in-charge / Panel operator.

Ensure line up of tank from OMS where routing is
to be done from S/I or Panel operator
Open battery limit valve, where routing is to be
done
Close the former routed battery limit valve.
Inform panel operator about completion of job and
ask for any change in r/d flow
26.23 TASK:
SR.
NO.
1
CHANGE OVER OF PRODUCT ROUTING
AHURALAN SOLUTION PREPARATION
DESCRIPTION
Inform S/I to arrange to connect Corrosion
Inhibitor (CI) drum.
Log initial tank dip in register
Top up the vessel with K9 bottom / H. Naphtha up
to required level
Transfer required amount of CI to tank (1:99 ratio)
Circulate solution for 3-4 hr.or Start nitrogen in
Sparger of ahuralan tank for proper mixing of the
solution
Log final tank dip in register
Start / adjust dozing to respective columns top, as
per requirement.
Log CI transferred in chemical register
STATUS
Yes/No
Remarks
26.24 TASK:
SR.
NO.
1
2
3
4
5
6
AMMONIA SOLUTION PREPARATION
DESCRIPTION
Take required quantity of DM water in the tank

Dissolve 1/2 cylinder of (20kg) ammonia in it.
Sprinkle water on ammonia cylinder for fast
condensation.
If cylinder exhausted, mark it and update in register
& inform S/I to replace with maintenance help
Log final tank dip in register
Start / adjust dozing to respective column top,

as per requirement.
Log ammonia consumed in chemical register
26.25 TASK:
SR.
NO.
1
Remarks
Inform S/I
Log initial tank dip in register
STATUS
Yes/No
CAUSTIC SOLUTION PREPARATION
DESCRIPTION
Inform S/I
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.
Dilute / top up the preparation tank with DM water

up to the required level.
Transfer required amount of fresh caustic in the tank

as per the strength to be prepared.
6
7
Circulate the solution for 4 hrs

Collect sample & inform S/I to check strength of the
solution by laboratory
STATUS
Yes/No
Remarks
8
9
Adjust dozing rate or replace spent caustic in

vessels, as per requirement
Log in chemical register
26.26 TASK:
AMMONICAL CAUSTIC SOLUTION
PREPARATION (NON-CRITICAL)
SR.
NO.
1
DESCRIPTION
STATUS
Yes/No
Remarks
Inform S/I
2
3
4
5
Transfer 10% caustic solution in the preparation tank

Dissolve ammonia in it, as per procedure
Circulate it for 4 hr
Transfer the solution to the tank from where dozing is
done
Adjust dozing as per E1 boot water PH
26.27 TASK:
CAUSTIC REPLENISHMENT IN NAPHTHA / LPG
CAUSTIC WASH SYSTEM (NON-CRITICAL)
SR.
NO.
1
2
3
4
5
6
7
8
DESCRIPTION
Inform S/I, panel operator and ETP
Open 2-3 thread the vessel drain to spent caustic
degasser tank (AU5 / GRE)
Inform panel operator to open drain line SDV (In
AU5)
Drain at slow rate. Continuously watch fall of
vessel level. Do not leave the place. Pure LPG /
Naphtha should never be drained to the degasser
vessel
After draining is over, isolate the drain valve &
inform panel operator to close the SDV
Line up caustic receiving to the vessel
Start pump taking suction from fresh caustic tank
& receive up to the required level.
Ensure receiving from DCS panel & from local
STATUS
Yes/No
Remarks
LG
Stop pump & inform panel operator
26.28 TASK:
WATER REPLENISHMENT IN NAPHTHA / LPG CAUSTIc
WASH SYSTEM (NON-CRITICAL)
SR.
NO.
1
2
3
4
5
6
7
8
9
DESCRIPTION
3
4
5
STATUS
Yes/No
Remarks
Open 2-3 thread the vessel drain to spent caustic

degasser tank (AU5 / GRE)
Inform panel operator to open drain line SDV (In
AU5)
Drain at slow rate. Continuously watch fall of
vessel level. Do not leave the place. Pure LPG /
Naphtha should never be drained to the degasser
vessel
After draining is over, isolate the drain valve &
inform panel operator to close the SDV
Line up DM water receiving to the vessel
Start pump taking suction from DM water tank &
receive up to the required level.
Ensure receiving from DCS panel & from local
LG
Stop pump & inform panel operator
FLARE KOD DRAINING
DESCRIPTION
Remarks
Inform S/I, panel operator and ETP
26.29 TASK:
SR.
NO.
1
STATUS
Yes/No
Inform S/I, panel operator

Open up-stream drain fully & down stream drain
valve as per requirement for slow draining
Drain to CBD. If draining is required to be done
in OWS, keep running water hose on it.
Do not leave the place
After draining is over, isolate the drain valves.
Ensure that the valves are holding, leave the
place. Inform panel operator
CHAPTER-27
LIST OF GAS/SMOKE DETECTORS
List of gas detectors & CCTV

AU5
Sl.No.
Tag. No.
Gas Detector's Location
1
2
3
4
5
05AI-1101
05AI-1102
05AI-1103
05AI-1104
05AI-1105
Between 05 P005A/B
Between 05 P006A/B
Between 05 P007A/B
Between 05 P0050A/B
Between 05 P0014A/B
Sl.No
1
2
3
4
CCTV Location
At battery limit
Near P01E
On Instrument air vessel
Behind new heat exchanger area
CHAPTER-28
PROCESS FLOW DIAGRMS
CHAPTER-29
FURNACE DECOKING
PROCEDURE
Mechanism of decoking:
The principle mechanism of decoking with steam and air are spalling and burning.
During spalling period steam is admitted to furnace tubes while they are being heated in
the furnace. Comparatively cooler steam cools and the hot outer surface of the tube
induces thermal shock causing coke to crack and break away from the tube surface. The
broken particles are picked up by high velocity steam. As much as 80-90% of the coke
can be removed by spalling alone.
The burning period consists of injecting both steam and air simultaneously while the
furnace is fired at higher temperature. The air ignites and consumes any coke residue
remaining after spalling. Burning effectively removes all coke deposit but requires close
monitoring to prevent overheating of furnace tubes.
Decoking Procedure:
The general description of the procedure in sequence of operation is as follows.
1. After shutting down and steaming out, isolate and blind the heater coils from the
rest of the unit.
2. Reverse the swing elbows at heater inlet and outlet to decoking position.
3. Line up outlet of the coils to the decoking effluent.
4. Light furnaces as per standard procedure. At firebox temperature of 200-250 Deg.
C, introduce steam at about 5.5 T/hr in each of the coils.
5. Increase outlet temperature at the rate of 50 Deg. C/hr.
6. Commission service water quenches to decoking pot to reduce the temperature.
7. For uniform heating of tubes, use alternate burners and preferably utilize fuel gas
firing to obtain good control.
8. Spalling will be done simultaneously in all passes but air will be introduced only
to one pass at a time during burning cycle. During the period when air is
introduced to one coil steam flow to the other passes will continue for
spalling/cooling.
9. When the outlet temperature reaches 475-500 Deg. C, hold at this temperature till
no more coke comes out of the decoking pot outlet.
10. During this spalling period reverse the flow of steam to the coils every 2 hours to
get maximum of coke removed.
11. Through the coil connected to the decoking manifold gradually introduce air in
steps of 25 kg/hr limited to 400 kg/hr. Burning is evident from presence of black
colour in effluent from decoking pot.
12. In tubes having heavy deposition of coke the tube will glow when the coke is
being burnt. The tube skin temperature must never exceed 650 Deg. C.
Reduce/cut the air or increase steam flow to control temperature.
13. Take samples of effluent at points provided at effluent line in decoking pot and
analyze for CO2.
14. Flow should not be reversed during burning.
15. When two consecutive effluent gas analysis show less than 1% CO2, the decoking
is considered to be complete.
16. Repeat this procedure of burning for the other coils.
17. When decoking is complete gradually reduce the furnace firing till the box
temperature comes down to 250-300 Deg. C and put off burners. Get fuel oil and
fuel gas header blinded.
18. Increase steam rate to the coils to remove the residual ash and clean the tubes.
Precautions:
1. Heater temperature must be raised slowly in order to obtain an even distribution
of heat.
2. The damper should be closed as much as possible without creating pressure
condition in the heater. This will aid in obtaining uniform distribution of heat. It
will also prevent overheating of convection tubes.
3. A close watch should be maintained on the firebox, skin and outlet temperature.
This alone should not be guiding factor as thermocouples may be coked up or
damaged during normal run. Visual inspection of the furnace is very important for
judging and controlling decoking.
4. Coils should not be allowed to be overheated. In case cherry red color is observed
on the tubes, which is about 600-650 deg C, cut air immediately or stop air flow
altogether. Also increase steam if required.
NOTE: 1. During the decoking procedure a Decoking register is maintained wherein all the
skin temps, fire box temps, flue gas temps, steam flow rates, air flow rate and
direction are noted on hourly basis.
CHAPTER-30
EQUIPMENT DRAIN LINE
DECHOCKING PROCEDURE
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 dechoking. 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 dechoking
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 dechoking activity.
CHAPTER 31
INTER CONNECTION / ROUTINGS
UNDER RUP
INTERCONNECTIONS/ ROUTINGS UNDER R.U.P.

LIGHT NAPTHA :
1- One 6 routing
provided to
05FCV7218, and second 4
route
routing
light naptha to
ISOM (NHT)
through
light naptah return to AU-5 L.N. caustic
treatment section through 05FI-7213.

2-One 6 routing provided L.N. to route G.T. intermediate feed tanks and to HGU
feed tanks 1503/1504 through 05FCV 7217
and 05PC7216,
HEAVY NAPTHA:
1-One 4 routing provided to DHDT feed tanks through 05FCV6204.
ATF/SKO :
1-To route SKO to DHDT
feed tanks through 05FCV6201.6line.
2-To route SKO/ATF to ATF Merox
in RUP through 05FCV6202
6line.
GAS OIL:
1-Facility provided to troute Gas Oil through 05FCV 6205 to DHDT
feed tanks 8 line , and to FLO tanks in DHDT area through 8 line
( TK NO-730).
LONG RESIDUE /RCO;
1-Facility
provided to route HOT RCO to DCU through 10 line-
05FCV6203 and
routings.
cold RCO through 12 line via normal
cold RCO
Annexture-1
Modifications During M&I- 2013
Sub: AU5: Extension of Nitrogen through the plant area upto B/L.
Description of Present System:
Presently nitrogen from DHDS plant comes to AU5 through 2 header.
Nitrogen is mainly consumed in AU5 for the use of bubbling in corrosion
inhibitor solution tanks.
Description of Proposed Change:
A new 2 nitrogen line is extended from the Corrosion inhibitor tank to the unit
B/L. are provided at three locations to use the nitrogen.
Reason(s) of Asking for change:
During shut down and start up period initial and final steaming of different
columns . And vessels nitrogen is required as gas backup for avoiding vacuum.
Nitrogen to
AHURULAN
TANKfor
dilution
OPERATING CONDITIONS
TEMPERATURE:40 DEG.C
PRESSURE
:6.0KG/CM2
SEVICE
:Nitrogen
FUEL GAS HOOK-UP TO MSQ

A new hook-up has been made in the main F.G header line of AU-5 at B/L to MSQ
UNIT .in addition to the existing line.
.
An additional 6 hook-up has been provided from the upstream of main F.G
header at AU-5 B/L to upstream of 5PCV0204 to ensure the un -interrupted
supply of F.G to MSQ
The mentioned modification was done to ensure the un interrupted supply of F.G to
MSQ unit
SERVICE : Fuel gas

TEMP
: 45 DEG.C
PRESSURE: 6 KG/cm2
Sub: AU5: Desalter crude inlet temperature improvement

Introduction:
Nitrogen to Ahurlan
At present crude is preheated to 120-125 degc in preheat train-I exchangers. Crude from
tank for dilution
preheat train I goes to desalter 05V01A/B for desalting. Crude outlet from desalter goes
to Preheat train-II for further heat pick up. Desalter crude inlet temperature is maintained
around 120-125 degC
Description of Proposed Change:
It is proposed to improve the desalting crude inlet temperature by shifting exchanger 05
E6A/B exchanger (crude vs Kero CR) which is in preheat train-II to preheat train-I .
New 12 line connecting the tube side outlet of E05 exchanger to tube side inlet of
E06A/B exchanger.
New 12 line connecting the tube side outlet of E6A/B exchanger to the crude inlet line
of desalter
New 12 line bypassing the E06A/B exchanger.
Reason(s) of Asking for change:
Since Desalter crude inlet temperature to desalter is low (120 degC) as compared to 130135 degc required for better desalting. It is proposed to improve the desalting crude inlet
temperature by shifting exchanger 05 E6A/B exchanger (crude vs Kero CR) which is in
preheat train-II to preheat train-I . Only piping modifications are required for executing
the job.
Heat exchanger shell side and tube side temperatures (Present case)
Present actual
temperature C
Crude desalter inlet
temperature train -1
115-120
After modification C
132
Net improvement in preheat of desalter crude inlet = 5-6 C
PROPOSED:
EXISING :
LEGEND
Cooling water Back wash system:
During the M&I of APR-2013 All the over head condensers of CC-01
(05-EE-016A/B/C/D/E/F) & The over head condensers of CC-05( 05EE-017A/B/C) provided with back flushing system.The main purpose
was to increase the condenser efficiencies as well as to avoid fouling of
condensers
Increase the wash water temp.to desalter:
. During the M&I of APR-2013 , A 3 line with isolation valve was made in
the 05-EE-012A/B/C O/L, to route the wash water to 05- EE-013D/E/F
tube side to exchange heat with HEAVY NAPTHA Run down before
entering in to the desalter. By this wash water temp.raises upto 130Cto
140C. After exchanging heat, wash water enters to desalter .Still the system
is not yet commissioned due to non availability of bundles in EE-13D/E/F.
EE-13D/E/F
Installation of MOVs:
MOVs were installed in the following under mentioned locations.The objective is
to ensure the safe isolation during emergencies.
a. V-2 naptha ex(in the common suction line of 05-PA-5A/B/C&

05-PA-6A/B/C)
b. V-3 LPG ex(in the suction line of 05-PA-14A/B)
c. C-04 diesel ex(in the suction of 05-PA-11A/B)
V-2 MOV- 1602:

During APR-2013 M&I MOV-1602 Is installed in the V-2 naptha ex at
the common suction lines of 05-PA-05A/B/C&05-PA-06A/B/C.,This was
installed to ensure remote &safe isolation during emergencies.The
MOV-1602 is provided with local switch in the panel as well as in field.
V-3 MOV-1703:
During M&I of APR-2013 MOV-1703 is installed in the V-3 ex .in the
common suction line of 05-P-06A/B/C The purpose was to ensure the
safe& Remote isolation during emergencies,MOV-1703 can be operated
from both field& DCS.
V-4 MOV-1501:
During M&I of APR-2013 MOV-1501 is installed in the common
suction line of P-11A/B for the remote &safe isolation during
emergencies. The MOV is provided with local switch in the field as well
as in the panel
Provision of stubs in Flare header:
2-nos of stubs with isolation valves provided in the main flare header
system for future hook-up jobs
DCS System Upgradation:

DCS system was upgraded from CENTUM CS to CENTUM VP.
ANNEXTURE-2
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
passing 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 passivation/washing procedure as applicable to
that equipment.Similarly when 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, bamboos, 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.
SEQ/PN(GR-1)/SI/7.5.1/4/AU-5 OPERATING MANUAL
ANNEXTURE-3
HVLR-MONITOR
HIGH VELOCITY LONG RANGE MONITOR
ANNEXTURE-4
List of SEQMS DOCUMENTS OF AU-5
Following work instructions mentioned in detail in SEQMS manual

SEQ / PN (GR-1)/R/7.5.1 / 1
DAILY PRODUCTION MATERIAL BALANCE SHEET
LOG BOOKS OF AU-5
SEQ / PN (GR-1)/R/7.5.1 / 4
LABORATORY RESULTS OF AU-5
SEQ / PN (GR-1)/R/7.5.1 / 8
TANK DIPS OF AU-5
SEQ / PN (GR-1)/R/7.5.1 / 12
CHEMICAL CONSUMPTION RECORDS OF AU-5
SEQ / PN (GR-1)/R/7.5.1 / 16
UTILITY CONSUMPTION RECORDS OF AU-5
SEQ / PN (GR-1)/R/7.5.1 / 20
INSTRUCTION REGISTER OF AU-5
SEQ / PN (GR-1)/R/7.5.1 / 22
SEQ / PN (GR-1)/R/7.5.1 / 23
&
SEQ / PN (GR-1)/R/7.5.1 / 24
TRAINING RECORDS FOR OFFICERS& NON OFFICERS
LOG SHEETS OF AU-5
SEQ / PN (GR-1)/R/7.5.1 / 27
SEQ / PN (GR-1)/R/7.5.1 / 29
STEAM LEAK / WATER LEAK/HYDROCARBON LEAK SURVEY RECORD OF

ALL UNITS
OHSMS RECORD
SEQ / PN (GR-1)/R/7.5.1 /30

SEQ / PN (GR-1)/R/8.2.4 /31
RECORD OF PROCESS PERFORMANCE PARAMETERS

SEQ/PN(GR-1)/R/8.2.4/01

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PRODUCTION DEPARTMENT

Gujarat Refinery Units (GRU)

ATMOSPHERIC UNIT-V (AU -V)

SEQ/PN/(GR-I)/SI/7.5.1/4 (Rev No: 03)

: K.M. TAMBOLI (PNM)

INDIAN OIL CORPORATION LTD.

V-2 naptha ex(in the common suction line of 05-PA-5A/B/C&

ii) V-3 LPG ex(in the suction line of 05-PA-14A/B)

f) DCS system was upgraded from CENTUM CS to CENTUM VP.

PROCEDURES FOR EQUIPMENT TAKING OVER FROM MAINTENANCE

HOT WORK PERMIT

SIGNATORIES FOR FIRE PERMITS

ii) GENERAL SAFETY INSTRUCTIONS

iii) HVLR MONITOR

iv) LIST OF SEQMS DOCUMENTS

The vapor pressure of a liquid at a particular temperature is the equilibrium pressure

Boiling Point Diagram

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

A typical laboratory distillation setup.

The atmospheric Unit AU-V of Gujarat Refinery is designed to process 3.0

This unit was commissioned in the year 1997.

The unit was revamped during August/Sept 02 to increase the on stream

No of onstream hours in a year considered for design is 8000 hrs.

DESIGN FEED RATE

LPG (Ex Stabilizer)

2.4 FEED & PRODUCT SPECIFICATION

Specific gravity @15 oC

Vapor pressure 6.5

95% vol to contain

Lower limit to take care of

HIGH SPEED DIESEL

To take care of test margin

To take care of test margin.

To take care of test margin

Customer problem of filter

To take care of test margin

To take care of test margin

To take care of test margin

AVIATION TURBINE FUEL

Defense requirement. Product

Defense requirement. Product

To meet Defense requirement.

FEED & PRODUCT BATTERY LIMIT CONDITIONS

LPG Horton Sphere

Storage for DHDS unit

-15oC dew point

Characteristi BIS Spec.

Manf Justification/ Remarks

Test margin and cushion

In line with LSHS flash

PAVING BITUMEN (S-65/S-90 grades)

To take care of test margin

Atmospheric Distillation column

3.2 HEAT EXCHAGERS/COOLERS & CONDENSERS

05-FD-001-Cast Air pre-heater

Desalter 1st stage

Ahuralan soln. Vessel

LPG surge drum

Safety valve data

05-TT-002A/B-10% Caustic Dilution Tank