AVU Operating Manual Rev. 07

OPERATING MANUAL
FOR
ATMOSPHERIC & VACUUM DISTILLATION UNIT
INDIAN OIL CORPORATION LIMITED

PARADIP REFINERY
JANUARY – 2023
(Revision-07)
OPERATING MANUAL
FOR

PARADIP REFINERY
JANUARY – 2023
(Revision-07)
MANUAL NUMBER: PN/AVU/OM/U- COPY NO.

10 TYPE OF COPY
DEPARTMENT: PRODUCTION CONTROLLED
UNIT SECTION: ATMOSPHERIC UNCONTROLLED
AND VACUUM DISTILLATION UNIT ISSUED TO:
DOCUMENTS PRESENTED HEREIN CAN BE FREELY USED BY ALL
AUTHORISED PERSONNEL. RESPONSIBILITY OF THE
DOCUMENTS HOWEVER SHALL REMAIN WITH COPY HOLDER TO
WHOM IT WAS ISSUED INITIALLY.
Prepared By: Checked By: Approved By:
(Debbrata Mondal) (Manish Kumar) (Shashikant Kumar)

PNM CPNM DGM (PN)
OPERATING MANUAL
FOR
Revision History
Revision No. Revision Date Details of Revision Approved By
Revision-01 April 2016 CPNM

Revision-02 April 2018 CPNM
Revision-03 January 2019 See Annexure-I DGM (PN)
Revision-08
Revision-09
Revision-10
Annexure-I
DETAILS OF CHAPTERS UPDATED
Revision No Revision Details of Revision
Date
Revision-03 January Chapter No. 2:
2019 Chemical trade names of NA/CI/De-Emulsifier updated.
Chapter No. 3:
(a) Process scheme description of “NEW CAUSTIC DOSING

SCHEME POST DESALTERS
(b) Process scheme description of “HIGH TAN DOSING SCHEME”
in AVU
(c) Process scheme description of “PROVISION FOR ROUTING
OF V-08 O/H VAPOURS TO V-16”
Chapter No. 12:

MSDS of various chemicals used in AVU updated.
Chapter No. 13:

Additional interlocks for “1oo1 TRIPPING OF PUMP MOTORS IN
HIGH BEARING TEMPERATURE”.
Chapter No. 22:

Addition of “SOP for PCK run”.

2020 a) Process scheme description of “ROUTING OF CDU OFF-GAS
TO FCC-WGC SUCTION FOR MAXIMISING LPG
RECOVERY”
Chapter No. 010:

New Closed loop sampling system was implemented as per OISD
safety recommendation for Naphtha, Kerosene, AGO, VD, VGO,
HVGO. The same has been updated in the manual.
Revision-05 January Chapter No. 01 &03:
2021 Process RPIP scheme “Routing of side cut naphtha to NHT
hot feed, de-bottle necking of naphtha stabilizer”
Chapter No. 01 &03:

New jump over line “Routing of VGO/HVGO product to
crude tank circulation line”.

2022 Addition of SOP for Simultaneous Failure of 3 VR Pumps.

2023 New line for routing of VGO back wash to DCU storage tanks
via AVU battery limit
Chapter No. 03:
New jump over line “Routing of AGO product to crude tank
circulation line”.
Chapter No. 16:
Details of APC model implemented in AVU included in the
revision

PNM CPNM DGM (PN)
OPERATING MANUAL
FOR
DISTRIBUTION LIST
Copy No: Issued To: Department
Copy 1 of 6 Engineering Assistants Production
Copy 2 of 6 Panel Officers Production
Copy 3 of 6 Shift in Charge Production
Copy 4 of 6 Unit in Charge Production
Copy 5 of 6 HOD Production
Copy 6 of 6 Emergency Control Room HSE

PARADIP REFINERY
JANUARY – 2023
(Revision-07)
PREFACE
This manual has been prepared as per the reliability guidelines to facilitate the
operating personnel for safe and smooth commissioning and subsequent unit
operation of Atmospheric and Vacuum Unit of Paradip Refinery. The manual will
also serve the purpose of providing useful guidance to the new entrants for better
understanding of the unit operation.
Being a grass root refinery, the contents of this manual has been designed to make
it informative based on the input from all the possible sources including LSTK-
1, LSTK-A & OEM. At the same time it has been ensured that content of the
chapters like Pre-commissioning & Commissioning, Startup, Shutdown,
Emergency Handling Procedure and Trouble Shooting are based on years of
IOC’s operational experiences.
The manual has been updated in January 2023. The summarized list of updation
has been mentioned in Annexure-I.
All the operating parameters mentioned in this manual are as per design data
which may be changed during actual plant operating depending on the
requirement. All the information in this manual is for Production operating
personnel only and not to be divulged to anyone without the permission of the
issuing authority.

PNM CPNM DGM (PN)
Revision – 07
January’ 2023
INDEX
Sl.
Chapters Contents
No.
1 Chapter – 01 General
2 Chapter – 02 Design Information & Chemical Details
3 Chapter – 03 Detailed Process Description
4 Chapter – 04 Operating Variables
5 Chapter – 05 Job Responsibility
6 Chapter – 06 Pre-Commissioning & Commissioning
7 Chapter – 07 Normal Startup Procedure
8 Chapter – 08 Normal Shutdown Procedure
9 Chapter – 09 Emergency Shutdown & Handling
10 Chapter – 10 Sampling Laboratory Analysis
11 Chapter – 11 Plant Performance Monitoring
12 Chapter – 12 Safety System, Fire Fighting System
13 Chapter – 13 Interlocks
14 Chapter – 14 Inspection Requirement
15 Chapter – 15 Equipment Handover Takeover
16 Chapter – 16 DCS PLC Details
17 Chapter – 17 Utility & Auxiliary Network
18 Chapter – 18 Blind List
19 Chapter – 19 Standing Instructions
20 Chapter – 20 PFD
21 Chapter – 21 Work Permit Systems
Erstwhile CHAPTER -22 has been removed and maintained as

separate document from Rev. 07 onwards. SOP documents are
available separately in INTRANET and in HARD COPY
FORMAT
Doc. No:
OPERATING MANUAL PDR/AVU/OM
ATMOSPHERIC & VACUUM DISTILLATION UNIT Revision: 07
PARADIP REFINERY Issued : 01-Jan-2023
Validity: 31-Dec-2023
CHAPTER-01
GENERAL DESCRIPTION

Debbrata Mondal, PNM Manish Kumar, CPNM Shashikant Kumar, DGM (PN)
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1.0 GENERAL DESCRIPTION:

3.1 INTRODUCTION
3.3.1 UNIT OBJECTIVE
The objective of the Atmospheric and Vacuum Distillation Unit (AVU) is to provide a primary
separation of crude oils to produce straight run distillate products after suitable treatment and quality
upgradation in secondary process units. AVU in Paradip Refinery comprises of Crude Distillation
Section (CDU), Vacuum Distillation Section (VDU) and Naphtha Stabilizer Section (NSU).
AVU is the first process unit in the process of upgrading crude to valuable products and hence holds
a great significance in the refinery. It is also called the “mother unit” since it provides feed to all
major secondary units like Alkylation, NHDT, KTU, DHDT, VGO-HDT, and DCU.
AVU in Paradip Refinery was commissioned on 26th April 2015 and the total refinery was dedicated
to the nation on 07th February 2016 by the Honorable Prime Minister of India.
3.3.2 UNIT CAPACITY:
Atmospheric and Vacuum Distillation Unit (AVU) of Paradip Refinery is designed to process 15.0
Million Metric Tonnes per Annum (MMTPA) of design feedstock.
3.3.3 ON STREAM FACTOR:
AVU is designed for an on stream factor of 0.95%. This is based on 8320 hours of operation per
calendar year with a planned shutdown schedule in every 5 years.
3.3.4 NAMEPLATE CAPACITY:
AVU name plate capacity is 43,269 TPSD (Tonnes per Stream Day) based on the following feed
stocks.
Capacity Basrah Oman Kuwait
Feedstock Case Maya
TPSD Light Export Export
Light Crude 43269 50 wt.% 50 wt.% - -
Heavy Crude 43269 - - 60 wt.% 40 wt.%
3.3.5 TURNDOWN:

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The AVU is able to operate at a turndown ratio of 50% of design feed throughput while meeting all
product specifications.
3.3.6 DESIGN FEED CASES:
Light Crude Case:
The feedstock is a blend of Basrah Light and Oman Export Crudes in the ratio of 50:50 wt. %. This
case design the top section of the crude unit.
Heavy Crude Case:
The feedstock is a blend of Kuwait and Maya Crudes in the ratio of 60:40 wt. %. This case design
the bottom section of the crude unit.
3.3.7 ADDITIONAL FEEDS PROCESSED IN AVU:
The following additional hydrocarbon streams are processed in AVU in addition to crude.
i. Wild Naphtha from DHDT (maximum of 337.5 TPSD)
ii. Treated LPG from SR-LPG Treatment unit (maximum of 525.7 TPSD)
iii. Off Gas from NHDT
iv. Off Spec LPG for reprocessing in Stabilizer
As per requirement refinery slop is processed in AVU, which is blended with crude in the BOOT-3
area and fed to AVU along with the crude.

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CHAPTER-02
DESIGN INFORMATION

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2.0 DESIGN BASIS
3.1 DESIGN OBJECTIVE

The design of the AVU is consistent with the overall refinery objective of maximizing gasoline /
distillates and minimizing fuel oil. The design is flexible enough to handle crudes or crude blends
lighter / heavier than the design crudes with the overcapacities limitations. The design incorporates
features for optimizing energy utilization and recovery consistent with acceptable product
fractionation and economics.
3.2 UNIT SECTION & CAPACITIES

The different sections of AVU and their capacities are tabulated below:
Sl.
UNIT CAPACITIES
No.
1 CDU Section 15 MMTPA
2 VDU Section 8.7 MMTPA
3 NSU Section 2.92 MMTPA
4 Off Gas Treatment Section 0.1 MMTPA
5 VDU Sour Gas Treatment Section 0.015 MMTPA
2.3.1 CDU SECTION

The CDU section is designed to produce the following streams:
a. Overhead Gas stream which is routed to Naphtha Stabilizer Section for LPG recovery after
compressing in an off gas compressor.
b. Overhead Naphtha Stream which is routed to Naphtha Stabilizer Section for producing Stabilized
Naphtha and LPG separately.
c. Side Cut Naphtha Stream which can be routed to Naphtha Stabilizer as well as directly routed to
NHDT Unit.
d. Kerosene Stream which can be routed to KTU Unit and/or Kerosene Storage Tanks and/or upcoming
KHDS Unit.
e. Light Atmospheric Gas Oil (LAGO) Stream which is routed to DHDT Unit / Storage Tanks / HSFO
Tanks / Crude Tanks after blending with Heavy Atmospheric Gas Oil (HAGO) Stream with in AVU.
f. Heavy Atmospheric Gas Oil (HAGO) Stream which is routed to DHDT Unit / Storage Tanks / HSFO
Tanks / Crude Tanks after blending with Light Atmospheric Gas Oil (LAGO) Stream with in AVU.

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Provision exists for routing HAGO stream to VDU blending with Reduced Crude Oil (RCO).
g. Atmospheric Residue / Reduced Crude Oil (RCO) routed to Vacuum Distillation Section via VDU
furnace.
2.3.2 VDU SECTION

The VDU section is designed to produce the following products.
a. A Vacuum Off Gas stream (Vent Gas) which is routed to VDU furnace for burning after amine
treatment to reduce H2S content.
b. Hot Well Oil generated from overhead section of the VDU section is routed to DHDT Hot feed /
Storage.
c. Vacuum Diesel (VD) Stream is routed to DHDT / Storage.
d. Vacuum Gas Oil (VGO) stream is routed to VGO-HDT unit as direct feed / storage tanks / crude
tanks after blending with Heavy Vacuum Gas Oil (HVGO) stream.
e. Heavy Vacuum Gas Oil (HVGO) stream is routed to VGO-HDT unit as direct feed / DCU direct feed/
storage tanks / crude tanks after blending with Vacuum Gas Oil (VGO) stream.
f. Vacuum Residue stream is routed to DCU as direct feed / Storage tank / HSFO storage tanks.
g. A recycle Oil stream (normally not produced as product) can sometimes be routed to Vacuum Residue
products to control the VGO quality.
The HVGO stream is provided to maximize the ashphaltene recovery into the vacuum residue stream
(Delayed Coker Unit Feed) as well as to control the quality of the VGO HDT feed. The design also
incorporates a flexibility to route HVGO stream to the
Delayed Coker Unit to provide a means of controlling the properties (metals and
conradson carbon) of the VGO feed to the VGO HDT.
2.3.3 NSU SECTION

NSU section consists of the following streams:
a. An overhead gas stream which is routed to the fuel gas treatment section.
b. A CDU Sour LPG stream which is routed to the SR-LPG Treatment Section.
c. Sweet LPG (C3 rich stream) from Depropaniser is routed to LPG storage for blending in LPG streams.
d. Sweet LPG (C4 rich stream) from Depropaniser is routed to LPG Storage or Alkylation Unit.

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e. A full range stabilized Naphtha stream from Naphtha Stabilizer which is routed to NHDT / Storage
Tanks / GT tanks.
In addition to the above section, other sections include an Off Gas Treatment section which treats off
gas to remove H2S. The fuel gas is routed to Fuel Gas header and / or Indmax as per requirement.
2.3.4 OFF GAS TREATMENT SECTION

Off gas generated from CDU and NSU section are treated with Amine for removal of H2S. NHDT
stripper Off gas is also treated along with CDU/NSU off gas and then routed to FG header or
INDMAX for further C3/C4 component recovery. The Off gas generated from Depropaniser
overhead is directly routed to Fuel Gas header with treated off gas from amine section.
2.3.5 SOUR / VDU VENT GAS TREATMENT SECTION

Sour Gas generated from VDU seal pot drum along with gas from SR-LPG DSO separator is treated
for H2S removal in a packed column. The treated off gas is burned in VDU furnace.
3.3 DESIGN FEED

Light Crude Case:
The feedstock is a blend of Basrah Light and Oman Export Crudes in the ratio of 50:50 wt. %. This
case design the top section of the crude unit.
Heavy Crude Case:
The feedstock is a blend of Kuwait and Maya Crudes in the ratio of 60:40 wt. %. This case design the
bottom section of the crude unit.
AVU name plate capacity is 43,269 TPSD (Tonnes per Stream Day) based on the following feed
stocks.
Capacity Basrah Oman Kuwait
Feedstock Case Maya
TPSD Light Export Export
Light Crude 43269 50 wt.% 50 wt.% - -
Heavy Crude 43269 - - 60 wt.% 40 wt.%

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3.4 DESIGN PRODUCT SPECIFICATIONS
2.3.1 PRODUCT CUT POINTS

The AVU design is based on the following nominal TBP cut points:
TBP Cut Points
Product
Light Crude Heavy Crude
C3 LPG C3-C4 C3-C4
C4 LPG C4-C5 C4-C5
CDU LPG C3-C5 C3-C5
Straight Run Naphtha C5-178 C5-162
Kerosene 178-223 162-212
Atmospheric Gas Oil (Note-1) 223-350 212-349
Atmospheric Residue 350+ 349+
Vacuum Diesel 350-368 349-368
VGO 368-550 368-546
Heavy VGO (Note-2) 550-578 546-562
Vacuum Residue 578 + 562+
Notes:
1. Atmospheric Gas Oil is made up of Light and Heavy Atmospheric Gas Oil streams (LAGO &
HAGO). The nominal TBP cut point shown is for the blended AGO streams.
2. The heavy VGO (HVGO) end cut point is 562 Deg C max for the heavy crude
case in order to reduce the amount of metals and other contaminants to a
level acceptable to the VGO Hydro treater Licensor.
2.3.2 PRODUCT SPECIFICATION
AVU is designed to meet the following specification when processing the above mentioned crude
cases for processing in the downstream units.
Products Spec.
Stabilized Naphtha

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C4 in Naphtha 1.0 % vol

RVP (ASTM-D323) 55.9 kPa
Distillation (ASTM-D86): FBP 178°C max
Kerosene
Distillation (ASTM-D86): FBP 300oC max
Flash Point Abel (ASTM D-3828) 38o C min
Atmospheric Gas Oil (AGO)
Distillation (ASTM-D86): 95%vol 360oC max
Vacuum Gas Oil (VGO)
Distillation (ASTM-D1160): ATM FBP 625oC max
Vacuum Diesel
Distillation (ASTM-D86): 95%vol 360oC max
CDU LPG
C5 in CDU LPG (ASTM D-2163) TVP 2.0 %wt max.
@ 65°C (ASTM –D1267) 16.87 kg/cm² max
2.3.3 FEED STOCK CONTAMINANTS (VGO)

The AVU is designed to satisfy the following maximum permitted contaminant levels, which are
expected in the VGO product streams as feed to the VGO HDT.
Contaminant in VGO HDT Feed Heavy Crude : 60/40 Kuwait/Maya
Metals : Nickel, ppmw 1.42
Vanadium, ppmw 4.96
Conradson carbon, wt% 1.2
Sulphur, wt% 3.32
Total Nitrogen, ppmw 1,594
Bromine No., g/100g 2
Aniline point, 93
C7-Asphetenes, ppmw < 500

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3.5 FEED & PRODUCT BATTERY LIMIT CONDITIONS

Temp Pressure
Stream Origin/Destination
(OC) (kg/cm²g)
From storage
Crude feed 35 30
(201-TK-001-201-TK-011)
Wild Naphtha From Diesel Hydrotreater Unit 55 10
Treated LPG From SR LPG Treater 40 16.2
Stripped Water From Sour Water Stripper (SWS-I) 65 5
From Amine Regeneration Unit-I 55 31.5
Lean Amine
From Amine Regeneration Unit –II 55 24.5
Treated Gas To Fuel Gas System 55 5
CDU LPG (sour) To SR LPG Treater 40 20
C3 LPG To Storage 40 18.6
C4 LPG To Alkylation Unit 40 17
SR Naphtha To Naphtha Hydrotreater Unit 94 9.4
Kerosene To Kerosene Treater 40 6.0
AGO/ Vacuum Diesel/Hot
Well To Diesel HDT 80 10
Oil/Kerosene
VGO/H VGO To VGO HDT 153 10.5
Vacuum
To Delayed Coker Unit (DCU) 190 12.0
Residue/Heavy VGO
AVU/VDU/NSU
To Sour Water Stripper Unit (SWS-I) 50 6
Sour Water
Desalter Effluent
To Effluent Treatment Plant (ETP) 40 3.5
Water
To Amine Regeneration Unit (ARU-1) 52 8
Rich Amine
To Amine Regeneration Unit (ARU-2) 57 8

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3.6 FEED & PRODUCT STORAGE FACILITIES & STREAM CONDITIONS
Feed &
Product Stream Source/ Destination Tank Nominal Temp. (OC) Press.
Capacity (m3) (kg/cm²g)
Crude Tank
Crude Tank 59,555 35 30.0
(201-TK-001 to 11)
LPG Bullets
C3 LPG
(205-V-003 to 3,130 40 16.0
009/012/013/014)
LPG Bullets
C4 LPG (205-V-003 to 009 3,130 40 17.0
/012/013/014)
NHDT Feed Tank
(203-TK-001/002) 28,852 40 5.5
SR Naphtha
GT Tank
(110-TK-001/002) 6,015 40 5.5
DHDT Feed Tank
Kerosene 28,852 40 6.0
(203-TK-005/006)
DHDT Feed Tank
28,852 60 6.0
(203-TK-005/006)
VR Tank
30,763 60 6.0
(203-TK-007/008)
Atmospheric Flushing Oil Tank
6,783 60 6.0
Gas Oil (126-TK-001)
HSFO Tanks
10,840 60 6.0
(105-TK-001/002/003)
GT Diesel Tanks
6,015 60 6.0
(110-TK-004/005)
Can be routed to Crude tanks in case of ullage issues.
Storage Tank
Vacuum Diesel 28,852 60 3.0
(203-TK-005/006)
VGO HDT Feed Tank
VGO+HVGO 72,007 60 6.0
(203-TK-010/011)
Can be routed to Crude tanks in case of ullage issues.
VR Tank
30,763 190 12.0
Vacuum (203-TK-007/008)
Residue HSFO Tank
10,840 190 12.0
(105-TK-001/002/003)

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3.7 MATERIAL BALANCE
CDU
(50/50 Oman/Basrah) (60/40 Kuwait/Maya)
MT/Hr wt% MT/Hr wt%
CRUDE 1802.5 100 1802.5 100
GAS 2.1 0.12 1.5 0.08
LPG 19.1 1.06 11.6 0.64
NAPHTHA 327.2 18.15 248.4 13.78
KERO 130 7.21 130 7.21
LAGO 320 17.75 305.3 16.94
HAGO 50 2.77 50 2.77
AR (RCO) 954.1 52.93 1055.7 58.57
TOTAL 1802.5 100 1802.5 100
VDU
(50/50 Oman/Basrah) (60/40 Kuwait/Maya)
MT/Hr wt% MT/Hr wt%
AR 954.1 100 1055.7 100
Vacuum Diesel 59 6.18 47.9 4.54
VGO 481.8 50.5 434 41.11
HVGO 58 6.08 39.8 3.77
VR 350.5 36.74 529 50.11
Vent Gas 1.7 0.18 1.8 0.17
Hot Well Oil 3.1 0.325 3.2 0.3
TOTAL 954.1 100 1055.7 100
OVERALL BALANCE
Light Crude (50/50 Heavy Crude
Oman/Basrah) (60/40 Kuwait/Maya)
MT/Hr wt% MT/Hr wt%
CRUDE 1802.5 100 1802.5 100
GAS 2.1 0.12 1.5 0.1
LPG 19.1 1.06 11.6 0.6
NAPHTHA 327.2 18.15 248.4 13.8
KERO 130 7.21 130 7.2
LAGO 320 17.75 305.3 16.9
HAGO 50 2.77 50 2.8
Vacuum Diesel 59 3.27 47.9 2.7

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VGO 481.8 26.73 434 24.1

HVGO 58 3.22 39.8 2.2
VR 350.5 19.45 529 29.3
Vent Gas 1.7 0.09 1.8 0.1
Hot Well Oil 3.1 0.17 3.2 0.2
TOTAL 1802.5 100 1802.5 100
3.8 OUTSIDE BATTERY LIMIT ROUTING OPTIONS OF DIFFERENT STREAMS IN AVU
Sl. STREAM
SOURCE DESTINATION
No NAME
From Deporpaniser Overhead Drum
1 Fuel Gas Refinery Fuel Gas Header
(010-V-010)
Refinery Fuel Gas Header
2 Fuel Gas Amine KOD (010-V-017)
INDMAX WGC Suction
C3 LPG Pumps LPG Storage
C3 LPG
3 (010-P-019 A/B/C) Off Specification LPG Storage
Alkylation
C4 LPG Pumps
C4 LPG LPG Storage
4 (010-P-020 A/B/C)
Off Specification LPG Storage
Sour LPG
Deethaniser Bottom Pump
5 from Off Specification LPG Storage
(010-P-002 A/B/C)
De-ethanizer
Stabilizer Feed Bottom Exchanger Outlet
NHDT as Hot Feed
(010-E-037 A/B/C)
Stabilized
NHDT Storage Tanks
6 Naphtha Stabilized Naphtha Trim Cooler
GT Tank
(010-E-040 A/B)
Light Slop Tank
Side Cut Side Cut Naphtha Pump Hot feed to NHDT with Stabilized
7
Naphtha (010-P-014 A/B/C) Naphtha

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Sl. STREAM
SOURCE DESTINATION
No NAME
Hot Feed to DHDT with AGO,
Kerosene Product Air Fin Cooler (010- Vacuum Diesel & Hot Well Oil
AC-004)
KHDS (under implementation)
Kerosene Feed to KTU
8
Kerosene Product Trim Cooler (010-E- DHDT Storage Tank with cold AGO,
017 A/B) Vacuum Diesel, Hot Well Oil
Light Slop Tank
AGO Product vs Crude Exchangers Hot Feed to DHDT with Kerosene,
(010-E-103 / 203) Vacuum Diesel & Hot Well Oil
DHDT Storage Tank with Kerosene,
Vacuum Diesel, Hot Well Oil
AGO
9 AGO Product Air Fin Cooler HSFO Tank
(010-AC-005) Light Slop Tank
Crude Tanks (via Circulation Line)
VGO-HDT as Startup AGO.
Vacuum Diesel vs Crude Exchanger
To DHDT Unit as hot feed
(010-E-102/202)
Vacuum DHDT Storage
10 Diesel Vacuum Diesel Product Air Fin Cooler Heavy Slop Tank
(010-AC-005)
To DCU with Off Spec Vacuum
Products
VGO Product vs Crude Exchangers
VGO HDT as Hot feed with HVGO
(010-E-108/208)
VGO HDT Feed Tank with HVGO
VGO Heavy Slop Tank
11 VGO Product Air Fin Cooler
To DCU with Off Spec Vacuum
(010-AC-015 A-H)
Products
To Crude Tank via Crude

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Sl. STREAM
SOURCE DESTINATION
No NAME
Recirculation Line with HVGO
HVGO Product Steam Generator VGO HDT as Hot feed with VGO
(010-E-150) To DCU as Direct Feed
VGO HDT Feed Tank with VGO
12 HVGO HVGO Product Air Fin Cooler Heavy Slop Tank
(010-AC-015 A-H) To DCU with Off Spec Vacuum
Products
To Crude Tank via Crude
Recirculation Line with VGO
Recycle Oil Pump To DCU / VR Storage / HSFO
13 Recycle Oil
(010-024 A/B) Storage with Vacuum Residue
DCU as Hot Feed
Vacuum VR Product Circuit Steam Generators
14 VR Storage Tanks
Residue (010-E-151/251 A/B/C)
HSFO Tank
3.9 OVERFLASH
The CDU section is designed for an minimum of 5% over flash. Over flash is defined as the ratio of
liquid leaving the tray above the flash zone to the whole crude charge, expressed as a liquid volume
(LV) % at 15 Deg C.
The VDU section is designed to provide 10% over flash at the 578°C cut point for the
light crude case (562°C for the heavy crude case). Over flash is defined as the ratio of
total liquid leaving the bottom of the wash section to the fresh feed charged to the unit
(excluding any recycle) expressed as a liquid volume (LV) percentage at 15°C.
3.10 DISTILLATE STRIPPING

Distillate side streams from the crude column are stripped to improve fractionation. Steam stripping
is selected as required to meet product specifications. Selection of steam or reboiled stripping is also
considered based on total energy requirements and the potential for heat recovery within the CDU.
3.11 HEAT INTEGRATION

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The CDU section is heat integrated with the VDU section. Heat exchange across temperature pinch
point between hot and cold streams shall be minimized as far as practicable. The global approach
temperature for the crude preheat train at the pinch point is set to ensure economic heat recovery.
A target pinch delta temperature of 30 Deg C is applied. The CDU pre heat train is configured in two
parallel trains upstream and downstream of the flash drum, each train is provided with a Crude Charge
heater and a separate feed line to the CDU column.
The design includes facilities to isolate each train for on-line maintenance as required. The number
of pump arounds and their duties is optimized for heat recovery whilst meeting fractionation
requirements. Full utilization of pump around heat is made where practical. Heat exchange between
different streams that might result in unacceptable contamination of white oil product is to be avoided
where possible. Where heat exchanger leakage may result in product contamination, provisions for
repair while the unit remains on-line are made.
3.12 DESALTING
Desalting is a provided to reduce the salt level of the crude feed which reduces the salt content in
atmospheric residue to meet the requirements of the downstream units. Removal of salt also results
in less acid formation on hydrolysis in CDU furnace operating temperature resulting in better
corrosion prevention in CDU overhead circuit.
Two stage desalting is provided in two parallel crude trains. The desalters are designed to handle the
range of salts as specified below:
 Water & Sediments Content : 0.5 Vol%
 Normal Salt Content : 10 PTB (Pounds Per Thousands Barrel)
 Maximum Salt Content : 40 PTB (Pounds Per Thousands Barrel)
The desalters are designed to meet the following treated crude specification.
 Water & Sediments Content : 0.2 Vol% maximum
 Desalted Crude Salt Content : 0.7 PTB (Pounds Per Thousands Barrel)
 Desalter Effluent Water Oil Content : 250 ppm Wt max
The crude preheat train is designed to allow adjustment of the inlet temperature to the

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desalters for efficient operation in all operating cases. The desalters are specified for
operation without the use of de-emulsifying agents, however facilities for demulsifying agents
injection are also specified.
3.13 CRUDE PRE FLASH

Preheated crude is flashed in a flash drum to remove lighter hydrocarbons, which increases the energy
efficiency of the unit by removing lighter hydrocarbons.
3.14 CRUDE / VACUUM CHARGE HEATERS

The heater tubes are designed for a maximum radiant heat flux accepted by industry standard
(approximately as follows CDU: 32550 kcal/m2 h and VDU 27000 kcal/m2 h). The crude and vacuum
charge heaters are equipped with energy conservation features such as air pre heaters and steam
supreheaters to maximize heater efficiency to the highest possible level. (Target efficiency values of
92%). Both the Vacuum and CDU heaters are provided with decoking facilities.
3.15 CRUDE COLUMN OVERHEAD TEMPERATURE

Crude column overhead temperature is maintained at least 10 Deg C above the dew point temperature
of water vapor at the column overhead. This is to avoid any water condensation in the top section of
the column which could result in corrosion of this section.
3.16 STEAM INJECTION

Steam injection points are provided on each vacuum heater pass at suitable locations
and to the vacuum column bottoms stripping section. The VDU unit is designed as a
“wet” VDU. Superheated stripping steam injection is provided to the crude column bottoms
stripping section. Steam injection is under flow control.
3.17 AMINE SYSTEM

The AVU Unit design incorporates an amine scrubber for the removal of H 2S from the fuel gas
generated from CDU section as well as vent gas generated from in the
Vacuum Seal Gas Drum. Lean Amine to CDU amine section is supplied from ARU-II. Rich amine
is sent back to the same ARU. Treated off gas is sent to fuel gas system or Indmax as per requirement.
Lean amine for Vacuum Vent Gas is supplied from the Amine
Regeneration Train 1 (ARU-1) and rich amine returned to the same train for

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regeneration. The treated vent gas is sent to the Vent Gas KO Drum and then to the
low pressure burners in the Vacuum Charge Heater.
3.18 BLOWDOWN SYSTEM

For operation and maintenance purposes, provisions are made for hydrocarbon
blowdown to a Closed Blowdown System (CBD), which comprises five drums and
pumps allocated in different areas of the AVU. For safety purposes and to recover hydrocarbons
during relief valves operation, a Flare Knock-Out Drum and pumps are provided.
3.19 PROCESS CHEMICALS

Facilities are specified for introducing the following process chemicals:
a. Demulsifying Agent:
Demulsifying agent is introduced upstream of the desalter in order to aid separation of
any oil/water emulsions that cannot be resolved by electrostatic action alone. Provision of dosing
demulsifying agent is upstream of both 1st Stage (at battery limit) and 2 nd Stage desalter.
b. Antifouling Agent:
Anti-fouling agent is introduced into the crude stream in upstream as well as downstream of the
desalters to reduce fouling of the hot pre-heat train.
c. Corrosion Inhibitor:
Corrosion Inhibitor is introduced into the crude column and vacuum column overhead
lines in order to protect the column overhead systems from corrosion by chlorides and by hydrogen
sulphide.
d. Neutralizing Amine:
Neutralizing amine/ammonia is introduced into the crude column, vacuum column and naphtha
stabilizer overhead lines to neutralize acid gases and assist in the protection of the column
overhead systems against corrosion and fouling.
e. Tri-Sodium Phosphate:
Tri Sodium Phosphate is dosed in CDU / VDU furnace Waste Heat Boiler and Steam Generators to

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reduce corrosion in the tubes.
f. Caustic:
Caustic soda is injected, into the desalted crude to minimize corrosion in the crude column overheads.
However the effect of increased metal content in the vacuum residue on downstream units should be
monitored. Maximum allowable Na+ content in Delayed Coker Unit feed is 10 ppm wt. Provision
exists for dosing caustic in Desalter brine water (brine from Stage-II to Stage-I).
g. High TAN Chemicals:

AVU is designed for a crude having TAN no < 0.5 mg KOH/g without any specialized chemical
dosing. After commissioning, high TAN dosing system was installed where with chemical dosing
crudes having higher TAN numbers can be processed.
3.20 UNIT METALLURGY

The metallurgy for the AVU is based on the most onerous of the crudes. However, provisions to be
made for the refinery to process a portion of high Total Acid Number (TAN) crude, by employing
crude blending to keep the overall blend TAN below the threshold value of 0.5 mg KOH/g of crude
oil, above which upgraded materials of construction or specialized chemical dosing and monitoring
would be required.
3.21 TRAYS / PACKING
The CDU fractionator is specified with conventional seive trays. The valve trays are designed for
80% of the flood limit at design loads. All draw-off trays are of the non-fractionating type (Total draw
off). Each of the draws is provided with reflux which is pumped back to the tray below (no draw tray
overflows).
Each section of the vacuum column has packing of suitable height and type to effect the necessary
separation and/or heat transfer requirements. Packed sections are designed to a maximum of 70% of
flooding rate, and within the maximum pressure drop specified for the packing. The wash bed
immediately above the vacuum column flash zone is provided with suitable depth of packing to
minimize coking and entrainment (i.e. contaminant carryover) of residue materials into the Heavy
VGO. The wash bed is refluxed with Heavy VGO, i.e. as pump back reflux. The bottom residue
stripping section of the VDU column has valve trays
3.22 VACUUM COLUMN PRESSURE DROP

The vacuum column pressure drop is minimized, subject to selection of suitable internals.

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3.23 VACUUM SYSTEM

An ejector system, with after condensers, is used for the vacuum generating equipment.
3.24 VACUUM COLUMN TRANSFER LINE / INLET NOZZLES
The design of the vacuum column transfer line is such that nozzle inlet velocity is not to exceed 80%
of sonic velocity. The vacuum column flash zone is provided with a modern, proven feed inlet device
to minimize re-entrainment and enhance flash zone separation. A radial vane-type inlet
device is provided.
3.25 EXCHANGER CLEANING

Provision for on-line cleaning of exchangers prone to fouling is incorporated into the
design. This applies equally to the parallel pre-heat trains in the Crude Distillation Unit.
The ability and flexibility to isolate a train is considered in the design
3.26 PRODUCT DRYING

Product drying facilities are provided where required e.g. coalescer is provided for the
VDU Hot Well Oil routed to the Diesel Hydrotreater Unit.
3.27 FLUSHING
Provisions are made for flushing out of high pour point circuits in the event of an unplanned and
extended shutdown of the AVU.
3.28 WASTE MINIMISATION

Waste minimization techniques, minimizing emissions to air, water and land for both normal and
abnormal modes of operation are included where appropriate.
3.29 EFFLUENT STREAMS

All solid, liquid and gaseous effluent streams are defined, in terms of composition, flow rate and
hazardous character, for both normal and abnormal modes of operation.
3.30 MAINTENANCE SAFETY

Equipment most prone to pyrophoric combustion induced fires are the distillation columns in the
crude and vacuum distillation units. Accidents due to pyrophoric iron oxidations are entirely
avoidable if safe procedures for equipment handover are followed. The targets for these procedures

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are twofold:
 First, to remove all the combustibles

 Second, to remove or neutralize pyrophoric iron sulphide deposits by a
combination of steaming, hot water washing, blinding, cold water washing
and/or chemical injection for removal and neutralization.
The chemicals used for neutralization should be based on safety and health
considerations combined with existing IOCL procedures.

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CHAPTER – 03
DETAILED PROCESS DESCRIPTION

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3.0 DETAILED PROCESS DESCRIPTION:

3.1 CRUDE SUPPLY:
Imported crude oil unloaded from VLCC at SPM and sent to refinery crude oil storage tanks 201-
TK-001 to 018 (Except Tank-010, which is used as refinery slop tank). Nominal Capacity of each
tank is 59,500 KL. Crude is allowed to settle in tanks for draining water. Cold crude from the Crude
tank (free of water) is pumped by offsite crude charge pumps (201-P-001A/B/C/D/E) to AVU at a
pressure of 30 kg/cm2 g and temperature of 35 Deg C. Crude to AVU can also be fed from 11 nos.
of pipeline tanks. The tanks are operated by M/s IOTL on Build Own Operate and Transfer (BOOT)
basis. Tank dips and pump flows indication are available in AVU Panel in Main Control Room
(MCR).
3.2 1st PRE-HEAT TRAIN (PRE-DESALTER PREHEAT TRAIN)

The crude received inside AVU is split into two identical pre heat trains, Train-1 & Train-2 for
optimum heat recovery from various product and pump around streams. PI-1118, TI-1102 and FI-
1001 provided on the main crude line at the battery limit of the unit, to measures pressure,
temperature and total crude flow into the unit. PG-1171 shows local pressure of the crude at the
battery limit. FI-1002 and FI-1003 measures the crude passing through Train-1 and Train-2
respectively. Provision of dosing Demulsifier exists at battery limit in the common crude inlet header,
before splitting the flow into two separate preheat trains.
Crude routed to Train-1/Train-2, passes through the shell side of 1st pre heat train heat exchanger
010-E-102/E-202 (Vacuum Diesel Pump Around vs. Wet Crude) and heated up to 44/45 Deg C.
Crude outlet temperature ex 010-E-102/E-202 is controlled by TIC-1002/TIC-1502, which controls
the temperature by controlling vacuum diesel pump around flow through the bypass of the heat
exchangers 010-E-102/E-202. The Vacuum Diesel stream is cooled from 115/114 Deg C to 94/87
Deg C. Provision is given for Antifoulant, and desalter makeup water injection in the crude header
at the upstream of 010-E-102/E-202. The purpose of dosing at this location is to allow sufficient time
and turbulence for proper mixing of water and avoiding fouling in the heat exchanger trains.
Relevant P&ID No: PDRP4210-270-8110-25-010-1001 / 1101
Crude from the outlet of 010-E- 102/E-202 passes through the tube side of 010-E-103/E-103 (Wet
Crude vs. AGO Product) and gain temperature up to 49/52 Deg C. AGO product is routed in the shell
side of the heat exchangers and is cooled from 136/137 Deg C to 117/110 Deg C in the exchangers.
The heated crude ex E-103/203 then passes through the tube side of 010-E-104 A-D/ E-204 A-D
(Wet Crude vs. Top Pump Around) and heated up to 107/102 Deg C. Shell side fluid of the
exchangers is Top Pump Around (TPA) liquid from 010-P-004 A/B/C. TPA liquid flows through the
shell side of the exchangers and is cooled from 136/133 Deg C to 96/98 Deg C. The shell side and
tube side fluids of E-104 / 204 A-D is divided in two parts, one part going to E-104 / 204 A/B and

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other part going to E-104/204 C/D. The exchangers are stacked exchangers with A/B (A above B)
and C/D (C above D) shells stacked separately. The isometric of the piping of the shell side and tube
side ensures that the fluids (crude as well as TPA) is divided equally between all the exchangers.
Bypass provision exists in both shell side as well as tube side of the exchangers with common
isolation facility for A/B and C/D. TI-1008/1508 and TI-1009/1509 has been provided to monitor the
crude and TPA outlet temperatures.
Note:
The TPA fluid has chances of acidic compounds in the liquid stream. Hence the TPA exchanger outlet
temperature should be maintained as per design value. During idling of the unit, if the TPA fluid is
not drained then, the saturated moisture along with acidic fluids may accumulate and cause severe
corrosion leading to tube failure and product coloration. In view of the above, during shutdown /
idling, the shell and tube sides of the exchangers are to be drained to remove all fluids and kept in
inert atmosphere to avoid corrosion. Whenever this exchanger leaks, it is seen that the kerosene
stream color deteriorates but it does not affect the Naphtha stream color. Provision has been given
to collect samples of TPA at outlet of these exchangers during plant running conditions.
Crude outlet ex 010-E-104 A-D / 204 A-D split into two streams under split range flow controllers
HV-1017A & HV-1017B / HV-1517A & HV-1517B (for Train-II). The split is controlled by 010-
HIC-1017 [010-HIC-1517] and 010-HY-1017 [010-HY-1517], which regulate valves 010-HV-1017
A/B [010-HV-1517 A/B]. The average valve position ‘a’ is entered by the operator at 010-HIC-1017
[010-HIC-1517] (0-1) and the split ‘b’ between Valves 010-HV-1017 A & B [010-HV-1517 A & B]
is entered by the operator at 010-HY-1017 as the proportion of flow to 010-E-107 (0-1). Thus the
signal to Valve 010-HV-1017A [010-HV-1517 A] is 2*a*b*100% and the signal to Valve 010-HV-
1017B [010-HV-1517 B] is 2*a*(1-b) *100.
Crude ex E-104/204 CD passes through the tube sides of 010-10-E-107/E-207 (Wet crude vs. AGO
product) and 010-E-106 / E-206 (Wet crude vs. Kerosene Pump Around) in parallel trains, where
crude temperature is raised up to 120/121 Deg C at the combined outlet of both the exchangers.
In exchangers E-106/206, crude is heated by Kerosene Pump Around stream, where crude is heated
from 107/102 Deg C to 119/121 Deg C by cooling the Kerosene Pump Around stream from 177/179
Deg C to 142/132 Deg C.
In exchangers E-107/207, crude is heated by AGO product stream, where crude is heated from
107/102 Deg C to 122/121 Deg C by cooling the AGO product stream from 184/200 Deg C to
157/160 Deg C.

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The heated crude is combined at the outlet of E-106/107 (E-206/207 for Train-II) is then routed to
E-108/208 for further heating to 130 Deg C by exchanging heat with VGO product which in turn is
cooled from 184 / 183 Deg C to 150 Deg C. The heated crude at 130 Deg C is then routed to Desalters
for desalting.
Diagram-001: Process Flow Diagram of Preheat Train-I
Duty Tube Side Tube Side Shell Side Shell Side

Exchanger Service
Inlet Temp Outlet Temp Inlet Temp Inlet Temp
No T/S vs S/S
Gcal/hr Deg C Deg C Deg C Deg C
Vac Diesel PA
E-102/202 Vs. 3.6 / 4.1 115 / 114 94 / 87 35 44 / 45
Crude
Crude
E-103/203 vs 2.1 / 2.7 44 / 45 49 / 52 136 / 137 117 / 110
AGO Product
Crude
E-104/204
vs. 26.3 / 22.5 49 / 52 107 / 102 136 / 133 96 / 98
A/B/C/D TPA
Crude
E-106/206 Vs. 3.6 / 4.6 107 / 102 122 / 121 177 / 179 142 / 132
Kerosene PA

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Duty Tube Side Tube Side Shell Side Shell Side

Exchanger Service
Inlet Temp Outlet Temp Inlet Temp Inlet Temp
No T/S vs S/S
Gcal/hr Deg C Deg C Deg C Deg C
Crude
E-107/207 vs 3.1 / 4.6 107 / 102 119 / 121 184 / 200 157 / 160
AGO Product
Crude
E-108/208 vs 4.9 / 4.3 120 / 121 130 / 130 184 / 183 150
VGO Product
3.3 DESALTERS
3.3.1 DESALTING
Desalting is an industry term for the electrostatic process used for removing contaminants such as
salts, solids, water from crude oil at a refinery. Most of the contamination present in the crude oil are
present during production, however some time sea water can also contaminate the crude during
transportation. Salts present in the crude oil are in the form of brine, a solution of water and salts. In
addition the crude oil contains solids such as finely divided sand particles, clays, drilling muds, and
rust and scales accumulated during production and transportation to the refinery.
Before refining the crude oil, these impurities need to be removed for several reasons. Solids
contaminants can contribute to plugging of the equipment and scale formation. The more water
present in the crude oil, more energy is required to heat it to a certain temperature. Chloride salts,
found commonly in crude oil, can be responsible for formation of hydrochloric acid at temperatures
which are commonly encountered in furnace and distillation columns. Hydrochloric acid is extremely
corrosive and may lead to reliability issues. Removal of contaminants in crude oil can increase
distillation capacity, cut down on refinery fuel costs, reduce corrosion and plugging problems. For
these reasons desalting is the first and one of the most important refinery process.
3.3.2 DESALTING PROCESS
When crude oil enters the refinery, it typically contains a small amount of water, approximately 0.1
to 0.5 volume %. The water remaining in the crude oil contains insoluble particulate matter. To lower
the level of impurities in the crude oil, water (with low or nil contaminants) must first be added to the
crude (wash water). A special mixing device either static mixer or a control valve, mixes water with

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crude and disperses water to very fine small droplets. The emulsification of wash water ensures that
the wash water having low contaminants mixes properly with brine having high contaminants. The
resulting emulsion is then piped into a desalting vessel where the mixture is metered out at a very
slow velocity into an electric field. Inside the desalter there may be multiple electric field based on
the design of the desalter. The electrical field polarizes the water droplets and forces small water
drops to coalesce to form larger drop lets. The droplets of wash water form large drops that disengage
from the upward moving crude oil and begin to settle under the force of gravity. If the wash water
were not added in the desalter the total population of water droplets in the crude oil would not be
sufficient for efficient coalescence of water droplets to occur.
3.3.3 DETAILED PROCESS DESCRIPTION OF DESALTING PROCESS
a. Crude Oil Circuit
Preheated Crude from 010-E-108/E-208 enters 1st Desalter (010-V-102A/V-202A) after mixing with
wash water from 2nd Desalter across static mixer and mixing valve (010-PDV-1003/PDV-1503). The
process water is desalter water from the 2nd stage and may include up to 5% internal recycle. The pH
of the process water is to be controlled in such a way that the effluent water pH to be maintained
between 6.0 to 7.0. Most of the salts and sediments are removed in the 1 st stage and is carried out by
the water, hence it is directly routed to ETP. Process water to the 2 nd stage should be clear fresh no
fouling water having a pH of 6.0 to 7.0. The mixed water & crude after the mixing valve enters the
bottom of the desalter vessel, flows through an inlet header and then into the distributors. The
distributors are responsible for metering the crude oil at a uniform flow rate throughout each high
voltage field. One electrical field is produced by the lower and middle electrodes and the other is
produced by the middle and upper electrode.
Grid and metal bars and rods makeup the electrodes. The high potential gradient for the electric field
is furnished by electrical units located at top of the desalters. When crude oil enters the two electrical
fields the electrical charges in each water droplet are separated. That is the negative charge is
concentrated to one end of the droplet and the positive charge to the other end of the droplet. Each
negative end of each water droplet is attracted to the positive pole in the electrical field. Since the
electrical charges in each droplet are separated the negative poles in the droplet are attracted to the
positive pole of the other droplets. Almost immediately after the crude oil enters an electrical field
the water droplet begins to combine or coalesce as opposite electrical charges attract each other. The
coalescing action created by the attraction of the water droplets to one another creates larger and
larger droplets, until finally, water droplets are large enough to fall out of the crude oil by the force
of gravity. Large droplets fail through the crude oil and into the bottom of the desalter vessel. When
the desalter is in operation, the bottom 1/3rd or ½ of the vessel is filled with water. An interphase level
controller connected to a dipolar and/or capacitance probe at the oil/water interface control the rate

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at which the water leaves the desalter vessel in order to meet the water level that meets operational
specifications. Water exit the desalter through the effluent water disposal line. Treated water exit the
desalter through the collector pipe near the top of the vessel.
Desalted crude from the 1st stage out let enters into second stage after mixing with fresh water across
the static mixer and mixing valve (010-PDV-1004/PDV-1504). Pressure in the desalter (1st stage
21.4Kg/cm2g; 2nd Stage 20.4 Kg/cm2g) is maintained by 010-PIC-1019/PIC-1022 at the inlet of pre
flash column 010-V-003. Final Desalted crude at 130 ºC and 20.4 Kg/cm2g leaves from the 2nd
desalter and enters 2nd preheat train. For better desalting De-emulsifier injection provision is
provided at inlet of 1st pre heat train and outlet of 1st stage Desalter. The desalter vessels are protected
from over pressure by safety valves (010-PSV-1001A-B &010-PSV-1002A-B/010-PSV- 1001A-B
&010-PSV-1002A-B) which release excess pressure to crude column 010-C-001 flash zone.
Desalters drain is connected to CBD & OWS. Since, the salt content in the desalted crude directly affects

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the acid generation due to hydrolysis of the salts; desalter plays an important role in corrosion control of the
CDU/VDU Overhead circuit.
b. Water Circuit
Fresh wash water from desalter water surge drum (010-V-001) is pumped by (010-P-001A/B) at a
pressure of 35.5 kg/cm2g and is injected at inlet of 2nd desalter (010-V-102 B/V-202-B) across the
mixing valve (010-PDV-1004/PDV-1504) at a rate of ~ 8 vol % (Flow control by 010-FIC- 1008/FIC-
1508) of crude processed. The flow to the 2nd stage desalter is controlled by 010-FIC-1008 and 010-
FIC-1508 respectively for Train-I and Train-II respectively. Before entering the Second Stage
Desalter the wash water is preheated to 130oC first in the Desalter Water Feed / Effluent Exchanger
(010-E-113/E-213 A/B), followed by Desalter Water Feed / AGO product (010-E-116/E-216)
exchanger. Water from second stage desalter through pump (010-P-103 A-C / P-203 A-C) under
interphase level control is injected into the First Stage Desalter (010-V- 102A/V-202A) across the
mixing valve (010-PDV-1003/1503). The final effluent water leaves the First Stage Desalter under
interphase level control (010-LV-1002/LV-1502) after heat exchange in 010-E-113 / E-213, Desalter
Effluent Trim Cooler 010-E-152A-B/E-252A-B and discharged to the Effluent Treatment Plant at 40
ºC.
Since the effluent sometimes contains acidic compounds, provision has been given for caustic dosing
in the effluent water from 2nd stage desalter to the 1st stage desalter.
1st Stage Desalter Bypass 2nd Stage Desalter Bypass Crude Outlet
Normally No Flow Normally No Flow to 010-E-128
Antifoulant
010-V-102 A LC
010-V-102 B LC
Demulsifier
010-PDV-1003 A 010-PDV-1004 A
Crude Inlet
Ex-010-E-108
010-PDV-1003 B 010-PDV-1004 B
010-HV-1033 010-HV-1035
to E-102 Stripped Sour Water
010-FV-1127 010-FV-1125 Service Water

010-V-001
Caustic
010-P-102 A/B VGO Coalscer Water
010-P-103 A/B/C
010-FV-1005
010-FV-1009
AGO Product to E-202

010-FV-1509
010-E-116 010-E-113 A/B 010-FV-1008
010-P-001 A/B
AGO Product to Train-II
010-FV-1508
To ETP
010-LV-1002
010-E-152 A/B

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Schematic Diagram of Desalter Crude and Water Circuit

3.3.4 TYPICAL OEPERATING CONDITIONS
Parameters UoM Oman-Basrah Kuwait-Maya
Crude flow BPSD 174000 per Train 174000 per Train
API 33 27.5
Salt lb/1000 barrel 10-40 10-40
BS&W %Vol 0.5 0.5
Viscosity
cst 18/12.8/9.5 47.2/36.1/26.6
@20/30/40 Deg C
Type: From 2nd Stage Desalter Water

1st Stage
Process Water Total water from second stage desalter + 5% internal recycle.
Temperature 130-135 Deg C
2nd Stage Stripped sour water. Should be clear non scaling, 12ppm
Process Water NaCl Max.
pH of water should be such that the effluent water from the se

pH
desalter is maintained between 6-8.
Rate 8% by Volume + 5% Internal Recycle
Performance Requirement:
Desalted Crude < 0.05 ptb
BS&W < 0.2%
Oil < 500 ppm

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3.3.5 ENTRANCE BUSHING OPERATING GUIDLINES

Maximum Operating Condition 31 bar 148.9 Deg C
Startup/Shutdown Inert gas 0.35 bar
Startup/Shutdown 10 bar Upto 187 Deg C
Maximum Saturated Steam
3.4 2nd PRHEAT EXCHANGERS TRAIN

Desalted and dewatered crude from the 2nd stage desalter 010-V-102B/V-202-B passes through the tube side
of 010-E-128/E-228(Desalted crude / AGO product) and gains temperature up to 139 / 135 0C by exchanging
heat with hot AGO product. Crude from the O/L of 010-E-128/E-228 splits into two streams by HIC-1018A-
B/HIC-1518A-B.The part of the crude entering HV-1018A/HV- 1518A passes through 010-E-131/E-
231(Desalted crude / Kerosene PA) picks up heat from hot Kerosene PA, hot crude from the outlet of 010-
E-131/E-231 with a temperature of 170 / 153 0C passes through the tube side of 010-E-117/E-217 (Desalted
crude / Vacuum Residue Product) where it exchanges heat with hot Vacuum Residue Product and gains a
temperature 175 / 167 0C.
The other part of the crude passes through the tube side of 010-E-119/E-219(desalted crude/LAGO PA)
where the crude is heated to 1510C and then passes through the tube side of 010-E-118 A-D / E-218A-D
(Desalted crude / VGO PA) and heated to 181 /183 0C. Crude from the outlets of 010- E-117/E-217 and 010-
E-118A-D/E-218A-D combines and enters into the crude Flash vessel (010- V-003) at a temperature of 1800C
through PIC-1019/PIC-1022.Provision is given to process wild naphtha along with train-2 pre heated crude
to Flash vessel.

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Kerosene PA VR Product
T: 170 0 C T: 175 0 C
AGO Product T: 153 0 C T: 167 0 C
HV-1018 A
Desalted Crude Caustic
T: 139 0 C 010-E-131 010-E-117 PV-1019 A
ex Desalter Train-I PC
T: 135 0 C
010-E-128 LAGO PA VGO PA

T: 180 0 C
Flashed Vapours to
T: 181 0 C PV-1021 010-C-001
T: 151 0 C T: 183 0 C PC
PV-1019 B
HV-1018 B Wild Naphtha
50-100% ex-DHDT
(to Pass Flow CVs
010-E-119 010-E-118A-D 0-50%

(to crude Pumps
LC
Kerosene PA VR Product 010-FV-1121/22/23
010-V-003
T: 170 0 C T: 175 0 C
AGO Product T: 153 0 C T: 167 0 C
HV-1518 A
T: 139 0 C 010-E-231 Caustic Flashed Crude to 3rd
010-E-217 PC PV-1022 A
T: 135 0 C Pre-Heat Train
Desalted Crude 010-E-228 VGO PA

LAGO PA T: 180 0 C
ex Desalter Train-II
T: 181 0 C
T: 151 0 C T: 183 0 C 010-P-003 A/B/C
PV-1022 B
HV-1518 B
010-E-219 010-E-218A-D
3.5 CRUDE FLASH DRUM

Pre heated crude entering crude flash vessel gets flashed, lighter ends (vapors) from the top of flash vessel
is routed to the flash zone of the main crude distillation column, 010-C-001 under pressure control PIC-1021.
The normal operating pressure of crude flash vessel top is 3.5 kg/cm2 g.Pre flashed crude from the bottom of
flash vessel is pumped out by 010-P-003A/B/C to third pre heat train for further pre heating before entering
furnace. LIC-1010, a split range controller which controls flash vessel bottom level by manipulating Crude
flow to CDU furnaces pass balancer and charge crude blender control valves. Trip logics given to 010-P-
003A/B/C motors, in case of low level in flash vessel and ESD on the pump suction line closes then the
running motor will stop. Local manual trip switches are provided in the field to stop flashed crude pumps 010-
P-003A/B/C and also to close ESD in case of fire/emergency in flashed crude pumps. Three numbers of safety
valves are provided on pre-flash vessel overhead vapor line, which will pop and release the vapors to the crude
column, in case of excess pressure developed inside vessel.
Feed to the crude flash drum 010-V-003 from the first train is controlled by pressure controller 010-PIC 019
(direct acting). The set point is cascaded to one of two duty/standby pressure control valves 010-PV-1019 A/B;
which are selected by the hand selector 010-HS-1019. Similarly for the second train via
010-PIC-1022, 010-HS-1022 and 010-PV-1022 A/B. Overhead Pressure is maintained by 010-PIC-1021
(Direct Acting) which regulates the vapour outlet flow rate via 010-PV-1021. Minimum flow is maintained to
the pumps 010-P-003 A/B/C is maintained by spillbacks from each pump to the flash drum; the flow to each

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spillback is controlled by 010-FIC-1121, 010-FIC-1122, 010-FIC-1123 regulating 010-FV-1121,

010-FV-1122, 010-FV-1123 respectively.
3.6 3RD PREHEAT EXCHNAGER TRAIN

Flashed crude is pumped by 010-P-003A/B/C and routed to train-1 and train-2’s 3rd preheat exchangers. HV-
1019 A/B & HV-1519 A/B splits pump discharge into two streams for each train. One part of the flashed crude
sent via HV-1019A/HV-1519A passes through the tube side of 010-E- 122A-D/E-222A-D (flashed
crude/VGO), picks up heat from hot VGO product and heated up to 222 / 221 0C. Crude O/L from 010-E-
122/E-222 passes through the tube side of 010-E-123A-B/E- 223A-B(flashed crude/HAGO PA) heated up to
251/ 246 0C by hot HAGO PA at the exchanger outlet further passes through the tube side of 010-E-124A-
C/E-224A-C (Flashed crude/HVGO) picks up heat from hot HVGO and leaves from the outlet of 010-E-
124/224 at a temperature of 2920C.
The other part of flashed crude sent via HV-1019B/HV-1519B passes through the tube side of 010- E-129/E-
229(flashed crude/AGO) gets heated up to 205 / 195 0C. Flashed crude from the outlet of 010-E-129/E-229
passes through the tube side of 010-E-132/E-232(flashed crude/HAGO PA) picks up heat from hot HAGO
PA enters the tube side of 010-E-126/E-226(flashed crude/VR) and comes out of the exchanger at a
temperature of 232 / 2300C. Pre heated flashed crude from the outlet of 010-126 passes through the tube side
of 010-E-127A-K/E-227A-K (flashed crude/VR) comes out of the exchanger at a temperature of 3300C.
The pre heated flashed crude from the outlets of 010-E-124A-C/E-224A-C and 010-E-127A-K /E- 227A-K
combines together and enters 010-F-101/F-201 passes (8 no of Passes) at a pre heat temperature of 3010C. The
pre heated crude passing through 010-F-101/F-201 heated up to 3660C, enters the flash zone of 010-C-

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001(main distillation column).
3.7 CRUDE CHARGE HEATER

To achieve design flash temperature of the crude, preheated flashed crude at a temperature of 299/301 0C from
the outlet of 3rd pre heat trains of Train-1/Train-2, further heated to 355/3670C in the respective furnaces
(Train-1 010-F-101, Train-2 F-201). The crude charge heaters 010-F-101 and 010-F-201 are identical vertical
box type furnaces. 010-F-101/010-F-201 is an eight pass, balanced draft, dual fired heater of absorbed heat
capacity 66.42 MMKcal/hr. The duty includes Super heating coils of LP steam used for steam stripping in main
distillation column and side draw strippers of CDU and super heating coils of saturated MP steam coils.
Further to ensure satisfactory thermal efficiency of the heaters, the combined flue gases at a temperature of @
4500C escaping to the stack from 010-F-101/010-F-201 is drawn by ID fans via WHB (010-WHB-001) and
APH (010-APH-001) to recover heat and sent to main stack at a temperature of 140 0C, in turn producing MP
steam from the waste heat boiler and also increases combustion air temperature to 240 0C. Total feed flow to
010-F-101/010-F-201 is controlled by pass balancer under pre flash drum level control (LIC-1010) is distributed
in eight passes through flow control valves FIC-1018A-H/FIC-1518A-H.Combined passes coil O/L
temperatures(COT) of 010- F-101/F-201 is maintained around 355/3660C by TIC-1069/TIC-1569 through the
pass balance control system. Explosion windows are provided at the radiation zone which will open
automatically to release the pressure to atmosphere, in case the furnace gets pressurized. LP box purging steam
nozzles are provided at the bottom of the fire box floor area to purge out the unburnt hydrocarbons present

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inside the box and also to avoid the formation of explosive mixtures inside the box. Sight doors and peep holes
are provided at radiation zones and to observe fire box and burners.
Observation doors are provided at the convection bank near the soot blower’s area. Soot blowers are provided
at the convection zone area to blow off soot deposited on the convection bank’s hydrocarbon and steam coils.
Flue gas dampers are provided above the convection bank to control the draft. Draft gauges are provided at the
convection, arch and floor level to measure the draft at various zones. Pressure and temperature indications are
provided for each pass at I/L of convection bank, convection O/L to radiation I/L and at the radiation O/L of the
coil. Total 15 nos. (12nos. + 3nos. in WHB) of shoot blowers are provided in individual Crude Furnace.
For detailed startup / shutdown / normal operation procedure, please refer OEM Manual for
furnace attached as Annexure-I.
3.8 ATMOSPHERIC DISTILLATION COLUMN
The CDU column consists of 6 stripping trays, 40 fractionation trays and 5 nos. of Draw trays. The objective of
the column is to separate the heated crude oil to Off gas, naphtha, Kerosene, Light Atmospheric Gas Oil, Heavy
Atmospheric gas oil and Atmospheric Residue.
Overhead Section:
Overhead vapor from the top of the column is cooled in an air condenser (010-AC-007). AC-007 has 8 banks
A-H each having 2 nos of fans for cooling the overhead vapors. For controlling overhead corrosion, provision
exist for doing Neutralizing Amine and Corrosion inhibitor on the overhead line. For protection of over
pressurization of the column 8 nos of PSVs 010-PSV-1006 A-H is available. For inertisation and fuel gas back
up Nitrogen and Fuel Gas lines are available in the overhead line. The overhead has is routed to the overhead
line and is divided into all the banks of the air fin cooler. Provision exists to route sour from overhead receiver
boot to the inlet of the air fin cooler for washing purpose.
The temperature leaving the air cooler is controlled by 010-TIC-1087 which adjusts the speed of those fans fitted
with variable speed drives (50% of the total). Partially condensed overhead vapor enters the Crude Column
Overhead Receiver 010-V-005. The Crude Overhead Liquid level is controlled by 010-LIC-1022 (direct acting)
which cascades to the set point of flow controller 010-FIC-1030 (reverse acting) regulating valve 010-FV-1030.
The Sour Water liquid level is controlled by 010-LIC-1024 (Direct acting) regulating valve
010-LV-1024. Minimum flow to the Crude Overhead Liquid pumps (010-P-010 A/B) is maintained by a
spillback to the receiver; the flow to the spillback is controlled by 010-FIC-1072 (reverse acting) regulating
valve 010-FV-1072. Minimum flow to the Sour water pumps (010-P-011 A/B) is maintained by a spillback to
the receiver; the flow to the spillback is controlled by 010-FIC-1071 (reverse acting) regulating valve 010-FV-
1071. A start up line exist at discharge of 010-P-10 A/B to route the hydrocarbon from V-005 to CDU column
top section. This line is normally used during startup only. The column operates at a pressure 1.2 kg/cm2g and
temperature of 116 Deg C at the top. The minimum allowable top temperature is governed by the dew point of
the overhead stream. On operating the column top temperature below the dew point, chance of condensation of

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acidic species are there which may lead to corrosion.
Pressure in the Overhead Vapour Receiver 010-V-005 is controlled by regulating the flow of gas to the fuel gas
and the flare. Regulation is done by the split range controller 010-PIC-1072 (Direct acting). In the output range
45-0% this regulates the fuel gas inlet flow via valve 010-PV-1072 A. In the range 55-100% this
regulates the flow to the low pressure flare via valve 010-PV-1072 B.
Naphtha Draw Off Section (Tray No. 1-4 and Draw Tray D-1):
The naphtha distillation consists from Tray No. 1 -4 and Tray D-1. The Top Pump Around stream is drawn from
D-1 draw trays via pump 010-P-004 A/B/C. The level in this must be maintained to provide correct pump (010-
P-004 A/B/C) feed conditions. It is controlled by the level controller 010-LIC-1038 (direct acting). The level
signal comes from one of two duty/standby transmitters’ 010-LT-1038A/B which is selected by the hand selector
010-HS-1038. This acts as the primary controller and cascades to the Set point of the Reflux Flow controller
010-FIC-1037 (reverse acting); this regulates valve 010-FV-1037, sending liquid below tray D1. The TPA
stream is then pumped to TPA vs Crude Exchangers (E-104/204 A/B/C/D) where TPA stream is cooled from
the draw temperature of 136 Deg C to 96 Deg C. The Top Pump around (TPA) circuit of the Crude Distillation
Column, 010-C-001 provides reflux to the top section of 010-C-001. The temperature of 010-C-001 overhead
vapour is maintained by controlling the amount of heat removed from the TPA circuit. Under normal operation,
for a given unit throughput, the flow around the TPA circuit remains constant and the heat duty is controlled by
passing more or less flow through 010-E-104/204.
Naphtha is drawn from tray D1 and pumped via 010-P-004 A/B/C to the two trains. The split between the two
trains is controlled by 010-HIC-1014 and 010-HY-1014, which regulate valves 010-HV-1014A/B. The average
valve position ‘a’ is entered by the operator at 010-HIC-1014 (0-1) and the split ‘b’ between Valves 010-HV-
1014 A & B is entered by the operator at 010-HY-1014 as the proportion of flow to Train 1 (0-1). Thus the
signal to Valve 010-HV-1014A is 2*a*b*100% and the signal to Valve 010-HV-1014B is 2*a*(1-b)
*100%.
One stream goes to series of heat exchangers 010-E-104 A/B/C/D and the other to 010-E-204 A/B/C/D. The
recombined streams are then returned to tray 1 of Column 010-C-001. Temperature of the overhead vapour from
010-C-001 is controlled by a cascade from 010-TIC-1074 (direct acting) to the set point of wet crude/TPA
exchanger Duty Controller 010-QIC-1001 (reverse acting). The required flow of the TPA is set at flow controller
010-FIC-1036 (reverse acting).
The temperature of the TPA draw from tray D1 is measured by 010-TT-1090 B and the temperature of the TPA
return to tray 1 is measured by 010-TT-1090 A. The temperature difference is calculated by 010-TDI-1090.
The heat removed from the TPA is calculated by 010-QIC-1001 using the algorithm:
Q = (TD x F x CP) / (3600 x 1000)
Q : Heated Removed (MW)

TD : Temperature difference, 010-TDI-1090 Deg C

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F : TPA Flow, 010-FIC-1036 kg/hr

Cp : 2.470 (Average Specific heat), KJ/Kg Deg C
This value is used as the process variable for the PID control function of the block
010-QIC-1001.
Any increase in flow above the set point at 010-FIC-1036 will produce a decrease in output, a, which will close
both valves 010-QV-1002A and 010-QV-1002B by the same amount via calculation block 010-QY-1002, i.e.
total flow is reduced.
Any increase in duty above the set point at 010-QIC-1001 will produce a decrease in output, b, which will close
valve 010-QV-1002A and open valve 010-QV-1002B via calculation block 010-QY-1002.The result will be to
pass less liquid through the exchanger 010-E-104/204 and more through the bypass valve 010-QV-1002B, i.e.
duty is reduced.
Block 010-QY-1002 Calculates the positions of valves 010-QV-1002 A/B as follows:

c = a x (1-b)
d=axb
a : TPA Flow Rate 010-FIC-1036.OP
b : TPA Duty 010-QIC-1001.OP
c : Bypass Valve 010-QV-1002 B 010-QY-1002.OP.1
d : Exchanger Valve 010-QV-1002 A 010-QY-1002.OP.2
Overhead vapor temperature is measured by temperature transmitter 010-TT-1750. A partial power failure could
result in an increase in the temperature profile of the AVU Crude column. This in turn will increase the
temperature difference across the heat exchangers. In this case if the temperature measured by 010-TT-
1750 is greater than 140 Deg C, 010-TT-1750 High Alarm shall force 010-QV-1002 A/B to manual and maintain
the last output value.
The objective is to prevent the DCS from moving the respective valves in the unsafe directions. Later on
depending on the conditions prevailing, the operator may manually close the 010-QV-1002B, if required.
The four no of trays in the columns are normal sieve trays. The internal of the column is internally lined with
monel in this section as well as the overhead dome in view of high chances of corrosion.
Kerosene Draw Off Section (Tray No. 5-16 and Draw Tray D-2) & Kerosene Stripper:
Kerosene draw from the column is taken from D-2 via Kerosene PA pumps 010-P-005 A/B. From the same
suction line, a stream is routed to Kerosene strippers for stripping and subsequent routing to KTU/ Storage.
Kerosene ex P-005 A/B is routed to crude vs Kerosene PA exchangers. The flow is equally divided in two parts
for the two heat exchanger trains. Kerosene at a draw temperature of 200 Deg C exchanges heat with E-131/231
and gets cooled to 177/179 Deg C. The cooled kerosene stream then exchanges heat with wet crude in the

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exchangers E-106/206 and gets cooled to a temperature of 143/132 Deg C. The cooled Kerosene PA stream is
then routed back to 010-C-001 between Tray No 13 and Tray No 14.
Kerosene is drawn from tray D2 of 010-C-001 and pumped via 010-P-005 A/B to the two trains. The split
between the two trains is controlled by 010-HIC-1020 and 010-HY-1020, which regulate valves 010-HV-
1020A/B. The average valve position ‘a’ is entered by the operator at 010-HIC-1020 (0-1) and the split ‘b’
between Valves 010-HV-1020 A & B is entered by the operator at 010-HY-1020 as the proportion of flow to
Train 1 (0-1). Thus the signal to Valve 010-HV-1020A is 2*a*b*100% and the signal to Valve 010-HV-1020B
is 2*a*(1-b) *100%. One stream goes to series of heat exchangers 010-E-131and 010-E-106 and the other to
010-E-231, and 010-E-206. The recombined streams are then returned to tray 14 of Column 010-C-001. The
required flow of the Kerosene pump around is set at flow controller 010-FIC-1038 (reverse acting). Duty
controller 010-QIC-1003 is used to control the heat removed from the Kerosene pump around stream. The duty
is calculated as the product of the flow rate of the Kerosene pump around (010-FIC-1038), the temperature
difference (TDI-1095), and the average specific heat of the stream. The duty controller output splits to valves
010-QV-1004A and 0101-QV-1004B in order to maintain control by operating the two control valves
simultaneously in opposite directions.
Any increase in duty above the set point at 010-QIC-1003 will produce a decrease in output, b, which will close
valve 010-QV-1004A and open valve 010-QV-1004B via calculation block 010-QY-1004.The result will be to
pass less liquid through the exchangers 010-E-131, 010-E-121 and 010-E-106 and more liquid through the
bypass valve 010-QV-1004B, i.e. duty is reduced. Any increase in flow above the set point at 010-FIC-1038
will produce a decrease in output, a, which will close both valves 010-QV-1004A and 010-QV-1004B by the
same amount via calculation block 010-QY-1004, i.e. total flow is reduced.
Kerosene draw off to kerosene stripper is taken from the same draw as kerosene PA. A tap off from P-005 A/B
suction line is taken for feeding the kerosene stripper line. The Kerosene Stripper removes residual light
components from the liquid stream using LP Steam. The level in the column is controlled by 010-LIC-1014
(reverse acting) regulating the inlet flow rate via 010-LV-1014. The level signal comes from one of two
duty/standby transmitters’ 010-LT-1014A/B which is selected by the hand selector 010-HS-1021. Stripping
Steam injection flow rate to the column is maintained by Flow Controller 010-FIC-1020 (reverse acting)
regulating 010-FV-1020. Minimum flow to the product removal pumps 010-P-008A/B is maintained by a
spillback to the column; the flow to the spillback is controlled by 010-FIC-1021 regulating 010-FV-1021.
The kerosene product is cooled in an air fin cooler AC-004 and then further cooled in a trim cooler. Hot feed
routing to DHDT is done from upstream of the Air Fin Cooler.
LAGO Draw Off Section (Tray No. 17-29 and Draw Tray D-3) & LAGO Stripper:
LAGO draw off from the column is taken from D-3. The LAGO Pump around pump 010-P-006 A/B takes
suction from D-3. LAGO Pump around streams exchanges heat with Stabiliser Reboiler (010-E-38), Deethaniser
Reboiler and Depropaniser Reboiler. After exchanging heat, the cooled LAGO pump around stream again
exchanges heat with desalted crude in E-119/219. A chimney tray, tray D3, is used in the atmospheric column

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to provide a liquid draw off at the Light Atmospheric gas oil Pump Around. The level in this must be
maintained to provide correct pump (010-P-006 A/B) feed conditions. Level in the column of the LAGO product
is controlled by the direct acting level controller 010-LIC-1046. The level signal comes from one of two
duty/standby transmitters 010-LT-1046A/B which is selected by the hand selector 010-HS-1046.This
cascades the set point to 010-FIC-1040 regulating the reflux flowrate via 010-FV-1040.
LAGO draw off from the LAGO stripper is taken from the pump suction,
Controller 010-LIC-1016 (direct acting) controls the level in the column 010-C-003 by regulating the flow rate
of liquid added via 010-LV-1016. The level signal comes from one of two duty/standby transmitters’ 010-LT-
1016 A/B which is selected by DCS hand switch 010-HS-1022. Stripping Steam injection flow rate to the column
is controlled by Flow Controller 010-FIC-1023 (reverse acting) regulating 010-FV-1023
Minimum flow to the pumps 010-P-009A/B is maintained by a spillback to the column; the flow to the spillback
is controlled by 010-FIC-1024 regulating 010-FV-1024. Product removal flow rate from the LAGO stripper is
controlled by the reverse acting Flow controller 010-FIC-1014 regulating 010-FV-1014. The LAGO and HAGO
rundowns are mixed and passed through parallel trains heat exchangers. The split is controlled by 010-HIC-
1005 and 010-HY-1005, which regulate valves 010-HV-1005 A/B. The average valve position ‘a’ is entered by
the operator at 010-HIC-1005 (0-1) and the split ‘b’ between Valves 010-HV-1005 A & B is entered by the
operator at 010-HY-1005 as the proportion of flow to 010-E-129/132 [010-E-229/232] (0-1). Thus the signal to
Valve 010-HV-1005A is 2*a*b*100% and the signal to Valve 010-HV-1005B is 2*a*(1-b) *100%.
HAGO Draw Off Section (Tray No. 30-34 and Draw Tray D-4) & HAGO Stripper:
A chimney tray, tray D4, is used in the atmospheric column to provide a liquid draw
off at the Heavy Atmospheric Gas oil product. The level in this must be maintained to provide correct pump
(010-P-030 A/B) feed conditions. The Level in the column is controlled by the level controller 010-LIC-1050
(direct acting). The level signal comes from one of two duty/standby transmitters’ 010-LT-1050A/B which is
selected by the hand selector 010-HS-1050. This cascades the set point to the flow controller 010-FIC-1042 this
regulates the reflux flow rate via valve 010-FV-1042. A HAGO draw is removed from tray D4 and pumped via
010-P-030 A/B to series of heat exchangers and has a bypass stream. The heated flow is split between 010-E-
123/132 and 010-E-223/232. The split between the two trains of heat exchangers, 010-E-123 /223 is controlled
by 010-HIC-1015 and 010-HY-1015, which regulate valves 010-HV-1015 A/B. The average valve position ‘a’
is entered by the operator at 010-HIC-1015 (0-1) and the split ‘b’ between Valves 010-HV-1015 A & B is
entered by the operator at 010-HY-1015 as the proportion of flow to Train 1 (0-1). Thus the signal to Valve
Level in the column is controlled by regulating the inlet flow rate via valve
010-LV-1018. This is controlled by 010-LIC-1018 (reverse acting). The level signal comes from one of two
duty/standby transmitters’ 010-LT-1018A/B which is selected by DCS hand switch 010-HS-1023. Steam
injection flow rate to the vapour in the column is controlled by 010-FIC-1028
(reverse acting) regulating valve 010-FV-1028. Minimum flow to the pumps 010-P-029A/B is maintained by a
spillback to the column; the flow to the spillback is controlled by 010-FIC-1029 regulating valve
010-FV-1029. Product removal flow rate from the HAGO stripper is controlled by the reverse
acting Flow controller 010-FIC-1015 regulating 010-FV-1015.

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LAGO/HAGO combine together after P-09A/B and P-29A/B. This combined stream is then routed through heat
exchangers for preheat gain in crude circuit. Finally, LAGO/HAGO is sent to DHDT unit as hot or cold feed.
Provision for routing cold AGO to VGO-HDT also exists and is used generally in start-ups. One additional
process line has been provided for routing cold AGO towards crude tanks as per requirement via the crude
circulation line.
3.9 VACUUM CHARGE HEATER

RCO (AR) from 010-C-001 bottom at temp of 3570C passes through vacuum furnace 010-F-002 (12 pass
furnace) where it is heated up to ~ 4000C and fed into the flash zone of vacuum column, 010-C-007.
For details regarding description and operating instructions for VDU heaters, please refer to OEM
manual provided by M/s PETRON ENGINEERING attached in annexure.
3.10 VACUUM DISTILLATION COLUMN

The vacuum column consists of 6 stripping trays, 5 nos. structural packed beds & 5 nos. of Draw trays. The
column operates at a pressure of 17 mm Hg. with the help of three stage ejector system (EJ-001/002/003).
Overhead vapors from the top of the column is drawn through the ejectors 010-EJ-001/002/003 separately and
cooled. The condensed liquid collected in the hot well 010-V-013, via barometric legs under gravity.
In the hot well, water and oil is separated by maintaining required interface level. Hot well oil is pumped to
DHDT unit and uncondensed vapor from 2nd stage Ejector condenser routed to vacuum furnace LP burners via
LP amine scrubber 010-C-009.
Flashed AR is fractionated into four side stream yields (Vac. Diesel oil, VGO, HVGO, Recycle oil).Vacuum
diesel is drawn as first side draw from tray D1 at 1150C. Part of the draw is routed from pump discharge to
the column as IR above the bed-2 and the other part is cooled to 44 0C in preheat exchangers /Air Cooler and
sent back above bed-1 as vacuum diesel PA. Vacuum diesel as product from the downstream of 010-E-102 &
010-E-202 is routed to DHDT.
VGO is drawn as second side draw from draw tray D3 at a temperature of 250 0C and gets cooled to 1840C in
preheat exchangers/Air coolers and a part of VGO sent back to the column above bed-3 as VGO PA .The
remaining VGO further cooled and routed to VGO HDT at 1530C.
HVGO is drawn as the third side draw from draw tray D4 at temperature of 349 0C. One part of the pump
discharge sent back to the column as wash oil above bed D-5 the other part passes through preheat exchangers
gets cooled up to 2810C and split into two streams. One stream sent back above bed-4 as HVGO PA and the
other stream further gets cooled in E-149 & E-150 up to 1890C and routed along with VGO to VGO-HDT.

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New jump over line was erected on Dec 20 for VGO/HVGO product circulation along with fresh crude. Hook-
up point taken from VGO/HVGO product to storage line and is connected with crude start-up circulation line
and same has been commissioned. This line is used to avoid VGO/HVGO product tank build up when
downstream units under shut down/upset. Recycle oil is drawn as the 4th side draw from draw tray D-5 at a
temperature of 3800C and sent to feed inlet line of Vacuum furnace.010-C-007 bottom product (Vacuum
residue) pumped out by 010-P-025A/B/C passes through train- 3 pre heat exchangers and then split into two
streams. One stream is sent back to the column below the stripping section at a temperature of 265 0C as quench
to minimize cracking and the rest is further cooled and routed to DCU at 1900C. At AVU battery limit, a
process line from VGO-HDT joins along with VR stream to DCU tanks for routing VGO-HDT backwash.
3.11NAPHTHA STABILISATION SECTION

The vapor from crude column overhead receiver (010-V-005) routed to off-gas compressor via a KOD. The
compressor discharges to re-contactor drum 010-V-007 via air cooler 010-AC-008 and condensed Naphtha
from re contactor drum along with the Naphtha side cut stream from CDU enters the stabilizer 010-C-004,
Stabilized Naphtha is drawn from the bottom.
RPIP Scheme-Debottlenecking of Naphtha stabilizer, i.e. Side cut naphtha is routing to NHT hot feed line
bypassing naphtha stabilizer. The new line has been erected at last shut down July 20 and same has been
commissioned. So the side cut naphtha has provision to route to Stabilizer column and directly to NHT as per
requirement. The purpose of the scheme was to off load the stabilizer column which resulted in higher LPG
recovery.
The stabilizer column is a 44 tray column. Naphtha from the CDU section is preheated in the feed bottom
exchanger (010-E-037 A/B/C) where it exchanges heat with stabilized naphtha. The unstabilised naphtha is
heated from a temperature of 40 Deg C to a temperate of 159/155 Deg C. The heated naphtha is fed to tray no
26. LAGO Pump around stream is used for reboiling the naphtha at the bottom of the column. The normal
operating temperature at reboiler outlet is ~ 209/204 Deg C. The overhead stream from the stabilizer is cooled
in overhead air fin cooler (010-AC-009 A/B/C) to 55 Deg C and further cooled to 40 Deg C by trim cooler
(010-E-036 A/B). 010-P-015 A/B Stabilizer reflux pump provides the necessary reflux for distillation. The
column top temperature I maintained ~ 55-65 Deg C adjusting the reflux flow.
LPG from the overhead vessel, 010-V-008 is pumped to Deethaniser via 010-P-016 A/B/C. The stabilized
naphtha from the column bottom at temperature of 199 Deg C exchanges heat with unstabilised naphtha and
get cooled to about 94 Deg C. Naphtha at this temperature is routed to NHDT as hot feed. For routing naphtha
to storage, it is further cooled by air fin cooler 010-AC-010 up to 55 Deg C and then through trim cooler 010-
E-040 A/B to a temperature of 40 Deg C. Provision exists for routing stabilized naphtha to light slop, GT tanks
as per requirement. There is also a provision to route unstabilised naphtha directly to slop tank bypassing the
E-037 A/B/C and stabilizer column 010-C-004, which is normally used during startup and shutdown.

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The deethaniser column (010-C-005) is used to remove C2 components from LPG streams. In addition to the
C2 stream some amount of H2S is also removed. Feed enters to deethaniser on tray-1. Temperature of the
deethaniser column is maintained by using reflux from pump 010-P-018 A/B. Top temperature is maintained
around 62/65 Deg C. The required heat to the deethaniser is provided by reboiler 010-E-043 where heat is
supplied through LAGO PA stream. The reboiler outlet temperature is maintained around 84/86 Deg C.
Stripped gases from the overhead of the deethaniser is routed to off gas treatment column 010-C-010 for amine
wash. Pressure is controlled via a PIC provided at the column top. Deethaniser bottom product is normally
routed to SR-LPG unit. Treated LPG from SR-LPG is routed to Depropaniser. Provision exists to route LPG
directly to depropaniser 010-C-006.
Depropaniser is a 32 tray column. The column operating temperature and pressure are 45 Deg C and 14.9 kg/cm2
g pressure. Feed from SR-LPG Treatment section or Deethaniser is routed depropaniser tray no 16. Reboiling
heat is provided at the column bottom by LAGO PA Stream. The reboiler outlet temperature is maintained at 98
Deg C. Column top temperature is maintained at 45 Deg C by providing reflux via pump 010-P-019 A/B/C. C3
LPG is pumped to LPG bullets. C4 LPG from bottom of the column is routed to alkylation or LPG bullets as
per requirement. Provision exist to route C3 and C4 LPG stream to off spec bullets.
3.12OFF GAS TREATMENT SECTION

Off gas from recontacting drum (010-V-007) and off gas from NHDT are mixed and together treated in off gas
amine absorber. Lean amine from unit 84 is routed to off gas treatment section and rich amine is pumped via
rich amine pumps 010-P-033 A/B. Off gas from the AVU and the Naphtha Hydro treater (Unit 40) are scrubbed
of acid gases by an amine absorber 010-C-010. The flow of fresh/Lean amine is controlled by 010-FIC-4001
(reverse acting); regulating the flow of fresh amine from the Amine Regeneration to the Absorber via 010-FV-
4001. The liquid level in the bottom of 010-C-010 is measured by two duty standby transmitters 010-LT-4004
A/B which are selected by DCS hand switch 010-HS-4004. The level is controlled by 010-LIC-4004 (Direct
acting); this regulates the flow to the clean amine regeneration unit via 010-LV-4004. Treated gas from 010-C-
010 is sent to a knockout drum 010-V-017. Pressure is controlled in 010-V-0017 by 010-PIC-4005 (direct
acting); regulating the flow to the fuel pool from the drum via 010-PV-4005. Provision exists to route Fuel gas
to Indmax WGC Suction directly via pressure control valve 010-PV-4005A. Normally the fuel gas is routed to
Indmax to recover LPG. Off gas from PP is also routed to Indmax via the new line which is connected to the
fuel gas to indmax at AVU battery limit.
Amine from the knockout drum 010-V-016 and 010-V-017 and additional amine is pumped by 010-P-034 from
010-V-018. The Amine Blowdown Pump 010-P-034 to be started manually from field on High Level (010-LI-
4005) in Amine Blowdown Drum and shall be tripped on Low Level through DCS Interlock I-6210.
3.13 VDU VENT GAS TREATMENT SECTION

Vent gas generated from VDU ejector section is treated in a packed column 010-C-009. Lean amine from unit
83 is routed to the top of the bed. Rich amine from bottom of the column is routed back to ARU. Along with

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ejector off gas, vent gas from SR-LPG is treated in the amine wash column. After treatment the vent gas is
routed to a KOD. Outlet of the KOD can be routed to VDU furnace via a flame arrestor. Ejector off gas can also
be routed to atmosphere during unit disturbance and upset condition.
3.14 CHEMICAL DOSING

a. DEMULSIFIER (010-A-002)
Demulsifier is used for breaking the emulsion of water & crude to ensure proper desalting and minimum
carryover of oil along with brine. With the help of the dosing pump (010-P-035 A-D) 100% strength solution is
injected into crude two locations, at battery limit and at outlet of 1st Stage Desalters in both the crude trains.
Demulsifier Injection Point & Dosing Rate Details:

Dosing Chemical Dilution Dosing Location Desired Dosage
(ppm on Crude)
Crude Oil Feed at Battery Limit 3-5 ppm
Desalted Crude ex 1st Stage 3-5 ppm
Diluted with Naphtha
Demulsifier Desalter Train-I
Desalted Crude ex 1st Stage 3-5 ppm
Desalter Train-II
Note: Currently comprehensive chemical dosing for corrosion monitoring and prevention is being done by M/s
Vasu Chemicals. Proprietary chemical name for Demulsifier is VPC - 6514.
Details of the Dosing System:

Chemical Preparation Tank Tag No : 010-TK-002
Capacity : 7000 litres
Dosing Pumps Tag No : 010-P-035 A-D
Capacity : 80 litres/hr
Dis. Pr : 31.0 Kg/cm2 g
Power : 0.75 KW
b. ANTIFOULANT (010-A-003)
Antifoulant is dosed in crude to reduce fouling in the preheat exchanger circuit. Anti- foulant drum is unloaded
in vessel by air operated pumps and is injected with the help of dosing pump. By using dosing pumps (010-P-
036 A-D) 100% strength solution is injected into the crude.

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Antifoulant Injection Point & Dosing Rate Details:

(ppm on Crude)
Crude Oil Feed at Train-I 3-5 ppm
Neat Liquid
Antifoulant
No dilution
Crude Oil Feed at Train-II 3-5 ppm
Desalted Crude ex 2nd Stage 3-5 ppm

Desalter Train-I
Desalted Crude ex 2nd Stage 3-5 ppm
Desalter Train-I
c. CORROSION INHIBITOR (010-A-004)
Corrosion inhibitor solution is required to combat the corrosion of overhead system of columns. The chemical
creates a protective layer on the metal surface, thus minimizing the exposure of the corrosive acid species to the
metal surface. Corrosion inhibitor solution is prepared with the help of stabilized naphtha. Corrosion inhibitor
is unloaded from drums by air operated pump to tank where the inhibitor & stabilized naphtha, supplied from
stabilized naphtha run down line is mixed with vessel mixer thoroughly. Diluted Corrosion inhibitor is injected
by injection pump (010-P-037 A-F) to Atmospheric column, Naphtha Stabilizer and Vacuum column.

(ppm on flow)
Crude Distillation Column 3-5 ppm
(010-C-001) Overhead Line
Diluted with
Vacuum Distillation Column 3-5 ppm
Corrosion Inhibitor Stabilized
Naphtha
Naphtha Stabilizer Unit 3-5 ppm
Vasu Chemicals. Proprietary chemical name for Corrosion Inhibitor is VPC - 6685.
Dosing Pumps Tag No : 010-P-037 A-F
Dis. Pr : 13/7.2/6.0 Kg/cm2 g
Power : 0.37 KW
d. NEUTRALISING AMINE (010-A-005)
The requirement of Neutralizing Amine injection is to neutralize the HCl (hydrochloric acid) formed due to

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hydrolysis of mainly calcium and magnesium chlorides present in the crude oil in preheat exchanger circuit and
furnace tubes. It is monitored by measuring and maintaining pH of crude column overhead receiver boot water,
hot well drum sour water in CDU & VDU respectively. Dosing rate should be adjusted time to time to maintain
pH in the range of 5.5 to 6.5, because at this pH range, the overhead corrosion rate is minimum. Separate dosing
pump is provided to dose Neutralizing Amine at the Crude & Vacuum Column overhead with dosing pump
010-P-038 A-D.

(ppm on flow)
Crude Distillation Column
Diluted with 20-30 ppm
Neutralizing Amine Stripped Sour
Vacuum Distillation Column
Water 20-30 ppm
Vasu Chemicals. Proprietary chemical name for Corrosion Inhibitor is VPC - 6658.

Dosing Pumps Tag No : 010-P-038 A-D
Dis. Pr : 7.2/6.0 Kg/cm2 g
Power : 0.37 KW
e. TRISODIUM PHOSPHATE (010-A-006)
Trisodium Phosphate is dosed to foam a magnetite layer inside the Steam drums, Steam generators
& tubes to prevent corrosion and it forms insoluble phosphate of Ca & Mg, which are drained out
through blow down. It also slightly improves pH (Range 8-9) in boiler (steam generator) drums of 010-
V-024, 010-V-022. Trisodium phosphate bag is unloaded in vessel where there is a provision to make
the solution of 3% wt. by adding DM water.
Trisodium Phosphate is supplied as powder in bags which is used for preparation of the chemicals.

(ppm on flow)
Waste Heat Boiler Steam Drum 5-10 ppm
Tri Sodium Phosphate Diluted to 3% in CDU Heater 010-V-024
with DM Water Waste Heat Boiler Steam Drum 5-10 ppm
in VDU Heater 010-V-022

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Dosing Pumps Tag No : 010-P-039 A-B
Dis. Pr : 30.0 Kg/cm2 g
Power : 0.37 KW
f. CAUSTIC DOSING SYSTEM

Provision exists for dosing caustic to crude after desalter. The dosing is maintained about 0.5 to 1 ppm.
Na content in VR is monitored which should be < 10 ppm.

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CHAPTER-04
OPERATING VARIABLES

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NORMAL
PARAMETER UNIT LIGHT HEAVY
CRUDE CRUDE
FEED CONDITION
Feed Rate(For 15 MMTPA) m3/hr 2121.7 2044.2
Pressure kg/cm 2 (g) 30 30
Temperature Deg C 35 35
PRE DESALTER PREHEAT TRAIN
I/L Temperature Deg C 35 35
O/L Temperature Deg C 130 130
1st STAGE DESALTER
Pressure kg/cm 2 (g) 21.4 21.4
Water injection m3/hr 160 160
Pressure drop across mixing valve kg/cm 2 (g) 1.6-1.8 1.6-1.8
Interface level in desalters % 30 30
2nd STAGE DESALTER
Water injection m3/hr 88 88
Pressure drop across mixing valve kg/cm 2 1.6-1.8 1.6-1.8
Interface level in desalters % 30 30
POST DESALTER PREHEAT TRAIN
Kg/Cm2
Pressure 20.4 20.4
(g)
PRE FLASH VESSEL
POST FLASH DRUM PREHEAT TRAIN
Inlet/Outlet Pressure kg/cm 2 (g) 24.9/20.9 24.9/20.9
CRUDE HEATER
Inlet Temperature Deg C 299 301
Outlet Temperature Deg C 356 367
Inlet Pressure kg/cm 2 (g) 20.9 20.9
Outlet Pressure kg/cm 2 (g) 2 2
ATMOSPHERIC COLUMN
Column top temperature Deg C 116 116
Column bottom temp. Deg C 349 360
Column Top/Bottom pr. kg/cm 2 (g) 1.2/1.8 1.2/1.8
Flash zone temperature Deg C 349 360
Flash zone pressure kg/cm 2 (g) 1.65 1.65

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NORMAL
CRUDE CRUDE
Pump Around (PA's) draw/return temp
Top PA Deg C 136/96 133/98
Kero PA Deg C 200/143 192/132
LAGO PA Deg C 254/195 253/193
HAGO PA Deg C 307/247 310/249
Pump Around (PA's) flow
Top CR m3/hr 3114.9 3121.2
Kero CR m3/hr 486.6 465.7
LAGO CR m3/hr 1170.7 1068.5
HAGO CR m3/hr 955.1 949.6
Products draw-off temp
Hy. Naphtha Deg C 116 116
Side Cut Naphtha Deg C 96 98
Kero Deg C 200 192
LAGO Deg C 254 253
HAGO Deg C 307 310
Product Rate
Over head vapor Nm3/hr 67645 64652
Side cut Naphtha m3/hr 147 44
Kero m3/hr 199.8 201.4
LAGO m3/hr 494.4 466.6
HAGO m3/hr 77.6 76.4
RCO m3/hr 1287.6 1371.8
VACUUM HEATER
Inlet temperature Deg C 346 357
Outlet temperature Deg C 399 402
Inlet Pressure kg/cm 2 (g) 11 11
Outlet Pressure kg/cm 2 (g) 3 3
VACUUM DISTILLATION COLUMN
Feed rate m3/hr 769.6 1020.5
Column top temp. Deg C 60 60
Column bottom temp. Deg C 354 354
mm Hg. abs
Column Flash Zone Pressure 190 190
mm
Column Top Pressure 17 17
Hg.abs
mm
Column bottom Pressure
Hg.abs
CR’s draw/Return Temp.
Vacuum Diesel CR Deg C 115/44 114/42
LVGO CR Deg C 250/186 252/184
HVGO CR Deg C 345/281 349/280

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NORMAL
CRUDE CRUDE
CR’s Flow/IR’s Flow
Vacuum Diesel PA m3/hr 657.2 612.4
Vacuum Diesel IR m3/hr 153.1 140.4
LVGO PA m3/hr 1304.8 1211.4
HVGO PA m3/hr 926.5 889
HVGO IR/WASH OIL m3/hr 325.2 327
Recycle to Furnace m3/hr 130.2 139.5
Vacuum Resid. Quench m3/hr 115.7 156.4
Products draw-off temp
Vacuum Diesel Deg C 115 114
LVGO Deg C 250 252
HVGO Deg C 345 349
RECYCLE OIL Deg C 380 374
Vacuum Residue Deg C 354 354
Products Rate
Overheads m3/hr 2019331.3 2673120.2
Vacuum Diesel m3/hr 75.1 59.8
LVGO m3/hr 599.9 532.1
HVGO m3/hr 70.8 48
VR m3/hr 363.1 556.7
STRIPPING STEAM (LP)
Crude Column (C-001) MT/hr 22.43 24.24
Kero Stripper (C-002) MT/hr 5.1 2.25
LAGO Stripper (C-003) MT/hr 4.5 4.2
HAGO Stripper (C-008) MT/hr 0.67 0.67
Vacuum Column (C-007) MT/hr 13.37 20.34
EJECTOR STEAM (MP)
010-EJ-001/002/003
MT/hr 70.5 70.5
(MP steam @12kg/cm2 g & 210 Deg C)
NAPHTHA STABILISER
Feed m3/hr 375.7 344.7
Overhead Gas MT/hr 121.8 82.8
Stabilized Naphtha MT/hr 507.8 384.8
Reflux m3/hr 186.3 127.7
Feed Temperature Deg C 159 155
Top Temperature Deg C 70 72
Bottom Temperature Deg C 199 196
Top Pressure kg/cm 2 (g) 10.5 10.5
Reboiler inlet temp Deg C 199 196
Reboiler outlet temp Deg C 209 204
Naphtha Stabiliser Overhead Receiver
Temperature ºC 40 40

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NORMAL
CRUDE CRUDE
DE-ETHANISER
Feed m3/hr 37.6 33.1
Overhead Gas MT/hr. 2.89 0.929
Reflux m3/hr 4.1 1.3
De-ethaniser Overhead Receiver
DE-PROPANISER
Feed m3/hr 41.1 27.8
Overhead Gas MT/hr. 27.04 17.89
Reflux m3/hr 47.2 31
De-propaniser Overhead Receiver
Pressure Kg/Cm2 (g) 14.3 14.3
4.1 OPERATING VARIABLES:

4.1.1 ELECTRIC DESALTERS (010-V-101/201):
A) Water Injection Rate & Pressure Drop
Typically, the water injection rate to desalter is around 4 to 6 % vol. on crude. Since degree of desalting falls
sharply at less than 4% water, the injection rate should always be maintained at least 4%. Excessive injection
may cause difficulty in controlling interface level. Optimum water injection rate is 5%. If crude is Naphthenic,
water injection should not be done upstream of Preheat Trains. Pressure drop across mixing valve is adjusted to
achieve efficient contact between the salt in the crude and the injected water. Simultaneously, pressure drop
across mixing valve helps in proper dispersion/mixing of demulsifier. Too high-pressure drop can result in too
strong emulsion which in turn would require higher dosing of Demulsifier or may lead to loss of crude with

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brine or even carry-over of water along with crude. Too low a pressure drop would not ensure good mixing.
Hence the required degree of desalting would not be achieved and the Demulsifier also may not be effective.
B) Oil-Water interface level
Oil/water interface level should always be maintained at specified value (typically around 40%) by cross
checking the level (LIC) with the try lines. The general considerations would be:
Preferably a clear brine level be available at least at the bottom most try line. Drop in level may result in
unnecessary and expensive loss of crude alongwith brine water being discharged to ETP. In case of wide band
of emulsion level in the desalter, water level can be raised slowly to break the band in between the electric grid.
C) Pressure/Temperature
Temperature of crude oil coming to desalter should be such that the oil viscosity is sufficiently reduced to have
good desalting. For a clear interface, normally a temperature of around 130º C for crude to desalter inlet is
maintained. Desalter temperature can be adjusted by operating bypass of preheat exchangers. Desalter operating
pressure would be required so as to prevent vaporization of the crude at the operating temperature. High
temperature of crude at desalter inlet would cause fouling of exchangers at the upstream of desalter.
D) Demulsifier Injection
Demulsifying chemicals like Demulsifier are used to break stable crude-water emulsions. Demulsifier soluble
in hydrocarbon like kerosene is considered to be more effective. The amount of Demulsifier required to break
the emulsion depends on the type of crude, temperature & nature of emulsion.
E) Voltage & Amperage

Electrical panel of the desalter in the field consists of pilot lights, Voltmeter and Ampere meter. The Voltmeter
gives the voltage across the primary circuit of the transformer and the Ammeter gives the current flow. When,
water crude emulsion is tightly bound or if interface level is too high then pilot light flickers on the panel &
Amperage increases & Voltage decreases. Corrective action to break the emulsion or reduce the interface level
should be taken.
4.1.2 ATMOSPHERIC DISTILLATION:

A) Coil Outlet Temperature (COT)
The furnace coil outlet temperature is controlled to achieve desired yield of distillates and also a little quantity
of over flash for optimum distillate recovery. Quantity of over flash would be indicated by FI-1035 and typically
would be required around 3-5% vol. on crude feed. Thus once the desired yields of distillates are established the

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over flash quantity may serve as a guide to establish the required coil outlet temperature at the operating flash
zone pressure. Too high a temperature, say 359º C or higher, would on the other hand enhance the possibility of
cracking of the oil and associated coking etc. in coil tubes.
B) Column Pressure
The pressure in the column is regulated by a split range controller installed on 010-V-005. A release of gas from
010-V-005 may mean loss of potential LPG components and thus it is preferable to operate the controller
marginally on the makeup side. Lower the set pressure, lower would be the required temperature for
corresponding vaporization and less would be the fuel consumption at the furnace but higher would be the vapor
velocity at the Fractionator trays for the same through put. It means worse separation between two adjacent cuts
especially at high through puts. Also, the pressure required for full condensation of overhead vapors, by heat
exchange with circulating cooling water puts the limit for reduction of pressure possible. To avoid flaring from
the V-005 off Gas compressors K-003 A/B have been provided, which will recover additional LPG/Gas etc.
C) Product Draw Off Temperature
Withdrawal temperature of a side cut from the fractionator will influence the end point of this product. This
will be regulated by flow rate of the product withdrawn. An increase in withdrawal quantity in case of the one
side stream reduces the internal reflux and hence causing poor fractionation below this draw. This is indicated
by increase in temperature of the draw off tray as well as trays below it. For example, if LAGO draw is increased,
the tray temperature of LAGO will rise and the end points of LAGO will increase. Accordingly, the initial point
of HAGO will be higher. Again if HAGO withdrawal rate is not reduced to maintain its tray temperature, the
end points of HAGO will also go up. It follows; therefore that withdrawal of any side stream should not be
greatly increased to the extent that internal reflux below it is, adversely reduced.
D) Pump around Heat Removal
The heat removal from the fractionator by a pump around (PA) is proportional to the flow of the PA stream
multiplied by the difference between draw & return temperatures of this stream. Hence this heat removal may
be increased either by the increase in flow or by a reduction in return temperature of this stream. (The return
temp. of Top Pump around (TPA) is not advisable to be reduced below 95º C to avoid any localized condensation
and resultant acid dew point corrosion in the top section of the column) The objective of this heat removal by
PA stream is to reduce vapor load at particular sections of the Fractionator, where the vapor velocity would be
limiting w.r.t entertainment and flooding characteristics. At the same time, too high heat removal by PA would
reduce the internal reflux above the PA section to affect separation/products properties above the section.
A higher than normal Kero PA flow will remove more heat from column in Kero PA Zone. When this heat removal
becomes excessive, column top temperature shall also show a tendency of decline, requiring lower top reflux.
This will cause lower liquid transport between top tray and Kero. Hence, side cut Naphtha will be heavy and
Kerosene cut will be correspondingly lighter. High LAGO PA flows will tend to lower the temperature of LAGO
product draw-off, resulting in lighter product on this tray. Thus, HAGO will be lighter and Kero will also be
lighter. High HAGO PA flow will tend to lower the draw-off temperature of HAGO product, making LAGO,

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HAGO and RCO

E) Column Top temperature
By regulating amount of overhead reflux through FIC-1036 cascaded with TIC-1074, column top temperature is
controlled. At the same operating pressure, increasing the top temperature will result in increase of FBP and make
of Naphtha. Also, IBP of next cut i.e. Kero will increase. It is not advisable to reduce top temperature of the main
column below 116º C at 1.2 kg/cm2 (g) pressure to avoid steam condensation at the top section of the column and
resultant acid dew point corrosion. However, the actual dew point varies according to the steam flow rates to C-
001/002/003/008, off gas flow / composition and Naphtha flow from V-005.
4.1.3 NAPHTHA STABLIZER COLUMN:

Stabilizer removes the majority of Butanes and lighter Hydrocarbons from the naphtha stream.
A) Top Pressure & Temperature

High stabilizer top temperature will make overhead product heavy; even C5/C6 components may be carried into
LPG or Fuel Gas and condensing in the distribution lines afterwards. Lower top temperature attained by increasing
top reflux will reduce heavier ends in fuel gas, TVP (Total Vapor Pressure) of LPG may go up on account of
increased presence of C3 and lower components. To correct the situation, stabilizer top pressure may be decreased
slightly. Low stabilizer top pressure in the column will cause higher amount of Hydrocarbon compounds (C5+)
to escape into overhead system.
B) Bottom Temperature
Low low bottom temperature will result in higher than allowable vapor pressure (RVP) of Naphtha at the same
time it will reduce LPG/fuel gas make.
4.1.4 DE-ETHANISER:
High top temperature will make overhead product heavy; even C3/C4 components may be carried into Fuel Gas
and condensing in the distribution lines / Amine system afterwards. Lower top temperature attained by
increasing top reflux will reduce heavier ends in fuel gas. Low stabilizer top pressure in the column will cause
higher amount of Hydrocarbon compounds (C3 and C4) escaping into overhead system.
Too low bottom temperature will result in improper stripping of C1 & C2 from LPG.
4.1.5 DE PROPANISER:

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High top temperature will make overhead product heavy, C4 components may be carried into C3 storage bullet.
Lower top temperature attained by increasing top reflux will reduce heavier ends. Low stabilizer top pressure in
the column will cause higher amount of Hydrocarbon compounds (C4) to escape into overhead system.
Too low bottom temperature will result in improper stripping of C3 from C4 LPG it will make offspec butamer
feed.
4.1.6 VACUUM DISTILLATION:

A) Coil Outlet Temperature (COT)
This temperature determines the degree of vaporization with a view to both (i) the recovery of distillates during
vacuum fractionation, as well as (ii) the quality of Vacuum residue as feed for DCU. The maximum COT is
governed by the tendency of feed atmospheric residue to undergo cracking at high temperatures and thus is
restricted to say 425º C. The detrimental effects of cracking are coke deposition in heater tubes and increase of
non-condensable going to the ejectors. Column bottom stripping steam is varied without overshooting the
maximum permissible COT. At tower COT the fuel consumption at the furnace would be less but the requirement
of stripping stream at vacuum column bottom would be higher (and also consequently the vapor load in the column
trays and overhead system would be higher).
B) Stripping Steam
The purpose and effect of stripping steam to maintain desired quality of Vacuum Residue as discussed above. A
point to mention would be that an increase in stripping steam quantity significantly increases the vapor load of
the Vacuum Column, with a possible deterioration in fractionation, especially at high throughputs. This may be
of importance in maintaining the quantity w.r.t. end points of HVGO as feed stock to VGO HDT and its color.
C) Vacuum column Pressure
The column top pressure is controlled by 010-PV-3019.This spill back arrangement of non- condensable is
provided to prevent excessive creation of vacuum. The vacuum Column top pressure should be maintained around
17 MM Hg. Increase in pressure i.e. reduction in vacuum will result in reduction in yield of vacuum distillates
and may lead to cracking of the feed. Reduction in top pressure further may result in carry over of LVGO into
the system. Also carry over of asphaltenes may be observed into VGO on prolonged operation of Vacuum
Column.
It is of utmost importance to maintain to steady vacuum and temperature in the flash zone for obtaining maximum
yield and correct specs of products. Ensure that flash zone temperature and pressure are indirectly controlled by
heater COT and top pressure. Increasing the flash zone temperature will result in increased distillate yield but
cracking possibility is enhanced. If for any reason, vacuum starts falling, heater COT should be reduced.
Fluctuation in vacuum will impair product quality and cause mechanical stress in column internals.
D) Vacuum Diesel Draw Off

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Vacuum Diesel is maintained to control top temperature. The flow of Vacuum diesel CR is maintained such that
almost entire diesel component can be condensed in this zone. Higher CR flow will cause increased energy
consumption without much benefit. Decrease in CR rate increases the column top temperature and causes carry-
over of hydrocarbons into ejector system. Internal reflux is distributed over the packing below Vacuum diesel
draw off tray. It should be sufficient to wet the packing properly to affect mass transfer and achieve desired
fractionation efficiency.
The product withdrawal is maintained in such a way that the draw off temperature of diesel is maintained as per
stipulation. Increased withdrawal may result in carry-over of LVGO component in the HSD stream. Decrease in
withdrawal will result in Diesel falling into LVGO tray affecting VGO quality by making it light. The draw off
temperature increases with increased withdrawal and vice-versa.
E) LVGO Draw Off

Increased LVGO CR rate may lead to retention of vacuum Diesel components if LVGO product due to
condensation whereas decreased CR rate may lead to loss of LVGO component to Vacuum diesel due to less
condensation on product tray and subsequent carryover. The LVGO draw off rate is regulated in such a way that
the LVGO draw off temperature is maintained as per design. Higher draw off rate will increase LVGO tray
temperature and heavier components carry over into LVGO. Internal Reflux of LVGO should be maintained in
such a way that packing in HVGO section is adequately wet for proper mass transfer
F) HVGO Draw Off

Heat transfer requirement in HVGO section in largely achieved through HVGO CR flow. A higher than the design
CR rate will result in flooding of packing in HVGO section. Low CR flow rate will result in carryover of heavies
to LVGO section. Lower withdrawal rate the design will result in low draw off temperature causing lower recovery
of HVGO. Higher rate of withdrawal will result in increased tray temperature, leading to carry over of Asphaltenes
to HVGO. HVGO internal reflux provided below its draw off tray should be sufficient in quantity to arrest carry
over of Asphaltenes and heavier VR components into Slop distillate zone.
G) VR Quench
VR Quench flow is a part of Vacuum Residue run down to control the column bottom temperature around
393/363º C. Its purpose is to prevent coke formation at the bottom of the column by quickly cooling Vacuum
Residue column bottom from 393ºC to 237ºC (Light Crude) and 363º C to 242º C (Heavy crude).
H) Internal Refluxes
Internal Refluxes (IR) in Vacuum Column serve same purpose as in Atmospheric Column. IR streams wet
packing above respective product draw off. Inadequate flow of IR may lead to poor fractionation, affecting
product quality adversely. This shall be indicated by shift in boiling ranges of products.

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CHAPTER-05
JOB RESPONSIBILITY

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5.1 Job Responsibility of Plant Manager (PNM)
 PNM/SPNM is the unit in charge, who writes the instruction book for the daily unit operation and
activities
 The unit in charge is the controlling officer for the operating group working under him/her and
he/she will take care of his sub ordinates welfare, sanctioning leave and preparing monthly shift
rota for officers working in shifts (as per leave planning).
 As a unit in charge PNM/SPNM will represent in daily zonal meeting, RSM meeting as per
schedule and safety meeting.
 Responsible for arranging stationeries, chemicals, lube oil and tools and tackles from store.
 Identify the need of training requirement and arrange training program for the operating personnel
of his unit.
 Responsible for maintaining healthy working condition of all portable detectors, explosive meter
and H2S detector by sending them to Fire safety department for calibration as per schedule.
 Conduct mock drill for critical emergency operations
 Leads his team for achieving TPM, maintain records related to TPM.
 Responsible for implementation and maintaining quality system.
 Reading and Signing daily log sheets of shift in charges, panel officers and operators.
 Decides to carry out any critical maintenance job inside the unit during the normal operation.
 Decides to shut down the unit in critical situations and give instructions and guide lines for a smooth
and safe unit operation.
 During M&I shut down as a coordinator attends shut down meeting and writes daily instruction in
the shutdown instruction book to carry out the jobs safely with standard procedure.
 PNM/SPNM is the fire permit signatory of the unit who will sign the fire permit duly checked and
filled by the issuer and permitee.
5.2 Job Responsibility of Shift-in-charge
 Shift in charge is fully responsible of the unit and operating personnel’s of his shift.
 Man-to-Man relieving to be followed during shift change over.
 Read the previous two Shifts log and to be initialized with time and date in log book.
 Read PNM/SPNM instruction book and it is to be signed with time and date.
 Checking and signing of field and panel log sheets.
 Checking laboratory results and giving instruction to panel officers to achieve quality products with
consultation of PNM/SPNM.

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 Issuing notification and clearance in SAP to carry out day to day maintenance related jobs safely, and closing
SAP notification after ensuring the completion of job.
 Ensuring smooth unit operation as per the design operating parameters and standard operating procedures
written in the operating manual.
 Coordinating with other departments’ maintenance, process, quality control, utility inspection, off site, CPP,
ETP, fire & safety and RSM as per requirement.
 Responsible for conducting skill development program for operators.
 Optimizing unit operation, chemical & lube oil consumption and energy conservation.
 Guiding panel officers, field operators, maintaining housekeeping in control room and field area.
 In case of any disturbance in unit operation, routing the off spec product to slop tank in time to avoid product
tank off spec by informing to offsite shift in charge, PNM/SPNM and RSM.
 In the event of fire or major leak in the unit, shift in charge has to take his decision to shut down the unit and
the same is to be informed to PNM/SPNM and RSM immediately.
 If any operating personnel met with accident during duty hours shift in charge has to arrange ambulance
immediately, fill up the accident reporting form and inform PNM/SPNM and RSM.
 Shift in charge is the gas safety inspector to sign work permits after ensuring all pre conditions mentioned in
the permit is thoroughly checked along with the permittee
 Log book is to be written clearly without over writing and all activities carried out in the shift with respect
of time.
 Critical operations are to be mentioned separately in the log and the same is to be verbally informed to the
reliever.
5.3 Job Responsibility of Panel Officer
 Controls unit operation by regular monitoring the operating parameters from DCS and guide lines of the
operating manual and PNM/SPNM instruction to achieve quality products.
 Panel officer has to sign shift panel log as well as PNM/SPNM instruction book.
 Communicate with shift in charge and field operators to carry out smooth and safe unit operation.
 Panel officer can directly instruct field operators for any field related operations.
 In the event of disturbance in unit operation panel officer can take the decision to divert the product to slop
tank after informing offsite shift in charge, unit shift- in charge and PNM/SPNM.
 In the beginning of each shift, indication lamp test is to be done, if any fuse bulbs are noticed it is to be
replaced.
 Maintaining records like daily and cumulative crude is being processed, lab results, utility consumption and
interlock status.
 Coordinate with other departments like maintenance, off site, CPP, utility department, quality control,
process and secondary units directly related to AVU as on requirement.

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 During unit start up, shutdown and emergencies he has to give proper instruction and guidance to the field
operators through communication systems.
 Fill panel log sheet as per schedule, mentioning all activities carried out in the shift including the
instructions/information from his superiors received by phone.
 DCS panel should not be left unmanned.
5.4 Job Responsibility of Field Operators
 Responsible to carry out all operations instructed by shift in charge/panel officer, Routine jobs and to look
after the safety of the unit.
 Panel officer is to be kept informed before carrying out any field operation.
 The routine jobs are as follows: man to man relieving, Reading and initializing the previous shift log, regular
field visit, Filling correct data in the log sheets as per schedule, mentioning all activities carried out in the
shift, Follow up activities, Oil top up in rotary equipments, Ensuring healthiness of running/ standby
equipments, Sampling, Soot blowing, Knock out vessels draining, Product routing, Rotary equipment
change over as per schedule, Handing over and taking over of the equipments to/from maintenance,
Preparation of chemicals and housekeeping.
 Maintaining records of chemical/lube oil consumption and stock, Burner status, Equipment under
maintenance, running hours of rotary equipments and field test reports (pH of overhead vessels boot water,
strength of caustic/phosphate solution prepared, weathering, lead acetate test etc.)
 Any abnormalities noticed/observed is to be informed immediately to panel officer/shift in charge and the
same is to be mentioned in the field log sheet.
 Fire in the unit is to be informed to fire & safety, panel officer and shift in charge.
 In case of Major fire or hydrocarbon leak break MCP to call fire, inform panel officer about the area status,
inform shift in charge, continue firefighting from safe distance and try to cut off the source of fire.
 Responsible for keeping their own equipment clean and healthy by taking active participation in TPM.
 Vigilant in the duty area throughout his shift to avoid any leak or fire which may cause major loss/damage
to the unit by taking remedial action in time.
 Responsible to prevent any un-authorized persons/vehicle entering in the operational area.
 Responsible to stop any unsafe practice, unauthorized work is being followed by maintenance/contract
persons.
 Physical presence must be essential during any maintenance work or critical area where work is going on.
 Responsible for their own safety by using appropriate PPE’s for appropriate work.
 Following standard operating procedures, do’s & don’ts and vigilant in duty hours, identification and
attending abnormalities in time in the plant area will results uninterrupted production and safety of the plant.
 He should not leave his duty area without prior permission for smoking and personal requirements in the HR,
Finance or leave refinery gate.

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5.1 ISBL area divisions:

The Atmospheric Vacuum Unit (including SR LPG Unit) has been divided in six nos. of Areas. The area
and routine job responsibility for the engineering assistance (EA) are given below:
Area-1 : CDU Furnace
Equipment Tag No. Equipment / Facility Name
010−APH−001 Flue Gas Air Preheater (CDU)
010−DS−001 MP Steam Desuper heater (CDU)
010−E−030 SAPH (CDU)
010−F−101 Crude Charge Furnace Train 1
010−F−201 Crude Charge Furnace Train 2
010−K−001 AƒB Crude Charge heater FD Fan
010−K−002 AƒB Crude Charge heater ID Fan
010−SK−001 Crude Charge heater stack
010−SL−001AƒB Crude Charge heater FD inlet Air filter
010−SL−007 LP steam Vent Silencer (F−101)
010−SL−009 MP steam Vent Silencer (F−101)
010−V−023 Decoking Drum(CDU)
010−V−024 Steam Drum(CDU)
010−WHB−001 Crude Charge Heater Waste Heat Boiler
010-P-100 A/B/C Phosphate Dosing Pumps
010-TK-100 Phosphate Tank
Battery limit CDU Heater Area
Soot Blowers
Routine Job Responsibilities:
1. Visual checking & logging

2. Visual checking of furnace pass CƒV area, coil OƒL for any leak
3. Visual checking of individual burner for flame lengthƒImpingement
4. Burner changeoverƒ line up as per requirement
5. Coordinateƒfacilitate the maintenance job in the area
6. Carry out soot blowing and flue gas samplingƒ blow down sampling
7. Adjustment of dosing rate in accordance with blow down sample result

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8. Preparation of phosphate solution for phosphate dosing

9. IDƒFD changeoverƒstart , lube oil top up as per schedule
10. Sample collection as per scheduleƒrequirement
11. Permit clearence as per requirement
12. Shutdown valve field reset and latching as per requirement
13. BMS panel operationƒreset as per requirement
14. Strainer change over as per requirement
15. All hydrocarbon & utility heater area battery limit valve operation as per requirement
16. Safety valve checking ƒlineup
17. OWS & CRWS regular checking
18. Miscellaneous jobs as per operational requirement.
Note: The job distributions and responsibility are indicative only. The final distributions of jobs are to be as per
the shift−In−charge instruction.
AREA-2 : CDU Area

010−AC−007 A−H Crude Column OVHD Condenser
010−C−001 Crude Distillation Column
010−C−002 Kerosene Stripper
010−C−003 LAGO Stripper
010−C−008 HAGO Stripper
010−P−001−AƒB De−Salter Water Make Up Pump
010−P−004−AƒBƒC Top Pump Around Pump
010−P−005−AƒB Kerosene PA Pump
010−P−006−AƒB LAGO Pump Around Pump
010−P−007−AƒBƒC ATM Residue Pump
010−P−008−AƒB Kero Product Pump
010−P−009−AƒB LAGO Product Pump
010−P−010−AƒB CDU Overhead Liquid Pump
010−P−011−AƒB CDU Sour Water Pump
010−P−029−AƒB HAGO Product Pump
010−P−030−AƒB HAGO Pump Around pump
010−P−612 CDU Area Closed Blowdown Pump
010−P−501 AƒB Fire Water Booster Pumps
010−V−001 Desalter Water Surge Drum
010−V−005 Crude Column Ovhd Reciever, its CƒVs & PSVs

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010−V−612 CDU Area Closed Blowdown Drum

1. Visualƒphysical check up and logging
3. Pump changeoverƒstartƒstop, lube oil & seal oil top up as per requirement
5. Sample collection as per scheduleƒrequirement.
7. Shutdown valve field reset as per requirement
9. Air coolers startƒstop as per requirement
11. Miscellenous jobs as per operational requirement.
12. pH checking of boot water twice per shift.
Note: The job distributions and responsibility are indicative only. The final distributions of jobs
are to be as per the shift−In−charge instruction.
Area-3: Battery Limit & Stabilizer Area, SR LPG Treatment Section

010−AC−004 Kerosene Product Cooler
010−AC−005 AGO Product Cooler
010−AC−008 Recontactor Cooler
010−AC−009 Naphtha Stabilizer OVHD Condenser
010−AC−010 Stabilized Naphtha Cooler
010−AC−014 Vacuum Diesel Product Cooler
010−AC−015 VGO Product Cooler
010−AC−615 Condensate Atm Flash Drum
010−AC−616 Intermittent Blowdown Drum Air Cooler
010−C−004 Naphtha Stabilizer
010−C−005 De−ethaniser
010−C−006 De-propaniser
011−C−001 LPG Amine absorber
011−C−002 Extractor plus
010−E−035 AƒB Recontactor Trim Cooler
010−E−036 AƒB Naphtha Stabilizer Trim Cooler

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010−E−037 AƒBƒC Naphtha Stabilizer FeedƒBottoms Exchanger

010−E−038 Naphtha Stabilizer Reboiler
010−E−040 AƒB Stabilized Naphtha Trim Cooler
010−E−042 De−ethaniser OVHD Condenser
010−E−043 De−Ethaniser Reboiler
010−E−044 Sour LPG Trim Cooler
010−E−046 Depropaniser Overhead Condenser
010−E−047 De−Propaniser Reboiler
010−E−048 C4 LPG Product Cooler
011−E−001 Lean amine cooler
011−E−002 Caustic Heater
011−FA−001AƒB Flame arrestor
011−JS−001 Caustic prewash static mixer
011−K−001AƒB Air compressors & compressor package
010−P−002−AƒBƒC De−Ethaniser Bottoms Pump (Sour LPG)
010−P−013−AƒB Unstabilised Naphtha Pump
010−P−015−AƒB Naphtha Stabilizer Reflux Pump
010−P−016−AƒBƒC Naphtha Stabilizer Ovhd Pump
010−P−018−AƒB De−Ethaniser Over Head Pump
010−P−019−AƒBƒC C3 LPG Pump
010−P−020−AƒBƒC C4 LPG Pump
011−P−001AƒB Caustic prewash circ. Pumps
011−P−004 Water Caustic add. Pumps
011−P−005AƒB Water injection Pumps
011−P−006AƒB LPG productƒrecycle Pumps
011−P−007 Merox WS injection Pumps
011−P−008AƒB Caustic circulation pumps
011−P−009AƒB Wash naphtha Injection Pumps
011−P−010AƒB DSO Pumps
011−P−012 CCBD vessel pump
011−TK−001 Water break tank
010−V−007 Recontactor Drum
010−V−008 Naphtha Stabilizer Ovhd Reciever
010−V−009 De−ethaniser Ovhd. Reciever
010−V−010 Depropaniser Ovhd. Reciever
011−V−001 LPG amine knockout drum

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011−V−004 Oxidizer
011−V−005 Wash naphtha settler
011−V−006 Di sulfide separator
011−V−007 Di sulfide sand filter
011−V−008 Vent tank
011−V−011 Caustic closed blow down vessel
Battery Limit
Job Responsibilities:
2. Safety valve checkingƒline up
3. Pumpƒcompressor changeoverƒstartƒstop, lube oil & seal oil top up as per requirement
8. Air coolers startƒstop as per requirement
9. All hydrocarbon & utility battery limit valve operation as per requirement
11. Caustic make upƒdraining as per requirement
12. Catalyst dosingƒmake up as per requirement
13. Chemical preperation & dosing as per requirement
The job distributions and responsibility are indicative only. The final distributions of jobs are to be as per

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AREA-4 :VDU Furnace

010−APH−002 Flue Gas Air Preheater (VDU)
010−DS−002 MP Steam Desuperheater (VDU)
010−E−031 SAPH (VDU)
010−F−002 Vacuum Furnace
010−K−004 AƒB Vacuum Charge heater FD Fan
010−K−005 AƒB Vacuum Charge heater ID Fan
010−SK−002 Vacuum Charge heater stack
010−SL−002AƒB Vacuum Charge heater FD inlet Air filter
010−V−021 Decoking drum (VDU)
010−V−022 Steam Drum(VDU)
010−WHB−002 Vacuum Charge Heater Waste Heat Boiler
Soot Blowers
Battery limit VDU Heater Area
1. Visual checking & logging
2. Visual checking of furnace pass CƒV area, coil OƒL for any leak
3. Visual checking of individual burner for flame lengthƒImpingement.
4. Burner changeoverƒ line up as per requirement
6. Carry out soot blowing and flue gas samplingƒ blow down sampling
7. IDƒFD changeoverƒstart , lube oil top up as per requirement
8. Pump startupƒshutdown as per requirement.
12. BMS panel operationƒreset as per requirement
14. All hydrocarbon & utility heater area battery limit valve operation as per requirement
17. Miscellenous jobs as per operational requirement.

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Area:5-VDU Area

010−AC−016 Vacuum Diesel PA Cooler
010−C−007 Vacuum Distillation Column
010−C−009 Low Pressure Amine Scrubber
010−E−039 AƒB Diesel PA Cooler
010−E−053 A−M Booster Condenser
010−E−054 1st Stage Intercondenser
010−E−055 2nd Stage Intercondenser
010−E−058 VGO Seal Fluid cooler
010−E−149 HVGOƒMP Steam Generator
010−E−150 HVGO ProductƒLP Steam Generator
010−EJ−001AƒBƒC Booster Ejector
010−EJ−002AƒBƒC 1st stage ejector
010−EJ−003AƒBƒC 2nd stage ejector
010−P−021−AƒB Vacuum Diesel Pump
010−P−022−AƒBƒC VGO Product Pump
010−P−023−AƒBƒC HVGO Product Pump
010−P−024−AƒB Recycle Oil Pump
010−P−025−AƒBƒC Vacuum Residue
010−P−027−AƒB Hot Well Oil Pump
010−P−028−AƒB VDU Sour Water Pump
010−P−031−AƒB Rich Amine Pump (ARU−1)
010−P−036 AƒB VGO Seal Fluid Pumps
010−P−613 VDU Area Closed Blowdown Pump
010−V−011 Vent Gas KOD
010−V−013 Hot Well
010−V−014 Sour Gas Seal Drum
010−V−015 Hot Well Oil Coalescer
010−V−020 VGO Seal Fluid Surge drum
010−V−613 VDU Area Closed Blowdown Drum

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010−A−002 Demulsifier Dosing Package

010−A−003 Anti−foulant Dosing Package
010−A−004 Corrosion Inhibitor Dosing Package
010−A−005 Filming Amine Dosing Package
010−A−008 Phosphate Dosing Package
3. Draining condensate from KOD as per procedure.
4. Pump changeoverƒstart, lube oil top up as per requirement
9. StrainerƒFilter change over as per requirement
11. Chemical Preparation & adjustment of dosing rate as per requirement
12. Adjustment of dosing rate in steam generator accordance with blow down sample result
14. pH checking of boot water twice per shift.
Area-6: Preheat Exchanger, Desalter & Compressor Area

010−C−010 Fuel Gas Amine Absorber
010−E−057 AGO Seal Fluid cooler
010−E−102 Wet CrudeƒVacuum Diesel Exchanger
010−E−103 Wet CrudeƒAGO Product Exchanger
010−E−104 AƒBƒCƒD Wet CrudeƒTPA Exchanger
010−E−106 Wet CrudeƒKero PA Exchanger
010−E−108 Wet CrudeƒHot VGO Product Exchanger
010−E−113 AƒB Desalter Water FeedƒEffluent Exchanger
010−E−116 Desalter Water FeedƒAGO Product Exchanger

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010−E−117 Desalted CrudeƒVacuum Residue Product Exchanger

010−E−118 AƒBƒCƒD Desalted CrudeƒVGO Exchanger
010−E−119 Desalted CrudeƒLAGO PA Exchanger
010−E−122 AƒBƒCƒD Flashed crudeƒVGO Exchanger
010−E−123 AƒB Flashed CrudeƒHAGO PA Exchanger
010−E−124 AƒBƒC Flashed CrudeƒHVGO Exchanger
010−E−126 Flashed CrudeƒVacuum Residue Product Exchanger
010−E−127 AƒBƒCƒDƒEƒFƒGƒHƒJƒK Flashed CrudeƒVacuum Residue Exchanger
010−E−128 Desalted CrudeƒAGO Product Exchanger
010−E−129 Flashed CrudeƒAGO Product Exchanger
010−E−131 Desalted CrudeƒKero PA Exchanger
010−E−132 Flashed CrudeƒHAGO PA Exchanger
010−E−151AƒBƒC Vacuum ResidueƒLP Steam Generator
010−E−152 AƒB Desalter Effluent Water Cooler
010−E−202 Wet CrudeƒVac Diesel Exchanger
010−E−204 AƒBƒCƒD Wet CrudeƒTPA Exchanger
010−E−206 Wet CrudeƒKero PA Exchanger
010−E−208 Wet CrudeƒHot VGO Product Exchanger
010−E−213 AƒB Desalter Water FeedƒEffluent Exchanger
010−E−216 Desalting Water FeedƒAGO Product Exchanger
010−E−217 Desalted CrudeƒVacuum Residue Product Exchanger
010−E−218 AƒBƒCƒD Desalted CrudeƒVGO Exchanger
010−E−219 Desalted CrudeƒLAGO PA Exchanger
010−E−222 AƒBƒCƒD Flashed crudeƒVGO Exchanger
010−E−223 AƒB Flashed CrudeƒHAGO PA Exchanger
010−E−224 AƒBƒC Flashed CrudeƒHVGO Exchanger
010−E−226 Flashed CrudeƒVacuum Residue Product Exchanger
010−E−227 AƒBƒCƒDƒEƒFƒGƒHƒJƒK Flashed CrudeƒVacuum Residue Exchanger
010−E−228 Desalted CrudeƒAGO Product Exchanger
010−E−229 Flashed CrudeƒAGO Product Exchanger
010−E−231 Desalted CrudeƒKero PA Exchanger
010−E−232 Flashed CrudeƒHAGO PA Exchanger
010−E−251AƒBƒC Vacuum ResidueƒLP Steam Generator
010−E−252 AƒB Desalter Effluent Water Cooler

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010−E−616 Blowdown Cooler

010−E−017 AƒB Kerosene Product Trim Cooler
010−E−616 Condensate Cooler
010−K−003 AƒB Off−gas Compressor & compressor package
010−P−014−AƒBƒC Sidecut Naphtha Pump
010−P−003−AƒBƒC Flashed Crude Pump
010−P−035 AƒB AGO Seal Fluid Pumps
010−P−102A ƒB 1st Stage Desalter Water Circulation Pump (Train−1)
010−P−103A ƒBƒC 1st Desalter Water Circulation Pump (Train−1)
010−P−202A ƒB 2nd Desalter Water Circulation Pump (Train−2)
010−P−203A ƒBƒC 2nd Desalter Water Circulation Pump (Train−2)
010−P−610 Crude Pre−Heat (Train1) Closed Blowdown Pump
010−P−611 Crude Pre−Heat (Train2) Closed Blowdown Pump
010−P−033−AƒB Rich Amine Pump (ARU−2)
010−P−034 Amine Blowdown Drum Pump (Water ƒ Lean Amine)
010−P−301A ƒB AVU LP Flare KO Drum Pump
010−P−614 NSU Area Closed Blowdown Pump
010−P−615 AƒB Suspect Condensate Pumps
010−V−004 Fuel Gas KOD
010−V−006 Off Gas Comp. Suction Drum
010−V−003 Crude Flash Drum
010−V−019 AGO Seal Fluid Surge drum
010−V−102 A 1st Stage Crude Desalter (Train−1)
010−V−102 B 2nd Stage Crude Desalter (Train−1)
010−V−202 A 1st Stage Crude Desalter (Train−2)
010−V−202 B 2nd Stage Crude Desalter (Train−2)
010−V−610 Crude Preheat Train−1 Closed Blowdown Drum
010−V−611 Crude Preheat Train−2 Closed Blowdown Drum
010−V−016 Off Gas KOD
010−V−017 Treated Off Gas KOD
010−V−018 Amine Blowdown Drum
010−V−301 LP Flare KO Drum
010−V−614 NSU Area Closed Blowdown Drum
010−V−615 Atm Condensate Flash Drum
010−V−616 Continuous Blowdown Drum

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1.Visualƒphysical check up and logging
2.Deaslter Try line checking
3.Carry out desludging as per schedule
4.Pumpƒcompressor changeoverƒstartƒstop, lube oil & seal oil top up as per requirement
5. Adjustment of dosing rate in steam generator accordance with blow down sample result
6.Coordinateƒfacilitate the maintenance job in the area
7. Draining of FG KOD , Compressor suction KOD, Condensate KOD & Flare KOD as per
procedureƒrequirement
8. Sample collection as per scheduleƒrequirement. pH checking of brine twice per shift.
Note: The job distributions and responsibility are indicative only. The final distributions of jobs are to be
as per the shift−In−charge instruction.

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CHAPTER-6
PRE-COMMISSIONING & COMMISSIONING

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6.0 PRE-COMMISSIONING PROCEDURES:
During the final stages of construction and on completion of construction, there is a large amount
of detailed preparatory work which should be done by operating personnel in cooperation with others
at the job site. The primary purpose of this work is to acquaint the operators with the equipments, to
inspect the equipments to make certain that construction was done exactly as shown on the piping and
instrument diagrams, to insure the equipment is free of debris and construction trash, to “run in” pumps
and drivers, and to commission all utilities and supporting facilities so that these will be ready for the
startup of the process equipment. Following sections provide brief information/guidelines for carrying
out pre-commissioning activities.
6.1 PLANT INSPECTION:
Following construction, it is necessary that a careful inspection be made of the equipments to ascertain
that the construction was performed exactly as indicated on the piping and instrument diagrams. This
can best be accomplished by checking all the equipments as per the pre-commissioning check list.
6.2 CLEANING OF LINES AND EQUIPMENTS
After completion of the unit erection and hydrostatic tests, all lines and equipment must be cleaned.
The aim of this operation is to eliminate all foreign materials, such as metal pieces, welding slags and
foreign matter which would otherwise block pipes, control valves and orifices and cause damage to
moving parts of pumps, turbines and compressors.
Flushing / Blowing Methods
Velocity flushing and blowing of some assembled piping systems may be found to be required during
the Pre-Commissioning phase, in order to achieve the necessary cleanliness requirements for
operation.
Detailed Pre-Commissioning procedures defining the procedure and precautions to be taken for the
flushing / blowing activities shall be prepared. These will also take into account all the relevant points
listed in the previous section of guidance notes on blowing / flushing by test pack.
Marked up P&IDs and plot plans shall indicate, the extent and definition of the flushing / blowing or
circulation operations and as necessary, indicating the following:
a) Flushing media e.g. air, water. Source and reservoir to be defined.

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b) Maximum pressures to be used.

c) Temporary safeguarding equipment installed, e.g. temporary relief valve.
d) Location of isolation blinds and valves
e) Location of inlet and flush / blow out points. (Flush media disposal considered).
f) Items of line instruments, fittings etc. which may have to be removed,
e.g. shut-off valves and in-line items, and requirements for temporary spools.
g) During the blow / flush all vents, drains, instrument taps etc, and shall be systematically opened
to atmosphere to check that they are clear.
h) Temporary piping strainers.
i) Temporary fittings and hoses.
j) Toolbox talks as required.
k) Safety precautions to be taken and personnel required to be advised / witness
l) Schedule and sequence of activities
For air blowing, a buffer vessel, either temporary or permanent, is used to build up the air pressure
which is then released over a short period of time through the pipes generating high velocities to blow
out any construction debris. The pressure let-down valve shall normally be on the upstream side of
the system to be blown, thereby generating high velocities. This method is known as piston blowing.
On large diameter piping where no buffer is available e.g. flare headers, the pipe can be pressured up
and the air released from the pipe, by opening valves at the pipe extremities. Velocities using this
method are typically low. This method is known as packing blow. Large pipes will be blown where
possible outside normal working hours to avoid interference with any ongoing construction activities.
The timing and details of large volume air blowing shall be co-ordinated by the EPCM-1 Pre-
Commissioning Group and the planned work will be described in a daily notification to the
Construction Superintendent, Sub contractor and other affected personnel.
Flushing / Blowing Matrix
AB-1 Air Blow Method 1 Air Blow Air blow in cycles until discharge is
visually clear.
Air blow in cycles until discharge is
visually clear and then dry to pre-
AB-2 Air Blow Method 2 Air Blow & dry
determined dewpoint. Oil-free air to
be used

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Air blow in cycles until target plate at

Air Blow to target & discharge is clear and then dry to pre-
AB-3 Air Blow Method 3
dry determined dewpoint. Oil-free air to
be used
Piping is chemically cleaned to
CC Chemical Clean Chemically cleaned
approved procedure
Service flush -Hydrotest dump flush
Water Flush followed by flush with service fluid
F-1 Service Flush
Method 1 until normal fluid qualities are
attained at discharge.
Water Flush Hydrotest dump flush until discharge
F-2 Hydrotest dump flush
Method 2 is visually clear
Water Flush Hydrotest flush with Hydrotest dump flush with air assist
F-3
Method 3 air assist until discharge is visually clear.
Oil flush oil system to cleanliness
Forced circulation oil criteria as per API 686 or to Vendor
F-4 Oil Flush
flush criteria, whichever is the more
stringent.
Blow line with applicable pressure
Steam Blow steam until visually clear or minimum
SB-1 Process steam blow
Method 1 15 minutes, allow to cool for 4 hours
& repeat blow
Blow line with HP steam to target
Steam Blow Target Plate Steam plate to agreed criteria.
SB-2
Method 2 Blow Note: Blowing method to be
confirmed, continuous or cyclical
Removal of instruments
Type of instrumentation and equipment, which would usually be removed:

Control valves
 Flow and restriction orifices

 Tight shut off valves
 Angle or needle valves
 Check (non return) valves
 In line temporary strainers
 Vortex and orifice flow meters
 ESD Valves

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General Guidance on Flushing and Blowing
a) Pipe work should normally be flushed / blown to an unrestricted open end, preferably at the lowest
point in the pipe work. Main headers will be flushed/blown first to an open end of approximately
equivalent line size, followed by each sub-header, then the individual sub-header branches.
b) Single hydro-test packs may be dump flushed or pack blown if this method is regarded as effective
for the piping size and configuration. Alternatively several hydro-tests packs may be combined for
this to give extra volume. A quick opening temporary valve (ball/butterfly) at the flush/blow outlet
will also increase the effectiveness of a dump flush or packing blow.
c) A dynamic flush / blow from a temporary air reservoir, head tank or pressurised system such as
the fire main may be used for combined test packs. Upstream vessels may be used for this purpose,
where convenient.
d) Water volumes and disposal / recycling will need to be considered if water flushing is the preferred
method. Low chloride demineralised water should be used on stainless steel/alloy piping.
Combined water and air may also be considered for some large lines.
e) Where ever possible, the pump suction lines should have the spool removed and hand cleaned.
When reinstated and the suction strainer replaced the pump can then be energised and be used to
flush the downstream piping. NB: -This method will not generally be used until the System
containing the pumps has been released as RFSU (i.e. dynamic operation of the pump will normally
occur only after RFSU).
f) During flushing/blowing activities, all vents, drains and instrument taps will be systematically
opened to atmosphere to check they are clear.
g) Where vessels are used as a reservoir for flushing water, these will be continuously vented to
atmosphere through adequately sized open connections or man-ways to prevent vacuum formation
and to prevent over filling.
h) Temporary pressure relief valves may be required on permanent vessels used as air
reservoirs, if the supply air pressure exceeds vessel / system design pressure.
i) Air blowing will always be started at low velocities and the rate progressively increased. This
is to avoid hazards at the blow out points in the unlikely event of large objects / pieces of debris
being present.
j) Piping and equipment insulation and newly painted surfaces in line with the blow out point are
liable to be damaged by the force of the air and any objects being expelled from the pipe so these
require to be protected.
k) Flushing / blowing into or through heat exchangers or in-line equipment will not be permitted
until the upstream piping has been proven clean.
l) Temporary closures may be required to enable flushing/blowing operations to be executed
within certain systems.

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6.3 DRY OUT OF LINES AND EQUIPMENT
General Guidelines for Dry Out of Lines and Equipment

After completion of hydro testing or water flushing operations, it is most important to remove water
from lines and equipment to prevent the possibility of corrosion damage and rust accumulation.
In the case of most systems, immediately following completion of piping hydro testing and flushing
operations, all lines and equipment will be thoroughly drained and all free water will be removed prior
to the reinstatement of the removed in-line pipe fittings and instruments. The piping is to be air blown
to confirm cleanliness and this also serves to remove any standing or free water remaining.
Final Drying shall be accomplished by blowing the wet pipe work with dry compressed air and
checking all low point drains. This drying by sweeping with dry air will generally follow directly from
the reinstatement of the in-line items. Where it is timely and efficient to do so, the air dry-out may be
deferred until several test packs can be combined and dried simultaneously.
6.4 COMMISSION UTILITY HEADERS:

The various utility systems should be tested and placed into service as soon as the construction
schedule allows so that utilities are available for plant pre-commissioning and commissioning.
After pressure testing has been completed:
1. The system is inspected for conformity with relevant P&I drawings
2. Scale and construction debris are removed using most convenient medium (water, steam, air
blowing)
3. Tightness tests are carried out to ensure that leakage due to damaged gaskets, un-tightened flanges,
and left open drains or vents are rectified
4. Air is displaced with steam or nitrogen for systems containing hydrocarbons (fuel gas), holding
oxygen content in the system below prescribed limits.
5. Steam lines are warmed up gradually to prevent damage by condensate (or water) hammering before
steam traps and condensate lines are placed in service.
6. Instrument air system is air-blown as carefully as possible to remove oil or grease.
7. Instrument air system is dried, as much as possible, with air available in the plant.
8. During the preliminary operations, alertness and care is required from the operators, for example:
i.High level points should be vented frequently to eliminate air from liquid lines (like water)
ii.Low level points should be frequently drained to eliminate water or condensate from vapor lines
(like steam and fuel gas).
iii.Pump operation checked for vibration, high power absorption and cavitation, due to suction filter
blockage by dirt accumulation.
iv.Instrumentation carefully observed for manual operation which is generally required during start-
up and/or final tuning and setting.
The utility lines should be cleaned, preferably with the fluids which will run through them.

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A. Steam
Disconnect or by-pass all steam traps, open all vents and drains to the atmosphere and slowly let
steam into the system. First flush the main headers, disconnecting the flanges at the end of piping
systems, followed by the branch lines up to the equipment and inlet of steam traps.
Initially the line will be cold and there will be considerable condensation of steam in the headers.
Should this steam condensate be pushed through the lines at high velocity by the incoming steam,
water hammering will occur which may distort the lines and cause serious damage. In the event
of water hammering, reduce inlet steam flow rate and drain the condensate from the low points of
the system.
Shut off the vents when the system is considered free from air and when it is adequately flushed,
start the steam traps and check their operation.
B. Plant Air
Flush the system with air, execute seal tests with air and eliminate moisture by blowing.
C. Instrument Air
Disconnect all pneumatically operated equipment from the instrument air system, pressurize the system
with air, check and rectify leakages.
All moisture should be eliminated by means of repeated blowing. Finally, install the filters and connect
up the users.
D. Cooling Water
Disconnect the inlet flanges of water coolers and wash the lines; when clean water is seen emerging,
reconnect and continue with the washing. When washing is completed, a tightness test should be
performed and the system commissioned. Note any abnormal pressure losses in the system during the
pre-start up check.
E. Nitrogen
Perform tightness test of the network with air. Once the seal test has been completed, purge the network
with nitrogen, blowing through intermittently to eliminate all the air. Commission the nitrogen system.
F. Service Water
This system shall be washed completely by flushing first the main headers and then the lines
branching off to service stations and equipment inlets. Thereafter a leak test should be performed
and the system should be left in service.
G. Amine
Perform tightness test of the network with air. Once the seal tests have been completed and
immediately before commissioning purge the network with nitrogen, blowing through

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intermittently to eliminate all the air. Commission the system by introducing hydrogen by
opening the battery limit valve.
H. Caustic
Disconnect the inlet flanges of connected equipment and wash the lines; when clean water is seen
emerging, reconnect and continue with the washing. When washing is completed, a tightness test
should be performed and the system commissioned. Note any abnormal pressure losses in the
system during the pre-start up check
I. Flare
Perform tightness test of the network with air. Once the seal tests have been completed and
immediately before commissioning purge the network with nitrogen, blowing through intermittently
to eliminate all the air.
6.5 RUNNING OF MACHINERY (PUMPS & DRIVERS)
Running-in of Electrical Motors
 Ensure that electric motors have the power supply at the right voltage since higher voltage
may cause damage.
 Check rotation with the motor uncoupled from the operating machine.
 Run-in for a minimum of four hours uncoupled, verifying operability.
 Check for proper greasing of bearings.
 Check the temperature of bearings and for excessive vibration.
 Check the insulation resistance.
1. Proper installation and operation of pumps and drivers is essential for trouble-free performance.
The pumps and drivers should receive careful handling during initial run-in. The initial run-in of
pumps is generally done by circulating water through the new equipment. Temporary strainers
are installed in the intake of the pumps. During run-in of pumps, the strainers may cause some
restriction of flow, as debris collects in the strainers, and the flow to the pump will fall off. In
this event, it will be necessary to limit the flow of centrifugal pumps by throttling the discharge
valve. Avoid restricting the discharge to the extent that it will cause internal slippage and
excessive heat generation. The pump must not be permitted to cavitate, i.e., "losing suction,"
which may cause damage to the pump. In starting a centrifugal pump, the rotation should be
brought up to speed as rapidly as possible. An operating speed is attained rapidly and
automatically with motor drive pumps and the usual motor starting control.
2. The development of discharge pressure is essential to flush and lubricate the wearing rings.
Subsequently, it is advisable, where practical, to close the pump discharge immediately prior to
shutting down a centrifugal pump, to maintain maximum flush through wearing rings.
3. The discharge valve, of an operating positive displacement type pump, rotating or reciprocating,
should not be closed as this will cause over pressuring.

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4. Pumps in hot service must be gradually warmed to near operating temperature before placing in
service. Uneven expansion of the internals and casing may cause seizure and damage when
starting.
5. Following is a check list for prior-to-run-in:
6. The manufacturer's operating instructions should be reviewed for any specific precautions
that should be observed.
7. Check that the overall installation is complete.
8. Verify that the pump and driver have been aligned for cold operation. There must be no undue
strain on the pump or driver by the piping.
9. Check the water piping. Verify that the water piping is connected, where required, to bearing
jackets, pedestals, stuffing boxes, etc.
10. Check the steam piping. Verify that the steam piping, where required, is complete.
11. Check the seal or gland oil piping. Conventionally packed pumps in hot service are generally
furnished with gland oil: verify that this installation is correct and complete. When a pump is
furnished with mechanical seals, verify that all of the components of the flushing system, such
as strainers, separator, restriction orifices and coolers, when required, have been correctly
installed and are clean. It is very important that the flush system be clean since the loss of flush
or dirty flush can cause the loss of seals.
a. Verify that packing or seals are installed.
b. Check that temporary strainers in suction piping, when required, have been installed.
c. Verify that bearings and shafts have been cleaned prior to final lubrication.
d. Check that the pump and driver are lubricated according to the vendor's lubrication
instructions.
e. Check the rotation of electric motor drivers uncoupled from the pump. Run-in uncoupled,
verifying operability.
f. Run-in, uncoupled from pump, the other non-electric drivers. During run-in of the driver,
overspeed trip bearings, controls, vibration, etc., are all satisfactorily checked to confirm
operability Abnormal conditions must be corrected before coupling to the pump,
12. The pumps are normally delivering a material of lighter weight than the water circulated
during initial run-in. The pump driver is sized for the normal pumping fluid, consequently
while pumping water, the electric motors are easily overloaded. To avoid overloading the
motor driving a centrifugal pump, the flow must be limited by throttling the pump discharge
valve. If possible, check the amp usage against the design.
13. The following list is for operating the pumps during run-in:
a. Rotate pump and driver by hand, verifying that they roll freely.

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b. Check that the water supply and delivery circuits are properly lined up.
c. Open the pump suction valves fully, venting air from the piping and pump, completely
filling it with liquid.
d. Establish cooling water flow, where required.
e. Check that the pump lubrication is satisfactory.
f. Make sure that electric power is available from the switch gear to the starter of the
electric motor drivers. For steam turbine drivers, the turbine is warmed by slowly
opening the exhaust valve back-in steam while draining water from the casing. The
exhaust valve is always fully opened before starting. Where the exhaust system is under
vacuum, the case must be warmed by gradually introducing the driving steam, after
opening the exhaust valve. In vacuum exhaust systems, sealing steam to the turbine shaft
labyrinths must be admitted to avoid loss of vacuum.
g. Barely open the discharge valve of a centrifugal pump and fully open the discharge valve
of a positive displacement pump before starting.
h. Start the pump and bring it up to speed immediately, observing the discharge pressure.
If the pressure does not build immediately, stop the pump and find the cause. Refill the
pump and restart when the previous difficulty is corrected.
i. When the discharge pressure of a centrifugal pump has increased satisfactorily after
starting, gradually open the discharge valve to obtain the desired flow rate.
j. In the event of unusual noise, vibration, overheating or other abnormal conditions, shut
the pump down immediately. Correct the cause before resuming operation. Continue
checking for abnormal conditions as these may occur after prolonged operation.
k. Check safety sealing. Mechanical seals should show no leakage. Conventionally packed
stuffing boxes must always be permitted to leak slightly, to provide some lubrication
and prevent overheating. Stuffing box gland nuts are generally only finger tight. A
mechanical seal may show some leakage on startup. After the pump has been started
and stopped a few times, the leakage should stop, if the seal leakage persists, then steps
are to be taken to correct the problem.
l. Operate the pump, directing flows through all suction and discharge piping circuits.
m. Inspect and clean screens as required.
n. Recheck and realign if required, after any disturbance of piping, such as after suction
screen inspection or cleaning.
o. In shutting down a centrifugal pump, close the discharge valve first, thereby
maintaining discharge pressure while the pump rolls to a stop. This also prevents valve
leaks. Positive displacement pump discharge valves must not be closed until the pump
is shut down and rolling stops.

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p. After all lines available to the pump have had suitable flushing, the temporary suction
strainer may be removed only after showing itself to be free of debris on two successive
examinations. The permanent strainers may then be installed where required.
q. Packing, in conventionally packed pumps normally not in water service, must be
replaced upon completion of run-in and screen removal.
6.6. INSTRUMENTATION CHECKING:

1. Testing and setting of all safety valves complete prior to operation.
2. Checking out all transmission systems of each instrument after installation
3. Testing of air system to all control valves. Control valves are removed while line flushing;
when replaced, this section of the air system should be retested
4. Checking of control valve operability, i.e., stem travel, action on air failure, etc.
5. Calibration of all pressure and temperature gauges.
6. Testing all instrument lead lines for leaks.
7. Checking sealing fluid, where required.
8. Calibrate all instruments and synchronize the transmitter and receiver readings for each
instrument
9. Installation of meter factor cards.
10. After line flushing, calibrate and install all orifice plates. Check the orifice plates for plate
direction, weep hole orientation and tag accuracy.
11. Check all instrumentation for correct metallurgy.
Before any instrument is activated, it is necessary to:
1. Ensure that all primary elements are installed in accordance with the drawing and
manufacturer's requirements
2. Pressure test all instrument air lines
3. Remove shipping restrictions, such as lead plugs, tie-down wires, protective coverings,
etc., that have been applied to protect the parts.
4. Recalibrate the instrument, even if it has been calibrated by the manufacturer (also,
calibrate the entire control loop)
5. Identify all field instrument by tag plates
6. Verify the continuity of circuits from the control panel to the field and back again.

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7. Verify the action of the actuating air signal on valve position.

8. Verify movements, such as valves by their controller, and controllers by their sensing
elements.
9. Check out the action of interlock and alarm circuits to ensure that tripping an interlock
relay from its sensing point will cause all the dependent instruments to act appropriately.
Calibrate field analyzer with standard gas mixtures of certified quality according to
manufacturer’s guidelines.
6.7 PROCEDURE FOR CHECKING INTERLOCKS:

Field instrumentation check
 Shut down/blow down/on-off valves: Check installation w.r.t. drawing
 Solenoid valves, air tubing connections, power connections, check air connections are
lined up with air headers and power connections are terminated into JB.
 Carry out continuity checks for the electrical circuit.
 Carry out solenoid actuation and release of air to the valve actuator upon the receipt of
power.
 Check the valve closure/opening w.r.t. pre decided design requirements (i.e. air to open
(FC), air to close (FO) or Fail last)
 Stroke testing of control valves and SDV/BDV’s to be carried out.
 Any additional checks deemed necessary by Instrument Engineering
team/Commissioning team.
 Field Instruments/Transmitters check for flow, pressure, temperature, level and other
instruments.
 Carry out calibration of all field instruments in line with the vendor catalogue and
datasheet values. (This may involve assistance from instrumentation supplier also).
A. DCS/ESD Work
 Ensure completion of DCS/ESD configuration in line with P&ID ‘s, C&E, Logic
diagrams, alarm and trip schedule
 Ensure completion of FAT and SAT of the DCS panels, logic and hardware/software.
B. Logic Simulation checks

(These activities needs to be further elaborated by DCS/PLC supplier)
 Carry out simulation tests for process upset conditions as per P&IDs, Cause & Effect
matrix and DCS/PLC logic.
 Carry out field simulated tests (with the help of operator in field and operator in control
room) to verify the connectivity and correctness of the measuring instruments with the
DCS/ESD and also check the effect of the change of process variable beyond the trip
setting on the identified SDV or BDV or on/off valve.

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 Carry out the tests for the start/stop of the equipment (pumps, compressors) upon variation
of process variable beyond the trip setting.
 Maintain a register of systematic logic checks
 Inconsistencies to be documented and rectified and close out register to be maintained.
 Check all the process interlocks and safety interlocks by simulating the process signal
right from the primary sensor and the effect of interlock in the field or associated elements
like annunciation or indication on local panel etc. (loop check)
 Configuration notes and DCS configuration checked. (function test)
 Calibration of controllers, transmitters, analysers, special instrumentation is done.
 Alarm and trip systems have been individually tested and adjusted to correct setting.
(function test)
 Function test of DCS and PLC to be carried out by DCS/PLC supplier/s and to be
approved by licensor.
 HWC DCS lamp test to be done and fused bulbs are to be replaced.
6.8 LEAK TEST:

A plant fitness test using air should be conducted to insure that all lines and process equipment
(excluding the process pumps and the compressor) are 'tight" prior to steam purging and gas
blanketing.
The basic procedure for this step consists of pressuring the vessels and lines in the appropriate
circuit to 1 kg/cm2g and then conducting the fitness test, the test pressure should be held for
a minimum of one hour, while every flange and joint in the system is closely examined for
leaks. For this the entire unit is divided into number of leak test circuit.

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A) LEAK TEST CIRCUIT:
Note:
Circuit 10: Leak test/pressure test of off gas compressor will be carried out by Nitrogen.

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Note:
Circuit 21: This leak test ckt has been divided in 2nos of ckt as 21 A & 21 B. For vacuum test 21-B to be
followed and for leak test 21 A+21 B to be followed with minor operational adjustment as marked up.

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6.9 HEATERS (10-F-101 / 10-F-201/10-F-002) DRY OUT PROCEDURE:
The refractory lining of the heaters needs to be dried out before being put into operation.
The purpose of the dry out is to:
 Remove the moisture
 Remove the chemical water and mechanical setting of the refractory
 Recrystallization of the refractory
Unfired concretes have very low permeability. Hence the contained water has to be removed slowly
and in a controlled manner to prevent high pressure being built up within the refractory structure, which
might lead to spalling and damage to refractory.
Most of the free water is removed under 120 deg C and chemical water removal starts from @ 250 deg
C onwards.
The following section describes details the refractory dry out procedure of atmospheric heater (010-F-
101 / 010-F-201) and Vacuum heater (010-F-002) heater.
1.0 Prerequisites
Following to be checked and made available before starting the heater dry out:
1. Ensure that all the system related to heater is complete as per the P&ID and related drawings.
2. Ensure that firefighting equipment has been tested and ready for use.
3. All the instruments of the heater are calibrated and are in line. All the required instrument signals are
available in DCS/local as applicable.
4. Functionality of the BMS system to be checked.
5. Utilities headers like cooling water, services water, instrument air, plant air, LP steam, MP steam,
nitrogen and fuel gas are commissioned.
6. Coils are flushed with water/air blown.
7. For smooth control during the dry out operation, fuel gas shall be used for firing the burners.
8. Trial run of ID fan FD fan is completed.
9. Ensure Soot blowers are placed in the retracted position.
2.0 Detailed procedure for fired heaters dry out: (General)

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A) GENERAL:
The heater dry out procedure must be carried out as per dry out curve (time / temperature curves).The
lining is dried out up to 500°C and then cooled down for inspection. Once the planned heating up has
commenced, it should not be stopped or interrupted. In case of unavoidable interruption the lining must
be kept warm. If cooling-down cannot be avoided, it must be done slowly and subsequent reheating
must be carried out in accordance with the original heating up procedure.
The following guidelines are valid in general for the refractory dry-out:
-There should be a continuous flow of air through the furnace to remove the moisture.
- Flame impingement should be avoided during dry out operation.
For the drying out follow the diagram, ensuring the following additional operative precautionary
requirements. Dry out detailed procedure unit wise is elaborated subsequently.
The flue gas temperature shall be read before the convection section.
Install extra temporary thermocouples in top of heater and before convection tubes. It is important to
monitor the flue gas temperatures, when radiant burners are used to carry out the drying.
If any temperature approaches the design temperature of (radiant and / or convection tubes) some means
of protection must be established.
Normally the convection tubes shall be cooled to maintain them under the design temperature. This
operation reduces the heat exchange in the convection walls making the heating procedure incomplete.
To assure a full dry-out of convection walls, it is acceptable to reach initially the design temperature of
convection tubes and to complete the dry out when the unit will go into operation, reaching the
operating temperature at a rate not exceeding 15 °C/hour
Dry out Curve-
 Raise the temperature from ambient to 120 °C slowly (Approx. 10~15 °C/Hour)
 Hold the temperature at 120 °C (+/- 10 °C) for 36 hours.
 Raise the temperature to 250 °C gradually @ 15~20 °C / Hour.
 Hold the temperature at 250 °C (+/- 10 °C) for 36 Hours.
 Raise the temperature to 500 °C gradually @ 15 ~ 20 °C / Hour.
 Hold the temperature at 500 °C (+/- 10 °C) for 36 Hours.
 Start gradual cooling @20~25 °C / Hour to 250°C and then switch off burner.
 Allow natural cooling
 Dry out shall be carried out in following manner.
 Obtain mechanical clearance from client.
 Box up
 Burner hook up
 Check all thermocouple

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 In case more thermocouple is required, temporarily install & provide connection to local &
temporary panels.
 Connect permanent thermocouple to the temporary panel.
 Identify the heater area as operational & restrict all erection, welding work with the specified area.
 Make provision for fire fighting
 Start pilot/ main burner with actual fuel gas
(Usage of external fuel is not recommended, in case of urgency the usage may be discussed)
 Control tube skin temperature with steam circulation.
 Establish temporary connection from steam header to heater coil & provide suitable draining
system.
 At drain point noise level is to be controlled.
 Coil metal temperature can be controlled with varying steam flow or spraying water on steam inlet
or removing insulation of inlet steam line.
 Avoid condensate entry to coil to avert water hammer within coil.
 Carry out dry out procedure as per attached graph
 Monitor flue gas temperature at stack damper outlet (tag no.)

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B) Operational steps involved in heater DRY-OUT
1. Line up heaters as per standard procedure.

2. If the heater dry out will take place one at a time, ensure that the fuel gas line to other Heater is isolated
and vice-versa.
3. Close the combustion air registers of all burners.
4. Warm up the firebox as much as possible just using the pilots. Increase the FG pressure to the pilots to
the max value consistent with proper pilot operation.
5. Once the max temperature attainable with the pilots as stabilized for 8 hours, proceed with lighting the
main burners.
6. Keep stack damper to minimum opening initially. The damper opening to be controlled manually base
on the draft and arch pressure. Arch pressure to be maintained 6 MMWC at the convection section inlet.
7. Once the main burners are lit, temperature of the heater shall start increasing gradually.
8. Light more burners as needed.
9. The temperature referred to in the curve is the top of the radiant section.
10. Monitor the refractory temperature in DCS.
11. Monitor the tube skin temperature in DCS.
12. Care needs to be taken while increasing the temperature to avoid hammering in the coils. If hammering
occurs, hold on raising the temperature until the hammering stops.
13. Rotate burners on hourly basis for uniform dryout of the refractory.
14. Increases the fuel gas pressures as required and rotate the burners to keep uniformity.
15. Monitor the skin temperature.
16. Monitor the pressure at various points inside the heater by means of local draft gauges
17. Regularly monitor the FD fans bearing temperature and for any abnormal sound.
18. Carry out the physical checking round the clock from the peep doors at regular intervals.
Frequently monitor the burners for flame stability, completeness of combustion flame length, tubes
impingement, etc.

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19. If deemed necessary to use MP steam in each pass coils through emergency steam line, once
temperature increased above 200 ° C after making sure that all the condensate has been drained off..
20. Stop the steam supply (if used) to the heater tubes and use nitrogen to remove any condensate from
the tubes. Maintain arch temperature of 200 deg C until no steam is coming out at the coil outlet.
21. Once the heater arch temperature has dropped to 150 deg C, put off all the burners, stop FD.
22. Stop pilots one hour after the last main burner has been stopped, and the purging operation has been
completed.
23. Allow the heater to cool naturally down to 60 deg C. The FD fans can then be started to further cool
the heater to less than 40 deg C for personnel entry.
24. In case of any disruption during the dry out cycle, stop FD fans immediately and close the outlet
damper to avoid faster cooling of the heater. Stop steam to the coils.
C) TAGS RELATED TO HEATER DRYOUT
FUEL GAS
Tag No Description
PI9023 Pressure Indication at B/L
FI9005 Flow Indication at B/L

LT1012 V-004 Level Transmitter
FURNACE 010-F-201
FI1574 FG to 010-F-201 Flow Indication
XZV 1522/1549 FG to 010-F-201 shut off valve

XZV 1523/1553 Pilot gas to 010-F-201 shut off valve
PCV1669 Pilot gas to 010-F-201 pressure control valve
PZT 1665 A/B/C FG to 010-F-201 low low pressure switches

PIC 1666 FG to 010-F-201 pressure controller

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FURNACE 010-F-002
FIC 3005 FG to 010-F-002 Flow Indication
XZV 3026/3048 FG to 010-F-002 shut off valve
XZV 3027/3052 Pilot gas to 010-F-002 shut off valve
PZT3080 FG to 010-F-002 low low pressure switches
PIC3079 FG to 010-F-002 low pressure switches
FURNACE 010-F-101
FI1074 FG to 010-F-101 Flow Indication
XZV1022/XZV1049 FG to 010-F-101 shut off valve
XZV1023/XZV1053 Pilot gas to 010-F-101 shut off valve

PZT 1165A/B/C FG to 010-F-101 low low pressure switches
PIC1166 FG to 010-F-101 pressure controller
FUEL OIL
Tag No Description
FO BATTERYLIMIT CONDITIONS
PI 9031 Pressure Indication at B/L
TI 9002 Temperature Indication at B/L
FI 9008(FO supply)/ Flow Indication at B/L

FI 9007(FO return)/
PDI 1076 Pressure Differential across strainer in FO supply to 10 F101/201
TI 9002 FO Supply Temperature

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FURNACE 010-F-101
PDIC-1162 Pressure Differential between steam and FO
FI 1079 FO Supply to 10-F-101 Flow Indication
FI 1080 FO Return from 10-F-101 Flow Indication
XZV 1024 FO Supply to 10-F-101 shut off valve
FDI 1081 FO flow differential between supply and return
XZV 1026 FO Return from 10-F-101 shut off valve
PV1161 FO Supply to 10-F-101 Pressure Control Valve

PI 1171 FO supply pressure to burners
PDZT 1083 A/B/C Low differential pressure switch between steam and FO
PZT 1172A/B/C Low Low FO pressure
FURNACE 010-F-201
PDIC-1662 Pressure Differential between steam and FO

FI 1580 FO Return from 10-F-201 Flow Indication

PZT 1672A/B/C Low low FO pressure

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FURNACE 010-F-002
PDV3085 FO Differential Pressure Control Valve
PDI 3118 Pressure Differential across strainer in FO supply to 10 F 002
FI 3052 FO return to 10-F-002 Flow Indication


PZT 3084A/B/C Low low FO pressure
010-F-101
Tag No Description
TI-1126-A to TI-1126-H 010-F-101 Convection Outlet Temperature Indication
PI-1036 A to PI-1036 H 010-F-101 Convection Outlet Pressure Indication
TI1067-A to TI 1067-H 010-F-101 Radiant Coil Outlet Temperature Indication
PI 1002-A to PI 1002-H 010-F-101 Radiant Coil Outlet Pressure Indication
TI 1127 A-H Convection tube skin temperature
TI 1117 A-H Radiant tube skin temperature
FV-1085 MP Steam flow to 010-F-101 convection section
TV-1134 Temperature control of LP steam to convection section
TI1133 Superheated LP Steam from 010-F-101 convection section

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TI1132 Superheated MP Steam from 010-F-101 convection section
FZT-1084A/B/C Combustion air flow low low
TI1111A/B/C/D 010-F-101 Arch Temperature
TI 1126A-H 010-F-101 Crossover Temperature
TI1204A/B,TI-1203A/B 010-F-101 Convection Temperature
TI-1149 A/B/C/D 010-F-101 Radiation Temperature
PZT1124 A/B/C 010-F-101 Radiant Box pressure Hi Hi Switch
AIC-1002 Oxygen analyser
010-F-201
Tag No Description
TI-1626-A to TI-1626-H 010-F-201 Convection Outlet Temperature Indication
PI-1536 A to PI-1536 H 010-F-201 Convection Outlet Pressure Indication
TI1567-A to TI 1567-H 010-F-201 Radiant Coil Outlet Temperature Indication
PI 1502-A to PI 1502-H 010-F-201 Radiant Coil Outlet Pressure Indication

TI 1627 A-H Convection tube skin temperature
TI 1617 A-H Radiant tube skin temperature
FV-1585 MP Steam flow to 010-F-201 convection section

TI1633 Superheated LP Steam from 010-F-201 convection section
TI1632 Superheated MP Steam from 010-F-201 convection section
FZT-1584A/B/C Combustion air flow low low
TI 1626A-H 010-F-201 Crossover Temperature

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010-F-002
Tag No Description
TI 3083 A - H 010-F-002 Convection Outlet Temperature Indication
PI-3039 A to PI-3039 L 010-F-002 Convection Outlet Pressure Indication

TI 3002 A - L 010-F-002 Radiant Coil Outlet Temperature Indication
PI 3010-A to PI 3010-L 010-F-002 Radiant Coil Outlet Pressure Indication
TI 3082 A-L Convection tube skin temperature

TI 3094 A-L Radiant tube skin temperature
TI 3028 Superheated LP Steam from 010-F-002 convection section
TI 3029 Superheated MP Steam from 010-F-002 convection section

FZT-3072A/B/C Combustion air flow low low in 010-K-004A suction
FZT-3073A/B/C Combustion air flow low low in 010-K-004B suction
TI 3083A-L 010-F-002 Crossover Temperature

TV 3021 MP steam Desuperheater

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APH /WHB SYSTEM
Tag No Description
010-F-101/201
TI-1208 WHB flue gas inlet temperature
PI-1039 WHB flue gas inlet pressure
XZV - 1028 WHB flue gas inlet ESDV
TI-1017 WHB flue gas outlet temperature
PI-1040 WHB flue gas outlet pressure
TI-1211 APH flue gas inlet temperature

XZV-1031 APH flue gas inlet ESDV
XZV-1029 APH & ID FAN bypass damper
XZV-1030 APH flue gas bypass damper

TI-1152 FD fan disc. temperature
PI-1182 FD fan disc. pressure
TI-1228 APH combustion air inlet temperature
PI-1212 APH combustion air inlet pressure

TV-1072 APH combustion air bypass damper
PI-1023 APH Pre-heated air outlet pressure
TI-1150/TI-1229 APH Pre-heated air outlet temperature
FV-1082 Pre-heated air flow to F-101

FV-1582 Pre-heated air flow to F-201
PV 1098 010-F-101/201 Stack Damper

TI 1210 010-F-101/201 Stack Temperature
PV-1035A/PV-1036A ID FAN suction c/v for 010-K-002A/B
PI-1138 ID suction pressure

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PI-1177/ PI-1178 ID discharge pressure 010-K-002A/B
PI-1210 Stack pressure
AI-1004(SOX),1006(NOX), Stack Analysers

1001(CO/CO2),1009(VOC),1010(PM)
PI-1074 BFW steam drum inlet temperature
TI-1205 BFW steam drum inlet pressure
FIC-1057 BFW steam drum inlet flow
LIC-1057 Steam drum level controller
XZV-1044 Steam drum inlet SDV

PI-1075 Steam drum pressure
TI-1206 Steam drum temperature
FI-1125 MP steam flow
010-F-002
TI-3100 WHB flue gas inlet temperature
PI-3096 WHB flue gas inlet pressure
XZV - 3012 WHB flue gas inlet ESDV

TI-3018 WHB flue gas outlet temperature
PI-3097 WHB flue gas outlet pressure
TI-3103 APH flue gas inlet temperature
XZV-3011 APH flue gas inlet ESDV

XZV-3061 APH & ID FAN bypass damper
XZV-3022 APH flue gas bypass damper

TI-3038 FD fan disc. temperature
PI-3094 FD fan disc. pressure
TI-3133 APH combustion air inlet temperature

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PI-3117 APH combustion air inlet pressure
TV-3019 APH combustion air bypass damper
PI-3043 APH Pre-heated air outlet pressure
TI-3078/TI-3134 APH Pre-heated air outlet temperature
PV 3118 010-F-002 Stack Damper
TI 3102 010-F-002 Stack Temperature
PV-3020/PV-3012 ID FAN suction c/v for 010-K-005A/B
PI-3098 ID suction pressure

PI-3033/ PI-3034 ID discharge pressure 010-K-005A/B
PI-3141 Stack pressure
AI3003(SOX),3002(NOX),3005(CO/CO2), Stack Analysers

3008(VOC),3007(PM)
PI-3036 BFW steam drum inlet temperature

TI-3105 BFW steam drum inlet pressure
FIC-3043 BFW steam drum inlet flow
LIC-3043 Steam drum level controller

XZV-3060 Steam drum inlet SDV
PI-3035 Steam drum pressure
TI-3104 Steam drum temperature
FI-3074 MP steam flow
6.10 PURGE AIR FROM THE UNIT AND GAS BACK UP:
This operation is generally carried out after the leak test. The purpose of this step is to remove air in the
unit before taking hydrocarbon into the system. Air is purged from AVU prior to the introduction of
hydro carbons, using LP Steam as the purging medium. Nitrogen purging should be used where the
temperature of LP steam could exceed the upper design limits of equipment, as with the desalter bushing
materials. Whichever medium is used, the O2 content should be less than 0.5% volume before

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hydrocarbons are introduced. Desalter, off gas compressor system, flare system and the fuel gas lines
will be purged with nitrogen .All other systems will be stream purged followed by fuel gas backing.
A) Steam Purging of Crude Section

At any point of time while doing the steam purge, the system pressure should not exceed more than
1.0-1.5 kg/cm2g.
At the completion of equipment steam-out, care must be taken when closing atmospheric vents.
Operators should not approach a vent until the steam flow has been reduced to a minimum, but
should close the vent valve prior to the final closing of the steam supply to prevent ingress of air in to
the equipment. With the vent valve and steam out valve closed, fuel gas must be admitted to the
system to prevent the possibility of a vacuum occurring during the cooling down of the equipment.
Similarly for N2 purge, the system pressure should be > 1.0 kg/cm2g. To eliminate the risk provoked
by condensation of steam and accumulation of water, if any, resulting in severe hammering in the
heater coils, the pilots of the Crude charge heaters as well as the vacuum heater and some burners
should be lit to maintain 150 deg C skin temperature in the heater coils in the firebox.
B) Preparations for Steam out

Carry out following jobs prior to steam-out operation:
1. Isolate all Pumps and Compressors.
2. Isolate all instruments related to steam out systems.
3. Ensure all PSVs associated to steam-out system are lined up (including spare PSV, to confirm the
passing of PSV during steam out, which can be hand over for maintenance).
4. Isolate cooling water to all coolers and condensers, drain the cooling water completely and keep
open the vents in cooling water side during steam out.
5. Stop the overhead condenser/product cooler fans and keep open the high point vents in exchanger
bundle during steam out.
6. Strainer assembly: Keep strainer and its bypass in line during steam out.
7. For 010-C-001 Crude column:
a. Isolate Corrosion inhibitor.
b. Isolate Amine Neutraliser.
c. Isolate Fuel gas.
d. Isolate Nitrogen.
e. Note: During steam out open drain at NRV d/s to ensure clear steam comes out for all the
above injection lines.

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f. Stop the Overhead condenser fans.

g. Close P-007A/B/C discharge to F-002(Vacuum heater).
h. Open P-007A/B/C discharge through
i. For Train-1: 010-E-127A-E(SS), 010-E-126(SS), 010-E-117(SS), 010-E-151A/B/C tube side
to start up recycle line.
j. For Train-2: 010-E-227A-E(SS), 010-E-226(SS), 010-E-217(SS), E-251A/B/C tube side to
start up recycle line.
k. Close E-127/227 shell out to C-007 as VR quench and to F-002 as VR Recycle.
8. Isolate the following for 010-V-005 (Crude column overhead receiver):
a. Fuel gas through PV-1072A.
b. LP Flare through PV-1072B.
9. Isolate following for 010-V-006 (Off Gas compressor Suction KOD): a. Nitrogen through FO-
2026.
10. Connect a LP steam hose in wild naphtha line at battery limit for Crude flash drum (010-V-003).
11. Keep close the control valves and open its bypass valve for the following circuits during steam
out. Ensure the upstream and d/s drains on these control valves are open:
a. TPA circuit
b. Kero PA circuit.
c. LAGO PA circuit.
d. HAGO PA circuit.
12. For 010-K-003A/B (Off gas compressor :
a. Drop the suction spool.
b. Drop the discharge spool.
c. Isolate N2 purge to K-003A/B.
d. Close all flare connections from the compressors.
13. For 010-C-004 (Stabiliser):
a. Isolate N2 purge at column overhead vapour line.
b. Isolate Corrosion inhibitor at overhead vapour line.
14. For 010-V-008 (Stabiliser Overhead receiver):
a. Close 010-PV-2018B & HZV-2008 to flare from the vessel
15. For 010-C-005 (Deethaniser):
16. For 010-C-006 (Depropaniser):

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b. Close HZV 2012 to flare from 10-V-010
17. For 010-V-009:
a. Isolate PV-2065/HZV-2013 to flare.
18. For Off gas KOD:
a. Isolate N2 connection to V-016 inlet from V-007/009.
b. Isolate 1st isolation valve of Off gas line from NHDT at battery limit.
19. For Amine Absorber:
a. Isolate 1st isolation valve on Lean Amine line from U-083 at battery limit
b. Isolate 2nd isolation valve on Rich Amine line to U-083 at battery limit
20. Keep all drains and vents on the columns, vessels, exchangers open to atmosphere or to OWS.
21. Keep both desalters isolated and bypassed
22. Connect temporary steam hose at P-007 discharge to purge out the VR system up to the battery
limit.
23. Connect temporary steam hose at Crude side of preheat train
24. In the steam out loop include the sour water outlet header from boots of 010–V-007/008/009/010,
till battery limit.
C) Steam out Operation for Crude section

Ensure the crude heater pilots are lit and the skin temperature of the coil is maintained above 150 deg
C
o Introduce emergency steam to all coils
o Commission steam to super heater coils
o Stripping steam to Crude column 010-C-001 through FV-1034,
o Stripping Steam to 010-C-008 (HAGO stripper) through FV-1028,
o Stripping steam to 010-C-003 (LAGO stripper) through FV-1023,
o Stripping Steam to 010-C-002 (Kerosene stripper) through FV-1020
o Steam at battery limit on wild naphtha line to V-003 (Preflash drum).
o Open steam to crude line at battery limit, d/s of desalter, and d/s of Preflashed crude
pump.
For Crude column over head:

o At Steam out point for V-005.(Crude column Overhead receiver)

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o At steam out point for V-006 (Off Gas suction KOD).

o At steam out point for V-007 (Recontactor drum).
o Connect steam at FV-1072/1030 to V-007 through AC-008.
o Connect steam hose on P-010A/B common discharge vent(1.5”)
For Stabilizer:
o At steam out point for V-008 (Stabiliser overhead drum).
o At Stabilizer bottom (010-C-004).
o Connect steam at FV-2017/2001 to C-004 through E-037A-C.
o Connect steam hose on P-015A/B common discharge vent (1.5”).
o Connect steam at shell side of E-038.
For De-Ethaniser:
o At steam out point for V-009 (De ethaniser Overhead drum)
o At De-Ethanizer bottom (010-C-005).
For De-Propanizer:
o At steam out point for V-010.
o At De-Propanizer bottom (010-C-006).
o Connect steam hose at sweet LPG feed line from Unit-011.

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o Connect steam hose at sour LPG feed line to Unit-011.
For Off gas KOD:

o Stripping steam from LS header.
o Steams purge of off gas at battery limit.
o Open the vent from V-016 top.
For Amine Absorber:

o Open the vent from C-010 top.
For Treated gas KOD:

o Open the vent from V-017 top.

Additional bonded hoses, suitable for steam duty should be connected up to equipment and piping where
hard piped steam out connections are not available. Condensate must be drained from all steam supply lines
before opening up to equipment. Open the vents and Drains on vessels and towers and all low point drains
on pipelines which are to be steamed out.
Slowly admit steam and gradually open the valves wide. Ensure a good flow of steam from all vents and
drains. Continue the steaming for 24 hrs. The steaming should be followed by gas backing to prevent air
ingress into the system and also to avoid vacuum inside the columns and vessels. Under no circumstances
should any equipment be subjected to vacuum. Close the vents, drains and pressurise the system up to 1.5
kg/cm2 with steam and check for leaks. Arrest the leaks.
Once the system pressure is stable, admit fuel gas into the system and gradually cut down the steam to the
system with all vents and drains in closed condition. Finally cut off Steam to the system and continue to
admit fuel gas into the system till there is a sharp rise in pressure in the system indicating the complete
condensing of all steam inside system. Close fuel gas and drain condensate from all low points Maintain a
slight positive pressure in the system with fuel gas. The system is now ready for admitting oil. Keep pilots
on in the heaters
D) Steam out Operation for Vacuum section:

1. Carry out following jobs prior to steam-out operation: Isolate all pump suction and discharge.
2. Isolate all instruments related to steam out systems in Vacuum section.

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4. Isolate following for 010-C-007:

i. Corrosion inhibitor.
ii. Amine Neutraliser.
iii. Nitrogen.
iv. Fuel gas
5. Isolate cooling water to ejector condensers, Vacuum diesel PA coolers.
6. Stop the following fin fans while doing steam out:
7. Vacuum diesel PA/Product coolers (AC-016/014).
8. Combined VGO product cooler (AC-015).
9. Close P-007A/B/C (Crude column bottom pump) discharge to F-002.
10. Close VR Recycle to F-002 and also to the VR pump discharge
11. Ensure all FLO supply to LTs is closed.
12. Line up VR Pumps discharge through E-127/227 A-E as start up recycle to F-002, as VR Quench
to C-007 and Keep superheated LP STEAM ready for steam out of 010-C-007.
13. To eliminate the risk provoked by condensation of steam and accumulation of water if any, the
pilots of the Vacuum heaters (010-F-002) and some burners if required may be lit to maintain
1500C on the coil skin.
14. Recycle oil loop: Line up from D5 of C-007 to P-024A/B suction isolation valve, discharge back
to C-007, P-024A/B vent back to C-007.
15. Keep close the control valves on the CR and IR circuits of the following system and keep open the
bypass. The drains on the upstream and downstream of the control valve should also be kept open
for steaming. Keep open the valves on the Strainers and its bypass for the following circuits during
steam out:
i. Vacuum diesel circuit.
ii. LVGO PA circuit (both in IR &CR).
iii. HVGO PA circuits (both in IR &CR).
iv. Wash oil circuit.
16. After completing the steam out without fail close strainer bypass. While doing the steam out for
these circuits keep open the vents on shell side for the steam generators and also ensure that the
steam generators are empty without BFW on their shell side. (E-149, 150, E-151A/B/C, E-
251A/B/C).
i. Vacuum column overhead section:
ii. Line up steam out connections for both compartments of V-013(Hot well drum).
iii. Line up from V-013 oil side to P-027A/B suction and water side to P-028A/B
suction.

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iv. Line up steam out connections for hot well oil coalescer.
v. Ensure coalescer vent is kept open; Line up boot back to hot well drum and top oil
out to DHDT till the battery limit.
vi. Sour gas seal drum (V-014): Line up vessel bottoms to hot well (V-013) and over
head gas to LP Scrubber (010-C-009).
17. Low pressure scrubber:
i. Line up steam out connections for LP Scrubber.
ii. Line up from C-009 bottoms to P-031A/B suction and P-031A/B discharge up to
battery limit and ensure battery limit isolation valve is closed.
iii. Line up Lean Amine line from battery limit to 010-C-009
Steaming Of vacuum section and Gas Back up:-

Open emergency steam to each pass of F-002. Ensure a skin temp of 150°C on the Vac. heater coils
before admitting steam to the coils. Open stripping steam to vacuum column. Do the steam out for
Vacuum section, in C-007,Vacuum diesel PA, Vacuum diesel products, LVGO,HVGO PA/Products,
wash oil circuit and VR circuits. Open the vents and Drains on vessels and towers and all low point
drains on pipelines which are to be steamed out. Slowly admit steam and gradually open the valves
wide. Ensure a good flow of steam from all vents and drains. Continue the steaming for 24 hrs. The
steaming should be followed by gas backing to prevent air ingress into the system and also to avoid
vacuum inside the columns and vessels. Under no circumstances should any equipment be subjected
to vacuum.
Close the vents, drains and pressurize the system up to 1.5 kg/cm2 with steam and check for leaks.
Arrest the leaks. Once the system pressure is stable, admit fuel gas into the system and gradually cut
down the steam to the system with all vents and drains in closed condition.
Finally cut off Steam to the system and continue to admit fuel gas into the system till there is a sharp
rise in pressure in the system indicating the complete condensing of all steam inside system.
Close fuel gas and drain condensate from all low points Maintain a slight positive pressure in the
system with fuel gas. The system is now ready for admitting oil. Keep pilots on in the heaters.
Note: At any point of time during steam out operation, the system pressure should never exceed more
than 1.5 kg/cm2g. Flares, Fuel gas and fuel oil systems should be nitrogen purged to reduce the oxygen
contents to below 0.5%. Lines containing low spots should be drained from LPD. Underground lines,
without drains, should be blown free of water. Before draining any vessel, a vent must be opened on
that vessel so that a vacuum will not be created on draining.
E) Purging off gas Compressors (010-K-003A/B)

a. Isolate the Compressors from its suction and discharge piping which undergo steam out operation.

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b. Strictly follow the Compressor vendor procedure to purge out with N2 to bring down the O2 content
of the compressor circuit to less than 0.5volume%.
c. Carry out the leak test of the system and ensure the pressure drop is 0.1 kg/cm2per hourmax.
d. Bottle up the compressor system with N2.
e. Ensure all compressor accessories are ready for service.
F) Vacuum test
a. Vacuum test is carried out on the vacuum system by pulling vacuum after carrying out the pressure
test with air.
b. The system is to be isolated from other systems before pulling vacuum.
c. A vacuum test on the vacuum tower and the associated overhead system will be carried out after
the VDU has been pressure tested with steam.
d. Tape all flanges on the VDU column, overheads system, and furnace.
e. Shut off the steam supply to the VDU. Ensure the system is maintained under slight positive
pressure. Fill up Hot well on water side and ensure the barometric legs are immersed in water level.
Commission cooling water to all overhead condensers on the vacuum column overhead.
f. Bring the ejectors on line starting from the smallest ejector ( 010-EJ-003 A/B/C), one ejector at a
time and reduce the pressure in the VDU to a maximum of 27 mm Hg. Route condensed water from
010-V-013 to OWS.
g. Close the steam and hold vacuum conditions for 4 hours and check for leaks. If the raise in pressure
(i.e. fall in vacuum) is in the range of 20 to 30 mm Hg/hr, then it is acceptable and the system is
considered as tight.
i. Break the vacuum with fuel gas, to slightly above atmospheric pressure.
ii. The flare headers are purged with Nitrogen and then the nitrogen is displaced with Fuel
gas. Flare headers should not be steamed.

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6.11 PRECOMMISSIONING SCHEDULE
Total Day
No. of Days Start Day End Day
Reqd.
Piping and P&ID Check
Loop Check and Format II issuance 150 -180 -31
Confirming Liquidation of Punch Points 141 -150 -10
Final Check of Liquidation in Format IV 41 -40 0

GSFC Audit 239 -180 58
OSBL Hook-ups Checking 11 -10 0
Equipments Check
Furnaces Check & Liquidation of Punch
91 -180 -90
Points
Columns , Vessels & Heat Exchangers

91 -180 -90
Check & Liquidation of Punch Points
Off Gas Compressor & Turbine Check &
21 -40 -20
Liquidation of Punch Points
Pumps & Air fin coolers Check &

91 -90 0
Liquidation of Punch Points
Electrical Related Checks

Proper Earthing of Motors, exchangers,
91 -180 -90
vessels, column
Push Buttons approach & checking of local

11 -10 0
control panel of Motors
Utilities Commissioning
Utility Line Flushing, Leak Testing, Drying
18 0 17
& Blowing

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Total Day
Reqd.
Utilities Commissioning (Plant Air,
Instrument Air, Fire Water, Service Water, 4 5 8
Drinking Water & DM Water)
Utilities Commissioning (Other than above) 11 58 68
Flushing and Blowing of Process Lines
Flushing of systems with identified medium,

41 18 58
Blowing,Drying ,Box up & Leak test
Chemical Cleaning of Equipments

Off Gas Compressor Suction/Discharge
11 30 40
Chemical Cleaning
Amine Degreasing of Amine lines 11 35 45
Preservation of Amine Circuit with inert

3 46 48
atmosphere
Alkali Boilout of steam generator System 21 25 45

Passivation of Cooling water System 6 10 15
Lube Oil circuit Preparation for compressor 6 50 55
Instruments Checking and Calibration

Instrument Loop checking (Open & Close
61 -50 10
loop)
Checking & calibration of transmitter (Flow,

31 -30 0
Pressure, Temp)
Checking of Orifice Plate 49 10 58
Witness calibration of the critical level

transmitters and reconfirm with local sight 6 70 75
glass for uniformity.
Control valve stroke checking 11 50 60

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Total Day
Reqd.
DCS & ESD checking Interlock checking 11 55 65
Confirm calibration of gas detectors,

11 60 70
continuity check of hooter and beacon.
MCP continuity check with fire station

12 55 66
control room
Confirm calibration of Analysers. 6 19 24
DCS Related Activities

Checking of DCS/ESD Graphics 121 -180 -60
Checking range of all instrument tags 21 45 65
Checking of alarm summary , alarm values

11 50 60
& Trip values
Simulation test of safety interlocks and

11 40 50
shutdown systems
Checking of Motor Running indication in

6 60 65
DCS
Dry run of PLC & critical instrument logics 16 25 40
Electrical Related Activities

Joint checking of lighting in Operating area 11 -60 -50
Check and confirm operation of plant
11 -51 -41
emergency lighting.
Checking of electrical continiuty for LPG

3 60 62
lines
Witness motor trial run of rotary equipment

(including all fans) in decoupled condition; 39 -68 -30
confirm for proper direction of rotation.
Communication/Detector System
Checking

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Total Day
Reqd.
Checking of fire fighting system, alarms,
8 45 52
MCP, Panel check up and preparedness.
Confirmation on installation of
communication system, Pagers, walkie- 11 -10 0
talkie, Field telephone.
Checking of installation & performance of

3 20 22
CCTV's
Valves Related Jobs
Checking & calibration of all safety valve 169 no’s 18 -27 -10
Smooth Operation & accessibility of all
4965 nos. 151 -180 -30
isolation valves
Checking of direction of NRV's 54 5 58
Column/Vessel
Seal Pan Leak test 21 -20 0
Chimney Tray Leak test 21 -20 0
Manway Box up 11 -10 0
Deblinding of all Column Nozzles 6 41 46
Final Box up 10 41 50
Rotary Equipments Test Run

97 Process
Pumps 34 27 60
Pump
Coupling of all pumps

Lube oil filling
Seal flushing system checking
Installed temporary strainers

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Total Day
Reqd.
Steam condensate drain and warm up before
line up turbine driven pump.
Mechanical run test of pumps
Off Gas Compressor 7 41 47
Coupling
Flushing of Lube oil circuit and dry the

circuit
Lube Oil filling and circulation
Instrument fixing
Line up of utilities to the package items
Identify leak if any & arrest the same
Checking the operation of the baring system
Ensure installation of coupling guard.

Installation of strainer
Compressor Leak test & Line up of dry gas

seal system
Mechanical run test of Compressor
Air fin coolers 66 motor 19 -30 -12
Coupling
Lube oil filling

Ensure installation of coupling guard & Fan
Mesh
Mechanical run test of Air Fin Coolers
Furnaces Pre-Commissioning
Flushing of Furnace Loops 98 system 33 10 42

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Total Day
Reqd.
Instrument functionality test & inter lock Close loop-
8 43 50
systems 87.I/L-56
Burner (pilot, Gas, Oil) alignment check 52 no’s 26 -35 -10
Ensure all Dampers opening/ closing and

marking of the close and open position of
8 43 50
duct dampers both manual and from DCS.
Calibration of Damper
Lube oil filling in FD/ID fan Gear Box

FD/ID fans - Motor trial run 8 27 34
Burner management system checking 6 51 56

Checking of Igniters 6 no’s 1 57 57
Checking of operability of isolation valves

of Pilot Burners, Gas burners, Fuel oil and 228 valves 21 -30 -10
atomising steam valves
Shoot Blowers - Motor trial run 49 no’s 10 27 36
Checking of Soot blowers and its
49 no’s 10 37 46
functionality, retreatability, Local panel
Operability & clearance of furnace explosion

8 no’s 1 43 43
doors
Box-up of Furnace after cleaning 10 46 55
Decoking System Checking 6 43 48
Preparedness of Refractory Dry Out 3 49 51
Refractory dry out 14 52 65

Checking of Refractory after refractory dry
11 60 70
out followed final box up
Checks prior to commissioning

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Total Day
Reqd.
Ensure readiness of associated offsite
10 51 60
storage facilities and line up to OSBL
Check and confirm that the spring supports

locks are unlocked before commissioning of
the line.
Loading of Chemicals
Internals Checking and cleaning of storage
6 Package 10 -89 -80
vessel
23 Dosing
Calibration of Dosing Pumps. 12 40 51
Pump
Loading of the chemical 12 54 65
Final Leak Test/Vacuum Checks

Final leak Check of all process systems 29 40 68
Vacuum check for Vacuum System 5 60 64
Inertization of Process Lines

Inertization of Process Lines by charging
6 65 70
N2/Steaming and subsequently charging FG
Civil Related Checks
Proper segregation of OWS and CRWS

31 -30 0
network and marking of manholes
Ensure that unit peripheral drains, pits etc

11 -10 0
are properly covered
OWS hookup before HC in 3 68 70
6.12 COMMISSIONING SCHEDULE

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Total Day No. of

Start Day End Day
Reqd. Days
Commissioning Activities of CDU
Steaming of Exchangers,Columns,Vessels 12 12 1 12
Gas backup and condensate draining 1 1 13 13

Crude reciept and water draining 1 1 14 14
Chemical solution preparation 1 14 14
Cold circulation & water draining 1 1 15 15
Furnace lightup,hot circulation and water draining 1 1 16 16
Increase of COT @25oC up to 200oC 1 1 17 17
Water draining from LP drains and pump suction

1 17 17
lines
Hot bolting at 200oC 1 1 18 18
Further temp. increase upto 250oC 1 18 18

Temperature raise upto 300oC & introduction of

1 1 20 20
stripping steam
Starting of product pumps & CR pumps as and

1 20 20
when level appears
Feed cut in and routing of RCO to storage tank

1 20 20
and further increase of temperature to 366oC
Unit Stabilization 1 1 21 21
Routing of Products 1 21 21
Stabilization of NSU section , LPG stabilizer &

2 2 22 23
splitter

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Total Day No. of

Start Day End Day
Reqd. Days
Commissioning Activities of VDU (Parallel)
Leak checking with Air and attending leaks if any 12 12 2 13
Vacuum pull test & vacuum drop test 2 2 14 15

Steaming for air removal 2 2 16 17
Fuel Gas back up & water draining 1 1 18 18
Reciept of FLO 1 1 19 19
Establishment cold circulation & water draining 1 1 20 20
Temperatures raising@20-25oC upto 180oC and

1 1 21 21
water draining
Replacement of FLO with RCO after stabilization

1 1 23 23
of CDU
Increase temperature upto 300oC 1 23 23

Further increase of temperature upto 350oC &
1 1 24 24
introduce stripping steam
Vacuum pull ,further increase of temperature

1 1 25 25
@20-25oC/hr. upto 400oC
Stabilization of the column by running CR &

1 1 26 26
product pumps
Routing of VR to DCU tanks. 1 1 27 27

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CHAPTER-7
NORMAL STARTUP PROCEDURE

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7.1 START UP PREPARATION:
Before initiating startup procedures of the unit ensure the completion of the following:
 All check lists jobs.

 All departmental clearance have been taken ensuring that all jobs are completed by Mechanical, Electrical,
Instrument, Civil, Inspection, Technical services and Fire & Safety.
 Mechanical Maintenance:
Box-up jobs, blinding/de-blinding, test run of all rotary equipments including steam generation equipments
pressure testing and safety valve calibration.
 Electrical Maintenance:
Motors no load run, Auto start motor testing, Area illumination check, Emergency light testing in the Main
Control Room and Field, Burner Igniters Check, Battery Backup Actual Time Period Check during 110V
DC supply failure, Earthing connections check of all rotary and static equipments and Communication
system check.
 Instrument Maintenance:
Loop check, Interlock check, alarm check as per set value on the controller, DCS operational check, all
pressure gauges with normal operating range markings, impulse line insulations, installation of orifice plate
and Control Valves according to the direction of flow, drain lines connected to instruments to a safer
locations ,CCTV and communication system check.
 Civil Maintenance:
Area cleaning including step ladders, overhead platforms, OWS piping thoroughness check, painting,
stencilling, insulation, installing safety sign boards, MSDS sign boards, SOP boards ,chemical handling
instructions, Dos and Don’ts boards and cleanliness of open channel.
 Inspection:
Column internals check, hydro test reports and furnace refractory checks, safety valves inspection report.
 Technical Services:
Column / Vessels internals and orientation of burner tips checked.
 Fire &Safety:
Availability of PPE’s,Firefighting equipments, safety showers operational check, availability of fire water
at all fire monitors inside and outside B/L. with adequate pressure, hydrants, deluge system check, smoke
detector check inside the control room and fire water booster pump operational check.
 Inform RSM, Fire & Safety, CPP, Water block, ETP, Unit electrical substation, OM&S and the secondary
units (DCU, DHDT, Alkylation, ARU, KTU, and VGO-HDT) and Quality control laboratory.
 Ensure all Chemical dosing solutions prepared in the respective storage vessels after utility commissioning.
 Ensure sufficient Lube oil and Chemical Stocks.
 Ensure the availability of PPE’s at their locations.

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 Make sure that all work permits issued were closed and no unauthorised work is carried out in the unit.
 Ensure Alkali boil out of all steam generating equipments is carried out. Boiler feed water line up and
building up water level in the steam producing equipments.
 Ensure all steam tracers had been commissioned after utility commissioning.
 Ensure electrical tracers, if any, switched on.
START UP PREPARATION (after M&I)
 Make sure that all jobs that were planned are completed including check lists.
 All department job completion clearance is obtained.
 Start-up clearance is obtained from all department head including DGM (PN). (Mechanical, Electrical,
Instrument, Civil, Inspection, Technical services and Fire & Safety).
 Make sure that all work permits issued were closed and no unauthorised work is carried out in the unit.
 All lines of battery limit are de-blinded.
 Make sure illumination and emergency lighting system in the unit checked.
 Make sure that the communication system ready for use.
 Area is cleaned & debris is removed from unit area.
 Instruments-Loop& interlock check is checked.
 Inform RSM, Fire & Safety, CPP, Water block, ETP, Unit electrical substation, OM&S and the secondary
units (DCU, DHDT, Alkylation, ARU, KTU, and VGO-HDT) and Quality control laboratory.
 Ensure all Chemical dosing solutions prepared in the respective storage vessels after utility commissioning
 Ensure Lube oil and Chemical Stocks.
 Ensure the availability of PPE’s at their locations.
 All rotary equipments are energised & direction of rotation is checked.
7.2 CDU-START-UP PROCEDURE:

Major Steps involved
Commissioning of CWS/CWR / SW / BFW
1. AI/AP commissioning.
2. LP/MP/HP steam commissioning
3. Steam tracer commissioning.
4. Flare line commissioning.
5. Taking of PSVs in line.
6. Fuel gas supply line
7. FO supply / return commissioning.
8. N2 commissioning.
9. CBD/ABD / CCBD commissioning.

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10. Control valve /XZV stroke checking.

11. F101/F201/F02 BMS (leak) checking
12. Chemical preparation.
13. BFW line up to Steam Generators & WHBs. (Vent valve open & generation valve closed)
14. Leak testing of C01/V5/V6 with steam /N2 and inertization.
15. Leak testing of C07 with steam /N2 and inertization.
16. Leak testing of C04/V7/V8 with steam /N2 and inertization.
17. Leak testing of V16/C10/V17 & FG return with steam /N2 and inertization.
18. Leak testing of C05/V9 with steam /N2 and inertization.
19. Leak testing of C06/V10 with steam /N2 and inertization.
20. Leak testing of 11C01/11C2 with steam /N2 and inertization.
21. All product & IR/PA circuit Leak testing & inertization.
22. Receive seal fluid in vessels (V19/V20) & establish flow to pumps.
23. Receiving crude into unit.
24. Line up and establish CDU cold circulation.
25. Establish Amine circulation in 10-C-009 & 10-C-010
26. Furnace light-up in CDU furnace. Raise temperature @15-20 deg.C/hr.
27. CDU hot circulation
28. Super-heated steam line up/preparation to CDU furnace.
29. Generated LP steam & super-heated steam circuit preparation /line up.
30. Routing of generated LP steam to refinery header.
31. CDU – VDU integration ( 320 deg.C )
32. Light up VDU furnace & raise temperature.
33. Super-heated steam line up/preparation to VDU furnace
34. Ejector steam system preparation.
35. Introduction of SS to C01 & Feed cut
36. Stabilisation of CDU and product routing.
37. Stabilization of stabilizer.
38. Introduction of SS to C07 & vacuum pulling
39. Stabilization of VDU.
40. Chemical injection.
41. Routing of WHB generated MP steam
42. Commissioning of De-ethaniser & stabilization
43. Commissioning of De-Propaniser & stabilization
44. Amine circulation establishment & caustic receiving in 11C01 & 11C02.
45. Commissioning of SR-LPG section.
46. Introduction of wash water to desalters & commissioning. Demulsifier injection.

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Steaming and Gas backup
Prerequisites
1. Isolate Pumps/Compressors suction & discharge.

2. Inform I/M to isolate instruments as per requirement.
4. Isolate cooling water to all coolers and condensers, drain the cooling water completely (if required) and
keep open the vents in cooling water side during the steam out.
5. Ensure overhead condenser/product cooler fans are at stop condition
6. Lines connected to flare to be kept isolated during steaming.
7. S/D valves (XZV’s) within the system related to steam charging/ draining/venting to be kept open
forcefully as per requirement.
8. High point vents in exchanger & column to be kept open during steam out.
9. Sour water header of individual vessel (as applicable) to be steam out with the respective vessel boot up
to battery limit.
10. Following lines to be isolated wherever applicable in the considered system:
a. Isolate Corrosion inhibitor.
b. Isolate Amine Neutralizing Amine.
c. Isolate Fuel gas.
d. Isolate Nitrogen.
e. During steam out open drain at NRV d/s to ensure clear steam comes out for all the above injection
lines.
CAUTION:
During steaming inline Control Valves to be isolated and respective control valve bypass to be open.
Inertization / leak testing of CDU section comprising of following major equipments (with steam)
1. 010-C-001
2. 010-C-002
3. 010-C-003
4. 010-C-008
5. 010-V-003
6. 010-V-005

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7. 010-V-006
8. 010-AC-007
9. 010-F-101/201
1. Ensure that instrument tapings thoroughness is checked from inside by inserting rod.
2. Column / vessel draw lines & bottom outlet lines thoroughness is checked by putting plenty
of water through that line & draining from respective pump suction strainer. Ensure that no
foreign mater is there in the line.
3. Ensure that all blinds are removed / blinded as per blind list.
4. Ensure that boxing up of vessels & column is done in presence of production personal.
5. Isolate all instruments from root valve.
Ensure the following:
1. LP/MP/HP steam in AVU is commissioned.
2. CWS / CWR/ BFW / SW are commissioned.
3. Flare line is commissioned.
4. FG line is commissioned.
5. All rotary equipments are energized. Rotation checked.
6. All controller / XZVs stroke checked.
7. Column pressure indication at DCS.
8. Force opens all products / CR pumps XZVs.
Procedure:
1. Isolate 1st isolation valve d/s of NRV at Corrosion inhibitor line. (Column top)
2. Isolate isolation valve d/s of NRV at Amine Neutralizer. (Column top)
3. Isolate isolation valve u/s of NRV at Fuel gas line. (Column top)
4. Isolate 1st isolation valve u/s of NRV at Nitrogen. (Column top)
5. Keep C01 / V05 / V03 instruments isolated from root valves.
6. Line up all required PSVs of above circuit (C01, V3, V05, and V6) in line & keep close its
bypass.
7. Line all AC07 segments in line.
8. De-blind V05 drain line to OWS, keeping CBD blinded..
9. Isolate C01 pressure controller (PV 1072A/B)
10. Force open P10 suction XZV
11. Line up P10A/B & P11A/B suction & close discharges. De-blind pump casing drain to
CBD/OWS
12. Line up both P-11 & P-10 minimum circulation (FV1072 & 1071) in line & keep 100%
open.

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13. Keep P10 discharge to V07 (FV 1030) & sour water level C/V (LV 1024) are closed /
isolated.
14. Keep P10 discharge to C01 (start up) 1st isolation valve closed, 2nd isolation open & drain
between above valves de-blinded.
15. Isolate both compressor inlet isolation valves. Open V6 inlet valve.
16. Isolate V7 pressure controller to V6, PV 2001.
17. De-blind V6 drain to OWS.
18. Isolate V3 inlet C/Vs( PV 1019A/B, PV 1022A/B)
19. Isolate wild naphtha (DHDT) to V3 at V3.
20. Line up V3 pressure controller (PV 1021) & keep c/v 100% open.
21. Isolate startup circulation (at B/L) & open its valve at V3.
22. De-blind FLO line drain at above circulation line between 2 valves, keeping 1st I/V closed.
23. Isolate light slop circulation to V3.
24. Isolate all 24 passes of F101 / F201 & its bypasses.
25. Isolate all 4 Desalter PSV bypasses.
26. Force open TPA pump suction XZV. Line up P4B/C suction & close discharges. De-blind
pump casing drain to CBD/OWS. Open P4A suction strainer, keeping discharge closed.
27. Isolate TPA hot & cold QV u/s i/v. De-blind its bleeder. Keep bypasses are closed.
28. Isolate TPA hot pump around (IR) C/V u/s i/v. De-blind its bleeder. Keep bypass closed.
29. Line up P5B & P8B suction & close discharges. De-blind pump casing drain to CBD/OWS.
Isolate pump warm up valves. Open P5A & P8A suction strainer, keeping discharge closed.
30. Isolate Kero hot & cold QV u/s i/v. De-blind its bleeder. Keep c/v bypasses are closed.
31. Isolate Kero hot pump around (IR) C/V (FV1039) u/s i/v. De-blind its bleeder. Keep c/v
bypass closed.
32. Line up LV 1014. Keep it 100% open.
33. Isolate FV1020 u/s i/v. De-blind its bleeder. Keep bypass closed.
34. Keep C02 stripper SS body block valve closed.
35. Force open LAGO PA pump suction XZV. Line up P9B & P6B suction & close discharges.
De-blind pump casing drain to CBD/OWS. Isolate pump warm up valves. Open P9A & P6A
suction strainer, keeping discharge closed.
36. Isolate LAGO hot & cold QV u/s i/v. De-blind its bleeder. Keep c/v bypasses are closed.
37. Isolate LAGO hot pump around (IR) C/V (FV1040) u/s i/v. De-blind its bleeder. Keep c/v
bypass closed.

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41. Force open HAGO PA pump suction XZV. Line up P29B & P30B suction & close
discharges. De-blind pump casing drain to CBD/OWS. Isolate pump warm up valves. Open
P29A & P30A suction strainer, keeping discharge closed.
42. Isolate HAGO hot & cold QV u/s i/v. De-blind its bleeder. Keep c/v bypasses are closed.
43. Isolate HAGO hot pump around (IR) C/V (FV1042) u/s i/v. De-blind its bleeder. Keep c/v
bypass closed.
47. Isolate SS valve at C01.
48. Force open AR pump suction XZV. Line up P7B/C suction & close discharges. De-blind
pump casing drain to CBD/OWS. Isolate pump warm up valves. Open P7A suction strainer,
keeping discharge closed.
49. De-blind C01 drain to OWS.
50. Open C01 vent fully.
51. Commission furnace (F101/F201) coil purging steam header.
52. De-blind steam out points at C2 / C3/ C8/ V3/V5 and V6
53. Maintain BEW level in 10V22.
54. Light up gas burner in F101 & F201 as per procedure. Maintain 200 deg C box temperatures.
55. Slowly introduce coil purging steam to each of 24 passes (1-2 thread).
56. Ensure steam flow to each pass by touching the line (temperature). See that there is no
hammering in the coil.
57. Slowly introduce steam to C2 / C3/ C8/ V3/V5 and V6 (1-2 thread). Ensure steam flow.
58. Wait till steam starts coming out from column vent and all product / PA pump suction
strainer & vessel drain (V3/V5/ V6).
59. Slowly increase steam flow (prefer furnace passes) so that condensate / steam comes out of
all above mentioned pump suction / control valve drain points.
60. Ensure that steam has come out of all drain points. (P3 / P4 / P5 / P6 / P7 / P8 /P9/ P10 / P11/
P29 / P30 / V3 / V5 and start up circulation line (FLO line) at B/L.
61. Also from all QV, IR drain points.
62. Pinch above pump suction / control valve drain points to vent mostly from column vent.
63. Increase system pressure to 1.5 kg. Do leak test of all disturbed flanges. Rectify the leaky
one.
64. Make sure that column pressure does not exceed 1.5 kg/cm2. Maintain this pressure by
adjusting steam inlet or by opening drain.
65. Do steaming for 6 hrs.
66. Slowly reduce steam in & maintain column pressure @ 0.2 -0.3 kg/cm2.
67. Pinch condensate draining from all draw pump / vessels.

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68. Introduce N2 from C01 column top & V6.

69. Waite till column pressure starts increasing.
70. Close column vent & steam in from all points. Ensure that all other drains are closed.
71. Put off furnace firing & blind FG.
72. Drain out condensate from all drains mentioned above & maintain 0.5 kg column pressure.
73. Blind all steam out points & column vent and drains.
Inertization / leak testing of CDU section comprising of following major equipments

(with Nitrogen)
1. 010-C-001
2. 010-C-002
3. 010-C-003
4. 010-C-008
5. 010-V-003
6. 010-V-005
7. 010-V-006
8. 010-AC-007
9. 010-F-101/201
Procedure:
2. Isolate isolation valve d/s of NRV at Neutralizing Amine. (Column top)
4. Isolate 1st isolation valve u/s of NRV at Nitrogen. (Column top)
5. Keep C01 / V05 / V03 instruments isolated from root valves.
6. Line up all required PSVs of above circuit (C01, V3, V05, and V6) in line & keep close its
bypass.
7. Line all AC07 segments in line.
8. De-blind V05 drain line to OWS, keeping CBD blinded.
9. Isolate C-01 pressure controller (PV-1072A/B)
10. Force open P-10 suction XZV
11. Line up P-10A/B & P-11A/B suction & close discharges. De-blind pump casing drain to
CBD/OWS
12. Line up both P11 & P10 minimum circulation (FV1072 & 1071) in line & keep 100% open.
13. Keep P-10 discharge to V07 (FV 1030) & sour water level C/V (LV 1024) are closed /
isolated.
14. Keep P-10 discharge to C01 (startup) 1st isolation valve closed, 2nd isolation open & drain
between above valves de-blinded.

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15. Isolate both compressor inlet isolation valves. Open V6 inlet valve.
16. Isolate V7 pressure controller to V6.PV 2001.
17. De-blind V6 drain to OWS.
18. Isolate V3 inlet C/Vs( PV 1019A/B, PV 1022A/B)
19. Isolate wild naphtha (DHDT) to V3 at V3.
20. Line up V3 pressure controller (PV 1021) & keep c/v 100% open.
21. Isolate startup circulation (at B/L) & open its valve at V3.
22. De-blind FLO line drain at above circulation line between 2 valves, keeping 1 st I/v closed.
23. Isolate light slop circulation to V3.
24. Isolate all 24 passes of F101 / F201 & its bypasses.
25. Isolate all 4 Desalter PSV bypasses.
26. Force open TPA pump suction XZV. Line up P4B/C suction & close discharges. De-blind
pump casing drain to CBD/OWS. Open P4A suction strainer, keeping discharge closed.
27. Isolate TPA hot & cold QV u/s i/v. De-blind its bleeder. Keep bypasses are closed.
28. Isolate TPA hot pump around (IR) C/V u/s i/v. De-blind its bleeder. Keep bypass closed.
29. Line up P5B & P8B suction & close discharges. De-blind pump casing drain to CBD/OWS.
Isolate pump warm up valves. Open P5A & P8A suction strainer, keeping discharge closed.
30. Isolate Kero hot & cold QV u/s i/v. De-blind its bleeder. Keep c/v bypasses are closed.
31. Isolate Kero hot pump around (IR) C/V (FV1039) u/s i/v. De-blind its bleeder. Keep c/v
bypass closed.
35. Force open LAGO PA pump suction XZV. Line up P9B & P6B suction & close discharges.
De-blind pump casing drain to CBD/OWS. Isolate pump warm up valves. Open P9A & P6A
suction strainer, keeping discharge closed.
36. Isolate LAGO hot & cold QV u/s i/v. De-blind its bleeder. Keep c/v bypasses are closed.
37. Isolate LAGO hot pump around (IR) C/V (FV1040) u/s i/v. De-blind its bleeder. Keep c/v
bypass closed.
41. Force open HAGO PA pump suction XZV. Line up P29B & P30B suction & close
discharges. De-blind pump casing drain to CBD/OWS. Isolate pump warm up valves. Open
P29A & P30A suction strainer, keeping discharge closed.
42. Isolate HAGO hot & cold QV u/s i/v. De-blind its bleeder. Keep c/v bypasses are closed.
43. Isolate HAGO hot pump around (IR) C/V (FV1042) u/s i/v. De-blind its bleeder. Keep c/v
bypass closed.

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47. Isolate SS valve at C01.
48. Force open AR pump suction XZV. Line up P7B/C suction & close discharges. De-blind
pump casing drain to CBD/OWS. Isolate pump warm up valves.
49. De-blind C01 drain to OWS.
50. Charge N2 from C01 top & V6.
51. Pressurize the system with N2 to 1.5 kg & do leak test of all disturbed flanges. Rectify the
leaky one.
52. Do hold up test. It should be ok.
53. Start purging the system with N2 (Pressurize to 1 kg & de-pressurize to 0.2 kg)
54. Depressurize to be done from V5 / C01 bottom, pump suction (after lining up suction), IR /
CR control valve drain periodically one after another.
55. Repeat the purging till O2 content is found within acceptable limit.
56. Keep system under positive pressure.
Inertization & leak testing of VDU Column including O/H Condenser and associated piping
(C7/C9/V11/V13/V14)
Procedure:
2. Isolate isolation valve d/s of NRV at Amine Neutraliser. (Column top)
4. Keep C07 instruments isolated from root valves (PG/PT etc).
5. Line up all required PSVs of C07 in line & keep close its bypass.
6. Vac diesel PA strainers D/s isolation valves (1A/B) & Reflux strainers D/s isolation valves
(2A/B)
7. VGO PA strainers D/s isolation valves (3A/B)
8. HVGO PA strainers D/s isolation valves (4A/B) & Wash oil strainers D/s isolation valves
(5A/B)
9. Recycle Oil PA – FV 3012 D/S isolation & bypass valve.
10. VR Quench: PA – PV 3008 D/S isolation & bypass valve.
11. Isolate P21/P22/P23/P24 and P25 all draw pump suction valves.
12. Pumps vent to C07 both isolation valves.
13. S/Steam both isolation & its equalization valves.
14. F02: all 12 passes d/s isolation & bypass valve.

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15. Tubulising steam i/v of all passes (convection & radiation).

16. Coil purging steam to all passes.
17. Isolate C07 steam out valve
18. Isolate all PSVs u/s & bypass valves.
19. Isolate C07 vent.
20. Isolate V14 water inlet valve.
21. Isolate V14 drain to CBD
22. Isolate P27A/B & P28A/B suction valves.
23. Isolate P27 minimum circulation line valve.
24. Isolate V13 drain to CBD.
25. Isolate V-13 both steam out line.
26. Isolate P-28 minimum circulation line valve.
27. Isolate V15 drain to V13.
28. Isolate C09 drain pot inlet.
29. Isolate P31 A/B both pump inlet valve.
30. Isolate both P31 A/B discharge to C09 (pump back).
31. Isolate C09 steam out point.
32. Isolate SR-LPG off gas to C09.
33. Isolate C09 PSV & its bypass.
34. Isolate lean amine in C/V (FV 4002).
35. Isolate N2 to C09 over head.
36. Isolate 10V11 XZVs for atmosphere & F02 by block valve.
37. Keep all ejector steam inlet XZVs closed.
38. Line up all ejector inlet valves.
39. Line up all E53 series HC outlet & off gas valve.
40. Line up E54 HC outlet & off gas valve.
41. Line up E55 HC outlet & off gas valve.
42. Line up all column / vessel related instruments. Keep their drain / vents blinded.
43. Keeping ground floor valves Isolated line up Nitrogen. (Column top)
44. Provide air connection at N2 line between valves at ground floor.
45. Pressurize C07 with air @ 0.2kg/hr rate to 1.5 kg.
46. Check all disturbed flanges with soap solution. Rectify if any.
47. After rectification is over, do holdup test at 1.5 kg & note fall rate. Maximum fall rate
allowed is 60mmHg/hr
48. Depressurize C07 from column top vent very slowly (0.2kg/hr).
49. Now prepare ejector steam. Close column vent after depressurization is over.
50. Fill water in V13 / V14
51. Line up V11 vent XZV to atmosphere.

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52. Remove air connection at N2 line between valves at ground floor

53. Slowly start taking ejector. Vacuum pulling rate @ 50 mmcw/hr. Ensure vacuum pulling rate
is maintained.
54. Pull vac. to 40 mmwc. Hold for 4 hrs. Maximum vac break rate is
55. If it fails in vacuum hold test check for any leakage and in case everything is found normal,
blind the following points.
o Strainer 1A/B, 2A/B, 3A/B. 4A/B, 5A/B d/s isolation valve’s u/s flange.
o P21/P22/P23/P24 and P25 suction valve d/s flange
o FV 3012 D/S isolation & bypass valve u/s flange.
o PV 30008 D/S isolation & bypass valve u/s flange.
o All pump vents.
o Stripping steam at U/s of isolation valve.
o V13/V14 / 10 V11 drain to CBD / OWS.
o C7 / C9 PSV bypass.
o SR-LPG off gas.
56. Again do vacuum hold test.
57. After vac hold test is over, break vacuum with N2 (Slowly). Remove air connection.
58. Send sample to Lab for O2 content.
59. If fails, again pull vacuum & break with N2.repeat till O2 content found within permissible
limit. (0.2% Vol.)
60. De-blind point no-63.
61. During product PA / IR circuit inertization, point no-63 leak testing is to be done.
62. Blind column vent.
63. Line up PSV as per requirement.
Stabiliser Circuit and associated piping:
C04/V7/V8 inertization (STEAM):

1. Line up AC08. All segment.
2. Isolate both compressor discharge valves. De-blind common discharge line drain point.
3. Isolate DHDT naphtha at B/L. Provide steam connection at B/L bleeder between two
isolation valves. Keep line up at AC8 inlet.
4. Isolate P10 A / B suction. Provide steam connection at PG point. Keep line up at AC 08
inlet.
5. De-blind V7 steam out point & vent to atmosphere.
6. De-blind n2 at compressor discharge.
7. Isolate V7 boot water C/V (LV 2004)

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8. Isolate PV 2011 & PV2001 d/s i/v & bypass. De-blind its bleeder.
9. Line up V7 PSV & close its bypass.
10. Open P13Asuction strainer. Keep its discharge closed.
11. Close p13B suction & provide steam connection to its PG point.
12. Force open P13 suction XZV.
13. Line up FV 2001 & FV 2017. Open 100% c/v.
14. Line up E37A/B both side.
15. Isolate off-spec. LPG at B/L. Provide steam connection at B/L bleeder between two isolation
valves.
16. Isolate p14 Suction. Provide steam connection at PG point. Line up LV 2001& keep 100%
open. Lineup it at P13 discharges.
17. Force open XZV 2011.
18. Line up AC10 & E 40A/B. Isolate E40 CWS & CWR. Keep water side vent open to release
pressure.
20. Isolate FV 2005, FV 2003 & FV 2004 d/s b/v. de-blind their bleeder.
21. Isolate naphtha to slop valve closed.
22. Line up C4 PSV & close its bypass.
23. De-blind n2 at C4.
24. Isolate CI at C04 top.
25. Line up AC009 & E 36A/B. Isolate E36 CWS & CWR. Keep water side vent open to release
pressure.
26. De-blind C4 steam out point & vent to atmosphere.
27. Isolate PV 2018B.
28. Line up PV2018A & keep 100% open
29. Line up V8 PSV & close its bypass
30. Line up FV 2002, FV 2006, Fv 2032& FV 2008. Keep it 100% open.
31. Isolate feed inlet to C5 at C05.
32. De-blind V8 steam out point & vent to atmosphere.
33. Open V7/V8 & C4 vents.
34. Charge steam in V7/V8/ C4 and from off spec. LPG B/L, NHDT B/L, P10 discharge, P13
discharge, P14 discharge,
35. Drain condensate from V7/V8/C4 drain (boot) & from bleeders of P13, FV 2003, 2004,
2005, P15, P16, compressor discharge header.
36. Pressurize whole circuit to 1.5 – 2 kg with steam by adjusting steam flow & reducing
draining.
37. Ensure that clear steam has come out of all above mentioned drain points.
38. Do leak test. Rectify leaky one.

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39. Thorough steaming for 6 hr.

40. Slowly reduce circuit pressure to 0.3 kg.
41. Back up with N2 from compressor discharge / C4.
42. Isolate vessel / column vent.
43. When circuit pressure starts increasing, close all drain point & steam supply.
44. Maintain 1 kg circuit pressure
45. Blind steam out points & vessel / column vent
46. Disconnect all steam supply connection & end blind.
47. After cooling, drain out condensate from all drain points & blind the drains.
Stabilizer C04/V7/V8 inertization (N2)
48. Line up AC08. All segment.

49. Isolate both compressor discharge valves. De-blind common discharge line drain point.
50. Isolate DHDT naphtha at B/L. Keep line up at AC8 inlet.
51. Isolate P10 A / B suction. Keep line up at AC 08 inlet.
52. De-blind n2 at compressor discharge.
53. Isolate V7 boot water C/V (LV 2004)
54. Isolate PV 2011 & PV2001 d/s i/v & bypass. De-blind its bleeder.
55. Line up V7 PSV & close its bypass.
56. Open P13Asuction & Keep its discharge closed.
57. Force open P13 suction XZV.
58. Line up FV 2001 & FV 2017. Open 100% c/v.
59. Line up E37A/B both side.
60. Isolate off-spec at B/L.
61. Isolate p14 Suction. Line up LV 2001& keep 100% open. Lineup it at P13 discharges.
63. Line up AC10 & E 40A/B.
65. Isolate FV 2005, FV 2003 & FV 2004 d/s b/v. de-blind their bleeder.
66. Line up C4 PSV & close its bypass.
67. De-blind n2 at C4.
68. Isolate CI at C04 top.
69. Line up AC009 & E 36A/B.
70. Isolate PV 2018B.
71. Line up PV2018A & keep 100% open
72. Line up V8 PSV & close its bypass

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73. Line up FV 2002, FV 2006, Fv 2032& FV 2008. Keep it 100% open. Isolate all these
rundown at B/L.
74. Isolate feed inlet to C5 at C05.
75. Charge N2 from C04 top & compressor discharge.
76. Pressurize the system with N2 to 5 kg & do leak test of all disturbed flanges. Rectify the
leaky one.
78. Start purging the system with N2 (Pressurize to 1 kg & de-pressurize to 0.2 kg).
79. Depressurize to be done from C4/V7/V8 bottom, P13,P14, P10, NHDT naphtha (B/L), PV
2001, Off-spec LPG (B/L), P15, P16 , FV 2008, PV 2018, E37 tube & shell side drain
periodically one after another.
Steaming of 010-C-010/V-016/V-017 (Off gas system):
Isolate the following:

1. PV 2011 U/s isolation & bypass valve.
2. PV 2065B U/s isolation & bypass valve.
3. V16 PSV bypass. Line up required PSV.
4. Off gas from NHDT battery limit.
5. FV 4001 & its bypass. And sample point.
6. P33A/B discharge.
7. V17 drain to ABD
8. PV 4005 bypass & sample point. Keep C/v lined up &100% open.
9. FG export battery limit 2nd valve.
De-blind the following:

1. Vent & steam out points of V16 / V17 & C10.
2. V16 / V17 & C10 drain to OWS.
3. FV 4001 bleeder.
Provide steam connection at:

1. PV 2011 bleeder.
2. PV 2065B bleeder.
Procedure:
1. Open V16 / V17 / C10 vent.

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2. Charge steam at PV 2011, PV 2065B, NHDT off gas battery limit, V16, V17 and C10.
3. Drain condensate from V16 / V17 & C10 drain to OWS.P33 casing drain, FV 4001 drain and
FG export battery limit drain.
draining.
5. Ensure that clear steam has come out of all above mentioned drain points.
6. Do leak test. Rectify leaky one.
7. Thorough steaming for 6 hr.
8. Slowly reduce circuit pressure to 0.3 kg.
9. Back up with N2 V16 inlet.
10. Isolate vessel / column vent.
11. When circuit pressure starts increasing, close all drain point & steam supply.
12. Maintain 1 kg circuit pressure
13. Blind steam out points & vessel / column vent
14. Disconnect all steam supply connection & end blind.
15. After cooling, drain out condensate from all drain points & blind the drains.
Inertization of V16 / V17 / C10 circuit (N2):

1. PV 2011 U/s isolation & bypass valve.
2. PV 2065B U/s isolation & bypass valve.
3. V16 PSV bypass. Line up required PSV.
5. FV 4001 & its bypass. And sample point.
7. V17 drain to ABD
8. PV 4005 bypass & sample point. Keep C/v lined up &100% open.
9. FG export battery limit 2nd valve.
De-blind the following:

1. V16 / V17 & C10 drain to OWS.
2. Bleeders of FV 4001, PV 2011, PV2065B, and NHDT off gas & FG export at B/L.
Procedure:
1. Charge N2 from V16 inlet.
leaky one.

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5. Depressurize to be done from C10/V16/V17 bottom, PV 2011 , PV 2065B, NHDT off gas at
B/L, P13P14, P10, NHDT off gas (B/L) and FG export at B/L. Drain periodically one after
another.
Inertization of C5/V09 circuit (Steam):

1. Isolate FV 2008, LV 2042, PV 2065A, PV2065B, V9-HZV-2013, C5 bottom to C6 at d/s of
FV 2010.
2. Isolate C5 bottom to off- spec at B/L 2nd B/V and C5 bottom to storage 2nd B/V.de-blind its
bleeder.
3. Full open FV 2009, FV 2011, FV 2023, FV 2030, FV 2031and FV 2010.
5. Close PSV bypass.
6. De-blind vent & steam out points of C05 / V09.
7. Provide steam connection at P02 & P18 PG.
8. Charge steam in C05 / V09 and from P02 & P18 PG.
9. Drain condensate from PV 2065A, PV2065B, FV 2008, FV 2009, FV 2011, LV 2042,
FV2010, FV 2023, FV 2030, and FV 2031.
10. Pressurize whole circuit to 3-4 kg with steam by adjusting steam flow & reducing draining.
11. Ensure that clear steam has come out of all above mentioned/available drain points & C5 /
V9 vents.
12. Do leak test. Rectify the leaky one.
13. Do steaming for 6 hrs.
14. Reduce steaming & maintain system pressure 0.3 kg.
15. Reduce draining from all points.
16. Back up N2 in the system. Wait till pressure starts increasing.
17. Close all drain points.
18. Close steam to system & V5/V9 vents.
19. Drain out condensate totally from all points.
20. Maintain system pressure 2 kg.
21. Remove / blind all inlet, vents & drains.

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Inertization of C5/V09 circuit (N2)

1. Isolate FV 2008, LV 2042, PV 2065A, PV2065B, V9-HZV-2013, C5 bottom to C6 at d/s of
FV 2010.
2. Isolate C5 bottom to off- spec at B/L 2nd B/V and C5 bottom to storage 2nd B/V.de-blind its
bleeder.
3. Full open FV 2009, FV 2011, FV 2023, FV 2030, FV 2031and FV 2010.
5. Charge N2 from C5.
leaky one.
9. Depressurize to be done from C5 re-boiler, V9 drain, PV 2065A, PV2065B, FV 2008, FV
2009, FV 2011, LV 2042, FV2010, FV 2023, FV 2030, FV 2031 and bleeders of off- spec &
storage line at B/L.
11. Keep system under pressure.
Inertization of C6/V10 circuit (Steam):

1. Isolate FV 2010, LV 2022, PV 2038A.
2. Isolate SR-LPG outlet, V10 HZV 2012, control valves of C3& C4 rundown to storage, C4
rundown to alkyl ate at B/L 2nd isolation valve.
3. Full open PV 2038B, FV2015,2038,2039, FV 2012, FV 2016, FV 2013, FV 2014, FV
2018,2035,2036 and C4 rundown to alkyl ate (FV 2013)
4. Force open XZV 2003.2004
5. Isolate CWS / CWR of E46, E 48. Open its vent.
6. De-blind vent & steam out points of C06 / V10.
7. Provide steam connection at P19 & P20 PG.
8. Charge steam in C06 / V10 and from P19 & P20 PG.
9. Drain condensate from PV 2038B, FV2015,2038,2039, FV 2012, FV 2016, FV 2013, FV
2014, FV 2018,2035,2036, FV 2010, LV 2022, PV 2038A, SR-LPG outlet, C4 rundown to
alkyl ate. Also drain from C6 re-boiler, V10 drain
draining.
11. Ensure that clear steam has come out of all above mentioned/available drain points & C9 /
V10 vents.
12. Do leak test. Rectify the leaky one.
13. Steaming for 6 hr.

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14. Reduce steaming & maintain 0.3 kg system pressure.

15. Pinch all drains.
16. Introduce N2 from C06 top. Wait till system pressure starts increasing.
17. Stop all drains & vents of V10/C6.
18. Stop steam from all supply points.
19. Maintain system pressure 1kg with N2.
20. Drain condensate from all drains.
21. Remove temporary steam connection.
22. Blind all vents/drains/steam out points.
23. Commission water to E46.
Inertization of C6/V10 circuit (N2):

1. Isolate FV 2010, LV 2022, PV 2038A.
2. Isolate SR-LPG outlet, V10 HZV 2012, control valves of C3& C4 rundown to storage, C4
rundown to alkyl ate at B/L 2nd isolation valve.
3. Full open PV 2038B, FV2015,2038,2039, FV 2012, FV 2016, FV 2013, FV 2014, FV
2018,2035,2036 and C4 rundown to alkyl ate (FV 2013)
4. Force open XZV 2003.2004
5. Charge N2 from C06 top.
leaky one.
9. Drain condensate from PV 2038B, FV2015,2038,2039, FV 2012, FV 2016, FV 2013, FV
2014, FV 2018,2035,2036, FV 2010, LV 2022, PV 2038A, SR-LPG outlet, C4 rundown to
alkyl ate and from C6 re-boiler, V10 drain
11. Keep system under pressure
12. Maintain system pressure 1kg with N2.
13. Blind all vents/drains/steam out points.
LEAK TEST FOR PRE HEAT TRAIN EXCHANGERS CIRCUITS (Crude side)
Leak test to be carried out by dividing the entire preheat exchanger circuits in following
loops:
1. From crude B/L to desalter (desalter bypassed) through pre heat train -1 heat exchangers.
2. Desalter Circuit (010-V-102 A/B & 010-V-202 A/B)

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3. From desalter O/L to Flash drum I/L through pre heat train -2 heat exchangers (PC isolated).
4. From flash drum bottom pump discharge to upstream side of furnaces pass control valves.
Crude from B/L to Desalter (Desalter bypassed) through pre heat train -1 & 2 heat
exchangers:
1. Isolate crude at battery limit.

2. Isolate all desalter inlet/outlet & keep bypass open.
3. Isolate V3 inlet all 4 PV D/S and bypass block valves.
4. Isolate DHDT wild naphtha.
5. Isolate desalted water, anti foulant & de-emulsifier dozing points.
6. Line up all HEs of this circuit.
7. Keep all drain vents closed.
8. Keep open all 4 trend 1& trend 2 HVs.
9. Provide N2 connection at battery limit.
10. Charge N2 in the circuit & do leak test at 7 kg.
11. Do hold up test.
12. During depressurization, drain out accumulated water (flushed material) from all available
drain points
13. Purge the circuit with N2 one trend at a time for at least 3-4 purges.
14. Depressurize from E117/ E118 A/B/C/D and E217/ E218 A/B/C/D
15. Send sample to QC for O2 content. Sample to be taken at low (0.3 kg) pressure
16. Keep circuit under pressure after purging.
17. Blind all drains.
18. Remove N2 connection.
Desalter Circuit (010-V-102 A/B & 010-V-202 A/B)

1. Ensure that C01 circuit inertization is over & under gas / N2 back up.
2. Ensure that desalter PSV bypasses are closed.
3. Close desalter inlet & outlet. Open its bypass.
4. Close individual desalter brine to ETP at manifold & open one brine pump strainer.
5. De-energize desalter.
6. Isolate all related instruments.
7. Open its vent & introduce steam.
8. Drain condensate from brine pump suction strainer & desalter drain to OWS.
9. Pressurize it steam to 4 kg & do leak test. Rectify the leaky one.
10. Depressurize to 0.3 kg by reducing steam flow.
11. Pinch all drain.
12. Open desalter PSV bypass. Back up gas / N2 from C01 column.
13. Drain total condensate.

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14. Box up pump strainer.

15. Blind vent & drain.
CAUTION:
No water flushing and steaming to be done in Desalter.
From Flash Drum bottom pump discharge to upstream of furnaces pass control valves:
1. Isolate crude at P3 discharge.

2. Isolate all pass C/v of F101 / F201
3. Line up all HEs of this circuit.
4. Keep all drain vents closed.
5. Keep open all 4 trend 1& trend 2 HVs.
6. Provide N2 connection at P3 discharge.
8. Do hold up test.
drain points
11. Depressurize from E124A/ E127 A & E127 F and from E224A/ E227 A & E227 F
12. Send sample to QC for O2 content. Sample to be taken at low (0.3 kg/cm2) pressure
Product & circulating reflux circuit inertization
TPA:
1. Isolate TPA QV (hot & cold)
2. Isolate TPA IA C/V.
3. Isolate P04A/B/C suction valve.
4. Isolate P14 A/B/C discharge.
5. Line up HEs of total circuit ( trand1&2)
6. Line up HVs to trand1&2. Keep C/v opened.
7. De-blind hot QV, cold QV, IA C/V bleeder.
8. De-blind total circuit HEs drain to OWS.
9. Provide N2 hose connection at P04A/B/C discharge.

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drain points.
14. Depressurize from all HE drain to OWS & QV, cold QV, IA C/V bleeder and P14.
15. Send sample to QC for O2 content. Sample to be taken at low (0.3 kg) pressure.
Kero CR/IR:
1. Isolate Kero QV (hot & cold)
2. Isolate Kero IA C/V.
3. Isolate P05A/B suction valve.
8. Provide N2 hose connection at P05A/B discharge.
drain points.
13. Depressurize from all HE drain to OWS & QV, cold QV, IA C/V bleeder.
LAGO CR/IR:
1. Isolate LAGO QV (hot & cold)
2. Isolate LAGO IA C/V.

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11. During depressurization, drain out accumulated water (flushed material) from all
available drain points.
HAGO CR/IR:
1. Isolate HAGO QV (hot & cold)
2. Isolate HAGO IA C/V.
drain points.
Kero Product:
1. Isolate P8A/B suction.
2. Isolate Min.cir FV 1021.
3. Line up AC04 & E17A/B.
4. Isolate FV 1070 (hot r/d)
5. Keep FV 1022A & FV 1022B 100% open. Close rundown at B/L.
6. Line up one kero to slop valve.
7. Close light slop at B/L & to V3.
8. Close AGO & L. Naphtha to slop.
9. Provide N2 connection at P8A/B discharge (PG)

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drain points.
13. Blow N2 & drain from both kero rundown & light slop at B/L for 1 Hr.
AGO Product
1. Isolate P-09A/B & P-29A/B suction.
2. Isolate Min.cir FV 1024 & FV 1029.
5. Isolate AGO to E057.
6. Line up AC 005.
7. Isolate AGO to storage, to HSFO tank, VGO HDT, DHDT hot feed at battery limit.
8. Isolate hot oil product to AGO, Kerosene to DHDT hot feed,
9. Full open FV 1068, TV 1082, and PV 1197.
10. Provide N2 connection at P9 / P29 discharge.
drain points.
14. Blow N2 & drain from all rundown at B/L for 1 Hr.
15. Keep system under positive pressure.
Vac.diesel CR/IR/Product:
1. Isolate P21A/B suction valve & vent to column.
2. Line up HEs (E102/E202) of total circuit ( trand1&2)
4. Full open TV 1002 & 1502.
7. Line up ac 14 & AC16 and E39
8. Isolate strainers 01A/B and 02A/B d/s isolation valves. De-blind its drain.
9. Isolate V. diesel to H. slop.
10. Isolate hot V. diesel to HDT at C/V.
11. Full open FV3 058A/B, QV 3003A, FV 3029. Keep QV 3003B closed.

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drain points.
17. Depressurize from all HE drain to OWS, strainers 01A/B and 02A/B drains and at battery
limit.
VGO CR/IR/product:
5. De-blind total circuit HEs drain to OWS. De-blind FV 3002A bleeder.
6. Isolate VR to VGO at E108/E208.
7. Line up AC 15
8. Isolate strainers 03A/B d/s isolation valves. De-blind its drain.
9. Isolate VGO to E58, H. slop/ VR, storage tank (B/L) and hot HVGO to VGO HDT (B/L).
10. Isolate VGO to E058 & VGO to heavy slop.
11. Isolate VGO to VR (circulation)
12. Isolate start up AGO & hot HVGO to VGO HDT. Keep FV 3002A full open.
13. Full open FV3002A/B, QV 3004A. Keep QV 3004B closed.
drain points.
19. Depressurize from all HE drain to OWS, strainers 03A/B drains and at battery limit.
HVGO CR/IR/product:
1. Isolate P23A/B/C suction valve & vent to column.
2. Line up HEs of total circuit ( Train-1&2)

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7. Isolate all three HVGO rundown control valves.
8. Isolate AR to HVGO at P23 discharge.
9. Full open FV3016, QV 3002A. Keep QV 3002B closed.
drain points.
15. Depressurize from all HE drain to OWS, strainers 04A/B and 05A/B drains and at battery
limit.
Recycle oil PA/product:

2. Isolate RO PA line FV 3012 d/s & bypass.
3. Isolate RO to VDU feed FV 3013.
4. Isolate RO to VR, FV 3064.
5. Provide N2 connection at P24 discharge.
7. Do hold up test.
8. During depressurization, drain out accumulated water (flushed material) from pump casing,
Fv 3012, FV 3013, FV 3064 drain.
9. Purge the circuit with N2 for at least 3-4 purges.
10. Depressurize from all above mentioned drains.

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AR circuit:
2. Line up FV 1124, FV 1164. Isolate at E127 / E227 inlet.
3. Isolate VR (VDU) circulation at E127 / E227 outlet. Keep this line lined up at VDU feed at
above P22 platform.
4. Isolate all F02 pass C/Vs.
5. Isolate RO to VDU feed FV 3013
6. Line up AR to HVGO keeping isolated at P23 discharge.
7. Isolate HAGO to AR at manifold.
8. Full open 18” F02 feed inlet valve.
drain points. (E127 / E227 inlet, AR to HVGO at P23, FV 3013, and F02 passes.)
13. Purge the circuit with N2.
VR circuit:
2. Isolate FV 1124, FV 1164 at E127 / E227.
3. Isolate VR (VDU) circulation at E127 / E227 outlet.
4. Isolate FV 3008 & line up VR quench from both trends.
6. Line up C07 LVs to trand1&2. Keep C/v open.
7. Line up VR ex E151/E251 to E108/E208. Keep B/V closed at E108/E208
8. Isolate Vac. diesel, VGO and HVGO to VR.
9. Close VR rundown to DCU tank, HSFO and hot feed.
10. Close unit circulation (VR) to V3.

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drain points.( E127 / E227 inlet, E108/E208 inlet, FV 3008, all HEs and rundown to DCU
tank, HSFO and hot feed at B/L,
SR-LPG: 11C01/11V1/11C2 circuit inertization

1. FV 002 & sample point.
2. C5 bottom to SR-LPG
3. VGO HDT LPG (B/L)
4. LV 001
5. C01 drain to ABD
6. V01 drain to ABD
7. P5A/B discharge (DMW)
8. C2 level controller FV 007.
9. FV 007
10. P01A/ P1B suction & discharge.
11. P06A suction & discharge
12. C01& C2 PSV bypass.
13. FV 004 & its bypass
14. LV 23 & its bypass.
15. LV 0011 (sp. Caustic to CCBD).
16. C01 / V01 / C02 drain to CCBD.
17. C01 / V01 / C02 vent.
18. Treated LPG to C06 & VGO at B/L.
 De-blind steam out points of C01 / V01 / C02

 Full open PV 022.
 Keep P6B suction / discharge open.
Procedure:
1. Provide instrument air connection at VGO HDT LPG line bleeder at battery limit.
2. Pressurize whole C01 / V01 / C02 circuit to 7 kg/cm2.

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3. Do leak test of all disturbed flanges. Rectify the leaky one.

4. Now do hold up test.
5. If ok, slowly depressurize the system.
6. Provide steam connection at VGO HDT LPG (B/L)
7. Slowly charge steam from VGO HDT LPG (B/L), C01 / V01 / C02.
8. Drain condensate from feed from C5 (B/L), C01/C02 / V01 drain to OWS.P01/ P6 casing
drain, PV 22 drain, treated LPG to C6 & VGO at B/L.
9. Increase system pressure to 1-1.5 Kg/cm2 by adjusting steam flow.
10. Steaming for 4 hrs.
11. Again check for any leakage. Rectify.
12. Slowly reduce steam to 0.3 kg system pressure.
13. Isolate C01 / V01 / C02 vent & most of the drains.
14. Open C1/C2 PSV bypasses fully for gas back up. (Ensure that flare line is commissioned.)
15. Isolate steam to C01 / V01 / C02, VGO HDT LPG (B/L).
16. Isolate vents of C01 / V01 / C02
17. Isolate all drain points.
18. Allow to cool for 4 hrs.
19. Drain condensate from all above mentioned drains.
20. Isolate PSV bypasses when system pressure becomes steady & positive.
SR-LPG regeneration circuit leak test:
1. LV 023 & its bypass.

2. Off gas to 10C09 / atm. u/s valve.
4. FV 004
5. FC 007
6. P8 suction / discharge
7. P9 discharge to P8 suction
8. V4/V5/V6/V7/v8 drain to CCBD/ OWS.
Line up the following:

1. Caustic to steam heater E2
2. V5 over head to P8 suction.
3. PV 42. Keep 100% open
4. FC 11. Keep 100% open

Page 147 of 592

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5. Provide instrument air connection at LV 29 & LV 23 bleeder.

6. Pressurize whole system to 7 Kg.
7. Do leak test & rectify if any.
8. If OK, depressurize the system to required pressure through V8 vent and P8 suction.
Line filling up with Flushing Oil
Flushing oil filling in TPA circuit

1. Isolate TPA QV (hot & cold)
2. Isolate TPA IA C/V.
4. Isolate P14 A/B/C discharge.
6. Line up HVs to trand1&2. Keep C/v closed.
8. Provide hose connection at E104 / E204 TPA side vent.
9. Provide FLO connection at P4A / P4B.
10. Charge FLO at P4 discharge & fill one trend at a time.
11. Vent N2 from HE vent and finally from QV / IA drain.
12. Remove Hose connection of vents & blind.
Flushing oil filling in Kerosene CR circuit:

1. Isolate Kero QV (hot & cold)
2. Isolate Kero IA C/V.
7. Provide hose connection at trend 1 / trend 2 HE vents.
Flushing oil filling in LAGO CR circuit

1. Isolate LAGO QV (hot & cold)
2. Isolate LAGO IA C/V.

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Flushing oil filling in HAGO CR circuit

1. Isolate HAGO QV (hot & cold)
2. Isolate HAGO IA C/V.
8. De-blind FLO at P30A / B.
Flushing oil filling in Kerosene product circuit:

1. Isolate P8A/B suction.
2. Isolate Min.cir FV 1021.
3. Line up AC04 & E17A/B.
4. Isolate FV 1070 (hot r/d)
5. Keep FV 1022A & FV 1022B 100% open. Close rundown at B/L.
6. Line up one kero to slop valve.
8. Line up kero to off-grade crude tank.
9. Close AGO & L. Naphtha to slop.
10. Provide FLO connection at P8A/B discharge (PG)
11. Charge FLO in the circuit.
12. Check sample at rundown C/V.
13. Remove FLO connection after filling is over.

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Flushing oil filling in AGO product circuit.

1. Isolate P9A/B & P29A/B suction.
2. Isolate Min.cir FV 1024 & FV 1029.
5. Isolate AGO to E057.
6. Isolate HSGO to AR.
7. Line up AC 005.
8. Isolate AGO to storage, to HSFO tank, VGO HDT, DHDT hot feed at battery limit.
9. Isolate hot oil product to AGO, Kerosene to DHDT hot feed.
10. Full open FV 1068, TV 1082, and PV 1197.
11. Line up AGO to slop.
1. Line up AGO to off-grade crude tank.
2. Close Kerosene & L. Naphtha to slop.
3. De-blind FOL at P29.
4. Provide hose at vents of all HE in this circuit.
5. Charge FLO.
6. Vent N2 from individual HE.
7. Check sample at battery limit.
9. Line up required rundown controllers & strainers.
Flushing oil filling in Vac. Diesel product & CR circuit

2. Line up HEs (E102/E202) of total circuit ( trand1&2)
4. Close TV 1002 & 1502.
7. Line up ac 14 & AC16 and E39
9. Isolate cold V. diesel to H. slop.
10. Line up cold V. diesel to VR. VR to be lined up to off grade crude tank.
11. Isolate hot V. diesel to HDT at C/V (FV 3058B). Provide a hose connection at its bleeder to
OWS.
12. Full open FV3058A/B, QV 3003A, FV 3029. Keep QV 3003B closed.
13. Isolate cold V. diesel to storage at B/L

Page 150 of 592

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14. Charge FLO from P21.

15. Open HV 1012A & fill trend 1. Route it to crude tank through AC14.
16. Check sample at Fv 3058B. After that drain from FV 3058A drain to OWS.
17. Provide hose connection at E102 vent & remove N2 from it.
18. Close V. diesel to crude tank & stop draining from FV 3058A.
19. Close FV 1012A & Open FV 1012B.
20. Fill trend 2 (Via AC16 / E39) and drain through strainer 1A/B drain to CBD/OWS.
21. Also drain from strainer 2A/B to CBD/OWS.
22. Check sample from all drain. It should be free from water.
23. Blind all drains/ vents.
Flushing oil filling in VGO product & CR Circuit

4. De-blind hot QV, cold QV bleeder.
6. Isolate VGO to E58.
7. Isolate start up AGO & HVGO to VGO hot feed. Close battery limit valve.
8. Full open FV 3002A & 3002B.
9. Provide hose connection to drain point between VGO hot feed battery limit bleeders.
10. Isolate HVGO to AC15.
11. Line up AC 15
12. Isolate cold VGO to storage. Provide hose connection to drain point between two isolation
valves at B/L to OWS.
13. Line up cold VGO to crude tank via VR line.
14. Isolate strainers 03A/B d/s isolation valves. De-blind its drain.
15. Provide hose connection to all VGO HE vent.
16. Full open QV 3004A.
17. Charge FLO from P22 discharge.
18. Open HV 3008A & flush out trend 1 material to crude tank.
19. Vent out N2 from each H/E of this trend.
20. Check quality at H. Slop manifold.
21. After that drain from battery limit.
22. Close HV 3008A & open HV 3008B & flush out trend 2 material to CBD through strainer 3.
23. Vent out N2 from each HE of this trend
24. Check drain sample. It should be free from water.

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25. Blind all drains/ vents.

Flushing oil filling in HVGO product & CR circuit

2. Line up E124 / E224 / E149 / E150.
3. Line up HV3007A & 3007B & keep them closed.
6. Isolate all three HVGO rundown control valves.
7. Isolate AR to HVGO at P23 discharge.
8. Full open FV3016, QV 3002A. Keep QV 3002B closed.
9. Provide hose connection at E124 / E224 vents.
10. Isolate HVGO to E149 from both train.
11. Charge FLO from P23.
12. Open HV 3007A.
13. Drain to CBD from str.4A/B drain.
14. Check sample at E124C.
15. If it is water free, close HV 3007A & open HV 3007B.
16. Drain through Str.4A/B till FLO becomes water free.
17. Close draining from Str.4A/B, start draining from Str. 5A/B.
18. After that line up E149 of both circuit.
19. Drain from sample point till it is water free.
20. Vent out N2 from E124/E224.
21. Blind all drains/ vents, after filling is over.
Flushing oil filling in Recycle oil product & CR circuit

2. Isolate RO PA line FV 3012 d/s & bypass.
3. Isolate RO to VDU feed FV 3013.
4. Isolate RO to VR, FV 3064.
5. Provide hose connection at FV 3012, FV 3013, and FV 3064 drain to OWS.
6. Charge FLO from P24. Drain from above mentioned drains.
7. Blind all drains/ vents, after filling is over.

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A) CHARGING COLD CRUDE INTO UNIT :

(*The description given here is as per stream/train-1, the same philosophy also applicable to
Stream/train-2)
 Before taking crude inside unit B/L, inform OM&S shift in-charge to start 201-P-001Crude
pump on minimum circulation keeping the C/V at the pump discharge line closed.
 Connect a hose at the low point drain at the u/s of AVU B/L main isolation B/V and open the
C/V by 5-10%.Crack open LPD and drain out water from the crude main header to a safer
location.(nearby OWS).
 Once crude appears from the drain, stop draining and crack open the B/L valve.
 Connect hoses properly in the crude O/L lines’ high point vent bleeders of the pre heat
exchangers 010-E-102, 010-E-103, 010-E-104A/B/C/D, 010-E-106, 010-E-107and 010-E-
108.These vent bleeder hoses are to be discharged at a safer location.
 Keep open high point vent bleeder at the O/L of 010-E-102, crack open crude I/L main B/V
and bleed out gases through the hose connected at HPV till almost full bore crude started
coming out. Keep the bypass B/V of the crude side open during filling and it is to be kept
closed after filling. Isolate HPV bleeder B/V and Open crude O/L B/V.
 Similarly fill crude pre-heat exchangers up to 010-E-104A/B/C/D.
 Take HV1017A/B on line and fill up the crude pre heat exchangers up to 010-E-108.
 After disconnecting the hoses from HPV bleeders, the respective bleeders are to be capped/end
blinded.
 Disconnect PT-1195 provided at Desalter top and connect hose to OWS drain for N2/fuel gas
venting. Open desalter 010-V-102A vent line B/V provided on, charge crude to desalter by
opening a few threads of I/L B/V. Ensure desalter safety by pass B/V to be kept closed. When
full bore crude starts coming out of vent line, close vent line B/V.
 Open vent line B/V of desalter 010-V-102B, Charge crude to desalter keeping the main O/L
B/V of closed. When full bore crude comes out of the vent line, isolate vent line B/V.
 Desalter vent line flanges are to be boxed up with PT as mentioned above immediately after
filling desalter with crude.
 Isolate the crude Inlet & Outlet of 010-V-102A & 010-V-102B.
 Open Desalters bypass line B/V.
 In the same manner (As in Preheat Train-1) fill crude in pre heat train-2 heat exchangers 010-
E-108,010-HV-1018A/B, 010-E-131,010-E-117,010-E-119 and 010-E-118A/B/C/D.
 Open 010-PV-1019A/B, take crude in flash drum, 010-V-003 and build up 50%-60% level.
 Drain all the water from the bottom of flash vessel V003.
 Prime and start P-003A/B/C pump and start filling crude in the same as described above in pre
heat train-3 heat exchangers through 010-HV-1019A,010-E-122A/B/C/D,010-E-123A/B

Page 153 of 592

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and010-E-124A/B/C and through 010-HV-1019B, 010-E-129,010-E-132,010-E-126and010-

E-A127A/B/C/D/E/FG/H/J/K.
 Gradually open the main O/L B/Vs of 010-E-124A, 010-E-127A and 010-E-127F and build
up sufficient level (50%-60%) in 010-C-001 through furnace passes control valves.
 While taking crude through pass control valves verify all alarms are responding for their set
values on the controller. (Low flow, low-low flow, valve opening, maximum valve opening,
Bad value etc.).
 Similarly take crude in Train-2 pre heat exchangers, Desalters 010-V-202A/B and 010-F-201
up to 010-C-001.
 Stop flash drum bottom pumps 010-P-003 after building up level in 010-C-001. Drain all the
water from the bottom of 010C-001. Prime 010-C-001 bottom pumps 010-P-007A/B/C.

Page 154 of 592

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B) LINE UP & ESTABLISH CDU COLD CIRCULATION:

Line up CDU cold oil circulation from the field as per the below mention valve status checklist & cold
circulation schematic
Crude side of
CRUDE TANK 201-P-001A-E Desalter
PHT-1
Crude side of Crude side of

010-P-003A-C 010-V-003
PHT-3 PHT-2
VR side(shell
010-P-
010-F-101/201 010-C-001 side) of E-
007A/B/C
127F-K/227F-K
Start up line by
VR side(shell VR side (shell
passing 010 V- VR side of E-
side) of E- side) of E-
003 to CRUDE 151/251A-C
117/217 126/E-226
TANK

Page 155 of 592

Crude Tank
HV-1017A 2nd Bypass HV-1018A
(201-TK-001 to 011)
1
E-107 E-117 E-131
010-V-102 A 010-V-102 B
1ST Bypass
B/L
S. No
PV-1019A/B
E-102 E-103 E-104B E-108 E-128
HV-1017B E-106 HV-1018B E-118A-D E-119

Crude
HV-1517A HV-1518A
201-P-001 A-E PV-1022 A/B
010-V-003
E-207 E-217 E-231
010-V-202 A 010-V-202 B
Prepared By:
E-202 E-203 E-204B E-208 E-228
HV-1517B E-206 HV-1518B E-218A-D E-219
Debbrata Mondal, PNM

FV-1018 A-H
COLD CIRCULATION HV-1019A
D1 E-124A-C E-123A-B E-122 A-D
E-127A-E
D2 HV-1019B 010-P-003A-C
010-F-101 E-127F-K E-126 E-132 E-129
PARADIP REFINERY
FV-1518 A-H
OPERATING MANUAL
010-C-001
HV-1519A
BED-1 E-224A-C E-223A-B E-222 A-D
D1 D3 E-227A-E
BED-2
010-F-201 HV-1519B
E-227F-K E-226 E-232 E-229
BED-3
D4
E-127 A-E
Checked By:
D3
Page 156 of 592

C-007
D5 VR Quench
BED-4
Crude line Battery limit both isolation (2nos.) valves
Manish Kumar, CPNM

HS-1025
ENABLE
Valve Operation Checklist

LIC-1028
D4
BED-5 FV1124
VR TO DCU
E-127 F-K
E-126 E-117 E-151A/BC
FV-3004 A-L HSFO Tank
D5
010-F-002 010-P-007 A-C

E-227A-E VR TO DCU
PV 3115 STORAGE
VR Quench
CLOSE
OPEN
010-P-025 A-C 2'’
NOTE:
Status as Before
CLOSE FV1624
OPEN E-227 F-K
Approved By:
E-226 E-217 E-251A/BC
Status as Before
Doc. No:
Revision: 07
PDR/AVU/OM
Status
OPEN
Shashikant Kumar, DGM (PN)

Vacuum Circulation
Issued : 01-Jan-2023
Doc. No:
S. No Valve Operation Checklist Status

Shell & Tube side inlet and outlet isolation valve of following exchangers to be line
2
up
E-102 (shell side) OPEN
E-103 OPEN
E-104 OPEN
E-107 OPEN
E-106 OPEN
E-108 OPEN
E-128 OPEN
E-131 OPEN
E-117 OPEN
E-119 OPEN
E-118 OPEN
E-122 OPEN
E-123 OPEN
E-124 OPEN
E-129 OPEN
E-132 OPEN
E-126 OPEN
E-127 A-E CLOSE
E-127 F-K Tube side isolation valve OPEN
E-127 F-K Shell side (VR) isolation valve CLOSE
Crude side bypass of E-127 A-K isolation valve CLOSE

Page 157 of 592

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Shell & Tube side inlet and outlet isolation valve of following exchangers to be line
3
up
E-202 (shell side) OPEN
E-203 OPEN
E-204 OPEN
E-207 OPEN
E-206 OPEN
E-208 OPEN
E-228 OPEN
E-231 OPEN
E-217 OPEN
E-219 OPEN
E-218 OPEN
E-222 OPEN
E-223 OPEN
E-224 OPEN
E-229 OPEN
E-232 OPEN
E-226 OPEN
E-227 A-E CLOSE
E-227 F-K Tube side isolation valve OPEN
E-227 F-K Shell side (VR) isolation valve CLOSE
Crude side (Tube side) bypass of E-227 A-K isolation valve CLOSE
4 010-P-007 discharge header to 010-F-002 (Vac. Furnace) isolation valve CLOSE

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5 010-P-007 discharge header to 010-F-002 (Vac. Furnace) bypass line isolation valve CLOSE
6 FV-1124 U/S & D/S isolation valve (AR Inlet to E-127 F) OPEN
8 VR inlet & outlet (shell side) of E-127 A & E-127 F isolation valve CLOSE
9 VR total bypass of E-127 A-K isolation valve CLOSE
10 VR quench to 010-C-007 ex E-127 A-K isolation valve CLOSE
11 Vacuum start-up recycle line to F-002 ex E-127 A-K isolation valve CLOSE
12 VR R/D to E-126 ex E-127 A-K isolation valve (TI 1057 U/S) CLOSE
13 VR inlet & outlet (shell side) of E-227 A & E-227 F isolation valve CLOSE
14 VR total bypass of E-227 A-K isolation valve CLOSE
15 VR quench to 010-C-007 ex E-227 A-K isolation valve CLOSE
16 VR start-up recycle line to F-002 ex E-227 A-K isolation valve CLOSE
17 VR R/D to E-226 ex E-227 A-K isolation valve (TI 1557 U/S) CLOSE
19 AR outlet ex E-127K to E-126 isolation valve OPEN
20 AR outlet ex E-227K to E-226 isolation valve OPEN
21 AR inlet to E-126 (shell side) isolation valves (2nos ) OPEN
22 AR inlet to E-226 (shell side) isolation valves (2nos ) OPEN
23 Shell side inlet & outlet isolation valves of following exchangers to be line up
E-126 OPEN
E-117 OPEN
24 Tube & Shell side isolation valves of E-151 A/B/C OPEN
25 Shell side inlet & outlet isolation valves of Following exchangers
E-226 OPEN

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E-217 OPEN
26 Tube & Shell side isolation valves of E-251 A/B/C OPEN

27 VR common outlet ex E-151 A/B/C isolation valve OPEN
28 VR common outlet ex E-251 A/B/C isolation valve OPEN
29 VR to DCU storage B/L isolation valve CLOSE
30 VR to DCU B/L isolation valve CLOSE
31 VR to HSFO storage B/L isolation valve CLOSE
32 VR to CDU start up recycle line isolation valve OPEN
33 Start-up recycle line to 010-V-003 isolation valve CLOSE
34 Start-up recycle line to crude oil tank B/L isolation valve (2nos) OPEN
35 Start-up recycle line isolation valve to crude line at ISBL CLOSE
36 Start-up recycle line isolation valve u/s of diversion to crude oil tank OPEN
37 Crude tank area isolation valve line-up in the startup recycle line OPEN
38 Ensure U/S & D/S isolation valve of PV-1019 A/B OPEN
39 Ensure U/S & D/S isolation valve of PV-1022 A/B OPEN
39 Desalters (010-V-102 A/B & 010-V-202 A/B) crude inlet & outlet isolation valves OPEN
 Inform OM&S/IOTL
 Enable 10-C-001 level control (AR routing through VR circuit) selector switch, HS1025
 Start 010-P-003 and 010-P-007
 Preflash inlet pressure controllers PIC-1019 & PIC-1022 are to be kept in Auto mode with set point
around 15.0 kg/cm2g.
 Establish cold crude oil circulation from Tank to Tank through VR R/D circuits by opening FV-1124
and FV-1624(VDU bypass lines at P-007 discharge) for train-1 and train-2 respectively.
 Continue cold oil circulation for about two to three hours. Then stop circulation and allow water to
settle down for about one hour.
 Drain out condensate from all low point drains of columns, vessels, pumps and crude pre heat
exchangers.
 Repeat the above operation (circulation followed by draining) two/three times till all water in the
crude circuit is drained out.

Page 160 of 592

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 During cold oil circulation ensure the reliability of all pressure, temperature, flow and level
indications/alarms. If required re-calibrate Bottom level indication of 010-C-001/010 V-003.
 Fill up the shell side & run down circuits of pump around heat exchangers of HAGO & LAGO with
FLO. (The said operation will be useful after feed cut to maintain steady flow of PA reflux, so that
stabilisation of the column in a short duration is possible.)
 After filling reboilers of stabiliser, De-ethaniser and De-propaniser with FLO, by pass the LAGO PA
circuit to reboilers till commissioning of the above sections.
 Stop cold circulation once water removal from the system is ensured.
C) COMMISSION BFW TO STEAM GENERATORS&WHB :

 Inform CPP before taking BFW.
 Fill BFW level up to 60% in MP/LP steam generators (010-E-149/010-E-150 in HVGO circuit, 010-
E-151A/B/C, and 010-E-251A/B/C in VR circuit).
 Fill BFW level up to 60% in 010-WHB-001 steam drum.
 Keep vent line B/V of the steam generators and WHB steam drum in open condition.
D) ESTABILISH AMINE CIRCULATION

 Open the B/L B/Vs of incoming Lean amine and outgoing rich Amine lines of 10-C-010.
 Inform ARU-2 and receive Lean Amine up to 60% level in 010-C-010 through 010-FV-4001.
 After building up 60% level, start 010-C-010 bottom pump 010-P-033A/B and send back to ARU-2,
under level control 010- LIC-4004 to establish circulation.
 Take Treated gas knock out drum, 010-V-017 top pressure controller 010-PV-4005 in line with set
pressure 5.0 Kg/Cm2g. Ensure 010-PV-4005 bypass B/V is kept isolated.
E) HEATER LIGHT UP:
CDU Heater light-up steps are given below for detail Refer: Chapter-15
Sl. Action FPR Checked
No.
Pre-Start Up Checklist for Furnace
1 Confirm that the individual pass flows (50 MT/hr in each Pass) and Total pass Panel
flows (400 MT/hr in each Furnace) are healthy in both F-101 & F-201. I/C
2 Take BFW in steam drum (V-24) up to about 50% and make the IZ-640 Panel
healthy. Keep the LIC-1057 in auto mode. I/C
3 Line up the vent of the vessel (V-24) to atmosphere by operating the manual Field
isolation valve at the vessel top. I/C

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No.
4 Line up vent from LP & MP superheating coils to atmosphere through XZV- Panel
9301/XZV-1528 (LP Steam to Vent) & HV-1030/HV-1032 (MP Steam to I/C
Vent).
5 Confirm that the pilot & main burner leak test for F-101 and F-201 is Panel
successfully conducted & remove hold up nitrogen from the pilot gas header, I/C
open the drain valve at the end of the pilot gas ring in both the furnaces. Field
I/C
6 Confirm that all the Indications are showing expected values. If any readings Panel
are showing abnormal get it attended from Instrumentation. I/C
7 Confirm the readiness of ID/FD fan from field (Cooling Water, Bearing Oil Field
etc) I/C
8 Energise ID & FD Fan Field
I/C
9 Confirm PV-1098 is 100% open and is in HIC mode. Panel
I/C
10 Confirm PV-1035 (F-101) and PV-1535 (F-201) are 100% open and in HIC Panel
mode I/C
11 Confirm XZV-1029 (WHB bypass) & XZV-1030 (APH bypass) dampers are Panel
OPEN. I/C
12 Confirm XZV-1028 (WHB I/L) & XZV-1031 (APH I/L) dampers are Panel
CLOSED. I/C
FD Fan Start up
13 Confirm IZ-631 (Emergency shutdown push button) is healthy Panel
I/C
14 Bypass the Interlocks (IZ-634, IZ-664, IZ-635, and IZ-643) simultaneously, Panel
through a common switch for start up bypass provided in the ESD Panel. I/C
15 IZ-634: CONSEQUENCES OF IZ-106, 107 (118 & 119) 633, 640, 644
IZ-664: CONSEQUENCES OF IZ-506, 507 (518 & 519) 633, 640, 644

Page 162 of 592

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No.
IZ-506: HH Arch Pr. (PZT-1624 A/B/C < +5.0 mm WC)
Failure of both ID Fans
IZ-507: HH COT (TZT-1623 A/B/C < 376 Deg C)
LL Total Feed Flow (FZT-1516 A/B/C > 280 MT/hr)
LL Pass Flow (FZT-9308 A/B/C > 35 MT/hr)
LL Combustion Ait Flow (FZT-1584 A/B/C > 22.5 MT/hr)
LL Combustion Air Pressure (PZT-9319 A/B/C > 20 mm WC)
Failure of both FD Failure
IZ-518: HH or LL Main FG Pr. (0.2 kg/cm2 < PZT-1665 A/B/C < 2.45 Kg/cm2)
IZ-519: HH or LL FO Pr. (2.4 kg/cm2 < PZT-1672 A/B/C < 7.0 Kg/cm2)
LL Diff Pr. between Steam & FO (PDZT-1583 A/B/C > 1.5 kg/cm2)
IZ-633: HH or LL Temp. At APH Outlet (128 Deg C < TZT-1212 A/B/C < 190 Deg
C)
IZ-640: LL Steam Drum Level (LZT-1055 > 15%)
IZ-644: HH or LL Pilot Gas Pr. (0.5 kg/cm2 < PZT-1667 A/B/C < 1.5 Kg/cm2)
IZ-635: FAILURE OF SINGLE FD FAN (010-K-001 A/B)

Failure of single FD Fan (010-K-001 A/B)
IZ-643: ONE ID FAN FAILURE

One ID Fan Failure during APH/WHB Bypass
16 100% Open the APH bypass valve TV-1072. Keep TIC in Auto mode with set Panel
point of 100 Deg C. I/C
17 Open discharge XZV of either K-001 A (XZV-1037) or K-001 B (XZV-1038) Panel
by pressing reset button either from field or ESD. I/C
18 Start FD fan from field and open suction damper and maintain discharge Panel
pressure 380-400 mm WC by adjusting suction dampers. I/C

Page 163 of 592

Doc. No:

No.
Field
I/C
19 Carry out heater purging for 20-25 minutes and stop the FD fan. Again FD fan Panel
to be started after pilot burners light-up. I/C
Field
I/C
20 Manually open the air flow control valves FV-1082 and FV-1582 and maintain Panel
flow about 20 MT/hr of in each furnace. Then set the FIC-1082 and FIC-1582 I/C
in auto mode with set point of about 20-25 MT/hr.
Monitor the Furnace arch pressure in both the furnaces PIC-1035 and PIC-
1535.
21 Start the 2nd FD fan and stabilize the furnace. Panel
I/C
Field
I/C
22 When steady state is achieved and the arch pressure is healthy, reset the Panel
following interlocks and make it healthy (IZ-107, IZ-507) I/C
Pilot Burner Ignition:
23 Ensure Pilot Leak Test is cleared from BMS Panel. Panel
I/C
Field
I/C
24 By pass (IZ-644 BA/BB (LL / HH Pilot gas Pr.)) & IZ-118/IZ-518 (LL & Panel
HH Main FG Pressure) through a common switch provided in the ESD I/C
Panel.
25 Reset the Pilot Block & bleed valves (XZV-1023, XZV-1053, XZV-1054) Field
from BMS Panel I/C
26 Insert the portable igniter in the burner which is to be lighted up. Field
I/C
27 Open one of the XZVs of the pilot burner by pressing respective switch in the Field
BMS panel. Open the manual isolation valve of that particular burner in the I/C
pilot gas line at burner platform
28 Within 10 seconds, try to ignite the burner by switching on the igniter Field
repeatedly. If the burner is not lighted within 10 seconds, the pilot gas I/C
shutdown valve will close automatically. Close the manual isolation valve.
29 Then try to ignite another burner, in the same manner as described earlier Field
I/C
30 Within 10 minutes of the opening of shutdown valves, at least one pilot burner Field
should be lighted up. Otherwise, the pilot Block & Bleed XZVs shall be I/C
shutdown.

Page 164 of 592

Doc. No:

No.
31 If the XZVs are closed, then do the leak tests again and again try to ignite the Field
pilot burners as described above. I/C
32 If one pilot is lighted up, continue ignition of other pilot burners in similar Field
fashion. I/C
33 Similarly light up Pilot burners in F-201 also. Field
I/C
34 When Pilot burners are light up and the pilot gas pressure is healthy, reset IZ- Panel
644 BA / BB from ESD Panel. I/C
SAPH Start up (in case to be taken in line)
35 Start the SAPH be manually opening the LP steam isolation valve Field
I/C
36 Monitor temperature through TI-1228. Panel
I/C
ID Fan Start up
37 Ensure SOB (SOB-508 / SOB-509) of ID fans in open condition. Field
I/C
38 If the ID fan is started within 30 minutes of common bypass of the interlocks Panel
(IZ-643, IZ-634, IZ-664, IZ-643) in the ESD Panel, it is not required to I/C
bypass again.
39 If ID fan is started after 30 minutes of bypass, again bypass these interlocks Panel
through the common switch in ESD Panel. I/C
40 Start ID fan from field. Open suction damper of the running ID fan and Panel
stabilise the ID fan. I/C
Field
I/C
41 Similarly run the second ID fan and stabilise. Panel
I/C
Field
I/C
42 Ensure ID fan suction dampers are in HIC mode. Panel
I/C
43 Manually match the output of PIC-1035 and PIC-1535 with the Opening of ID Panel
fans suction dampers (PV-1214 A & 1214 B). I/C
44 When the output matches the opening of the dampers, change the mode of PV- Panel
1214 A & 1214-B from HIC mode to HS mode. I/C
45 Change the PIC-1035 & PIC-1535 from Manual Mode to Auto Mode and give Panel
set point of -7.0-8.0 mm WC. I/C
Main FG Burner Ignition:
46 By pass (IZ-644 BA/BB (LL / HH Pilot gas Pr.)) & IZ-118/IZ-518 (LL & Panel
HH Main FG Pressure) through a common switch provided in the ESD Panel I/C
if Main Burner is not lighted within 30 minutes.

Page 165 of 592

Doc. No:

No.
47 IZ-118 / 518:
48 Reset the Main Gas Block & bleed valves (XZV-1022, XZV-1049, and XZV- Field
1050) from BMS Panel. I/C
49 Manually open the Main FG control valve PV-1166. Panel
I/C
50 By opening isolation valves at burner platform, ignite the main burner one by Field
one. I/C
51 When FG pressure is stabilised, take PIC-1166 in auto mode and set pressure Panel
at 1.2 Kg/cm2g. I/C
52 Similarly light up Main Burners of F-201 and keep the PIC-1666 in auto mode. Panel
I/C
Field
I/C
53 The burner light up to be done within 30 minutes of bypassing the interlock Panel
else, again bypass the interlock from ESD panel. I/C
54 When parameters are healthy reset the interlock IZ-118 and IZ-518. Panel
I/C
55 Gradually close the PV-1098 (in HIC mode) and let ID fan control the Arch Panel
Pressure through PIC-1035 and PIC-1535 automatically. (before closing MSD I/C
take clearance from S/I or Plant Manager)
Temperature Increase & Charging Steam to Convection Coils:
56 Increase the temperature of the Furnace box by adjusting FG pressure. Panel
I/C
57 When Box temperature increases to 250 Deg C, charge MP and LP steam from Field
header to Convection Coils. I/C
FO Burner Ignition:
58 Bypass the Interlock IZ-119 and IZ-519 from ESD Panel. Panel
IZ-119 / 519: I/C
59 Open the FO Supply and Return shutdown valve XZV-1024 and XZV-1026 Field
from BMS panel. I/C
60 Open the PV-1161 manually and then set it in Auto mode at a set pressure of Panel
4.0 kg/cm2 of FO pressure. I/C
LL Diff Pr. between Steam & FO (PDZT-1083 A/B/C > 1.5
kg/cm2)

Page 166 of 592

Doc. No:

No.
61 Manually open the steam PDV-1162 so that the PDIC value is about 1.8-2.0 Panel
kg/cm2. When PDIC is reached set is in auto mode. I/C
62 Now take FO burner in line one by one as per temperature requirement. Field
I/C
63 Similarly take the FO burners of F-201 in line. Panel
I/C
Field
I/C
64 When FO pressure and PDIC values are healthy, reset the Interlocks IZ-119 Panel
and IZ-519 from ESD Panel. I/C
Taking APH in Line:

65 Bypass IZ-633 & 643, when temperature of Flue Gas (TT-1208: Flue Gas TT Panel
at common duct) reaches 320 deg C. I/C
66 XZV-1031 to be open by pressing reset button either from field or ESD. Panel
I/C
67 XZV-1030 to be closed by pressing reset button either from field or ESD. Panel
I/C
SAPH Shutdown:
68 When the heated air temperature reaches the desired range, close the LP steam Field
valve to SAPH. I/C
Taking WHB in Line:
69 Bypass IZ-640 only (if done within 30 minutes of bypassing IZ-643, else Panel
bypass both IZ-640 and IZ-643), when temperature of Flue gas (TT-1208: Flue I/C
Gas TT at common duct) reaches 460 deg C.
70 XZV-1028 to be OPENED by pressing reset button either from field or ESD. Panel
I/C
71 XZV-1029 to be CLOSED by pressing reset button either from field or ESD. Panel
I/C
72 When, steam generation in WHB is started, gradually close the vent of the Field
WHB Steam Drum (V-24) and route the MP steam to superheating coils. I/C
74 When MP steam temperature has reached the desired value, route the MP Panel
steam to header. I/C
75 Similarly route the LP steam to stripping steam header as per requirement. Panel
I/C
F) CDU HOT CIRCULATION :

Page 167 of 592

Doc. No:
Crude side of
010-V-003 010-P-003A-C 010-F-101/201
PHT-3
VR side (shell VR side(shell side)

side) of E-126/E- of E-127F- 010-P-007A-C 010-C-001
226 K/227F-K
VR side(shell side) VR side of E-

010-V-003
of E-117/217 151/251A-C
Line up for hot circulation as per attached drawing/valve operation status.

Page 168 of 592

Crude Tank
(201-TK-001 to 011) HV-1017A 2nd Bypass HV-1018A
E-107 E-117 E-131

010-V-102 A 010-V-102 B
1ST Bypass
B/L PV-1019A/B
E-102 E-103 E-104B E-108 E-128
HV-1017B E-106 HV-1018B E-118A-D E-119

Crude
HV-1517A HV-1518A
201-P-001 A-E PV-1022 A/B
010-V-003
Prepared By:
E-207 E-217 E-231
010-V-202 A 010-V-202 B
E-202 E-203 E-204B E-208 E-228

HV-1517B E-206 HV-1518B
CDU HOT CIRCULATION E-218A-D E-219
FV-1018 A-H
& HV-1019A
D1 E-124A-C E-123A-B E-122 A-D
VACUUM CIRCULATION E-127A-E
D2 HV-1019B 010-P-003A-C
010-F-101
PARADIP REFINERY
E-127F-K E-126 E-132 E-129

FV-1518 A-H
OPERATING MANUAL
010-C-001
HV-1519A
BED-1 E-224A-C E-223A-B E-222 A-D
D1 D3 E-227A-E
BED-2
010-F-201 HV-1519B
E-227F-K E-226 E-232 E-229
BED-3
D4
Checked By:
D3 E-127 A-E
Page 169 of 592

C-007
D5 VR Quench
BED-4
Manish Kumar, CPNM

HS-1025
ENABLE
LIC-1028
D4
BED-5
FV1124
VR TO DCU
E-127 F-K
E-126 E-117 E-151A/BC
D5
010-F-002 010-P-007 A-C

E-227A-E VR TO DCU
PV 3115 STORAGE
VR Quench
010-P-025 A-C 2'’
FV1624
E-227 F-K E-226 E-217 E-251A/BC
Approved By:
Doc. No:
Revision: 07
PDR/AVU/OM
Vacuum Circulation

Doc. No:
S. No Valve operation checklist Status
1 Shell & Tube side Bypass isolation valve of E-117/217 OPEN
2 Shell & Tube side inlet & outlet isolation valve of E-127/227 A-E CLOSE
3 Start-up recycle line to 010-V-003 isolation valve OPEN
4 Start-up recycle line isolation valve u/s of diversion to crude oil tank CLOSE
 Start 010-P-007A/B/C and 010-P-003A/B/C and establish circulation through furnaces.
 Make sure crude oil is passing through all passes and verify flow variation as per C/V output.
 Take “Low-Low crude flow to furnaces/individual passes” inter lock in line.
 Start FD fans and Light up the pilot burners as per the BMS procedure (Refer: Chapter-15 for details).
 Gradually increase coil O/L temperature to 1500C @ 150C/Hr or less by taking fuel gas/fuel oil burners.
 Preflash inlet pressure controllers PIC-1019 & PIC-1022 are to be kept in Auto mode with set point
around 15.0 kg/cm2g.
 Charge LP steam to super heating steam coils (after draining condensate) when the furnace box temp
reaches 2500C, vent out through silencer by opening XZV-9301 and ensure the other s/d valve XZV
9302 is closed.
 Close observation of temperature indications must be required while increasing coil O/L temperature.
Particularly TI points of furnaces. (Skin temp.box temp).
 Take 010-V-003 top pressure control on line (010-PIC-1021), ensuring C/V bypass B/V and safety by
pass B/V are in closed condition.
 Hold furnace coil outlet temperature at 1500C for two Hrs.
 Drain water from all low point drain.
 Raise coil outlet temperature to 2500C @ 150C/Hr.
 Give clearance for hot bolting and hold this temperature till hot bolting job is completed
 Drain water from stripper’s and PA pumps suction from where pump suction strainer is removed
(Suction strainer of a single pump in each service to be kept removed).
 Visually check for any leak. (Manhole flanges, piping flanges, heat exchanger flanges, B/V gland leaks
etc.) If any, get it attended.
 While raising COT, column top temperature will slowly increase; more condensate will get
accumulated in the side draws.
 Drain condensate from strippers and PA pump’s suction.

Page 170 of 592

Doc. No:
 Open the suction B/V of all pumps (Products and Pump around) and drain condensate through casing
drain to OWS. After ensuring system is free of condensate, box up the suction strainers which were
opened for draining.
 As the column top temperature increases top pressure also tends increase. Increase the set point of
column top pressure from 0.5Kg/Cm2 to1.0 Kg/cm2.
 Start overhead air coolers as per requirement, Condensed hydrocarbon vapour& water vapour will be
collected in 010-V-005.
 When 010-V-005 level raised @ 60%, Start 010-P-10A/B for 010-C-001 top reflux through start-up
reflux line to maintain top temperature around 1100C
 When boot water level of 10-V-005 raised around 40%, Start 010-P-011A/B and route boot water to
SWS unit.
CAUTION:
Avoid draining of sour water into OWS system.
 Now increase coil outlet temperature @ 150C/Hr.

 When 40%-50% level built in D-1(TPA tray level), drain out condensate through pump 010-P-
004A/B/C casing, prime the pumps and start the required no of pumps and establish total pump around
reflux to maintain column top temperature.
 Keep continue the start-up reflux from 010-P-010 A/B discharge until CDU column is stabilised.
 Start more no. of air coolers as per requirement, Ensure overhead circuit line up bypassing OFF gas
compressors.
 When the COT increases there is a requirement of fresh crude make up to maintain column level.
 Line up Desalters Crude I/L & O/L B/V and take crude by opening PV-1019/1022 (take the 010-V-003
level controller LIC 1010 in manual mode) from DCS to make up 010-C-001 column level. Minimise
desalter bypass B/V opening.(keep it open by a few threads).
 When the furnace flue gas temperature reaches @ 4000C take 010-WHB-001 and steam drum 010-V-
24 on line (vent open) after starting ID fans (010-K-002A/B) on 50% load. Keeping APH in bypass
condition.
 Once dry steam started coming out of steam drum vent line, close the vent and pressurise steam drum
above normal MP steam header pressure and charge steam through MP steam heating coils of furnace
, vent out steam through silencer till the required temperature is attained.
 Now take silencer control logic on line and route the steam to unit MP steam header.
 Take de-superheating control valve TIC-1135 on line.
G) CDU & VDU INTREGRATION:

Page 171 of 592

Doc. No:
SL.
Description
No
1 Ensure that C-001 bottom temperature has attained 320 deg C.
2 Ensure C-007 bottom level (LIC-3011) is low 20-30%
3 Ensure E-127/227 both Shell & tube side bypass isolation valve are open (3-4threads)
4 Drain out accumulated settled water from P25A/B/C suction.
5 Open flow control valve of F-002 all passes.
6 Ensure VR quench (FV 3008) in close condition.
7 Ensure/Open equalization valves of P-25A/B/C discharge isolation valves.
8 Full open P25A/B/C common discharge.
9 Full open warm up valves of each pump at both discharge & casing drain.
10 Crack open 10” I/V at the O/L of E-127/227 for F-002 startup only.
11 Crack open 2” bypass isolation valve of F-002 18” feed inlet and ensure 18” valve is isolated.
12 Ensure that line temperature has started increasing in all the above mentioned three operation.
13 Monitor flow & rise of temperature in F02 passes.
14 Periodically open the valves mentioned at step 10 & 11 in small step.
15 Monitor flow & rise of temperature in F02 passes.
16 Check temperature rise by touching the lines mentioned in step 8, 10 & 11.
17 Slowly F02 pass inlet temperature will rise.
18 Allow build up level in C-007 up to 80%.
19 Isolate P-25A/B/C warm up.
20 Start one of P-25 as per SOP. Open discharge 1-2 thread.
Continue to run the pump at this condition till pump casing temperature has attained > 250 deg C
21
and F02 coil inlet & coil outlet temperature delta is minimized. It may take 20 – 30 minutes.
22 Open P-25 discharge valve more.
Simultaneously open F02 18” valve in steps & close FV 1124 / 1624 slowly as per requirement to
23
maintained C-001 column level.
When 18” inlet valve is fully opened, close 18” line bypass & VDU circulation valve at E127 /
24
E227 outlet manifold (F-002 startup only).
25 Observe VR heat exchanger condition.

Page 172 of 592

Doc. No:
26 If everything is ok, close E127 / E227 bypass slowly in steps.

27 Put stand by pumps under warm-up condition.
H) CDU FEED CUT:
 When COT increased to 3300C, charge stripping steam gradually to 010-C-001 after draining condensate
completely. Close silencer vent line B/V.
CAUTION:
1. Before introducing stripping steam ensure TPA is established and top temperature is
perfectly under control.
2. Drain condensate from the u/s drain of the stripping stem C/V and also from LPD at the
u/s B/V, near the column.
 Inform DCU/OM&S, route AR to DCU and bring CDU out of circulation (as per attached sketch/valve
operation status) by taking fresh crude through normal circuit.
CDU FEED CUT
1 Vacuum Residue to DCU B/L upstream isolation valve OPEN
2 CDU Stat-up recycle line from VR R/D line isolation valve CLOSE

Page 173 of 592

Crude Tank 2nd Bypass HV-1018A
(201-TK-001 to 011) HV-1017A AO4 AC5 AO5
E-117 E-131
E-107 010-V-102 A 010-V-102 B
1ST Bypass
B/L PV-1019A/B
E-102 E-103 E-104B E-108 E-128
AC4
HV-1017B HV-1018B E-118A-D E-119
E-106
Crude AC7 HV-1518A
HV-1517A
201-P-001 A-E PV-1022 A/B
AO6 AO7
010-V-003
E-217 E-231
Prepared By:
E-207
010-V-202 A 010-V-202 B
E-202 E-203 E-204B E-208 E-228
AC6

HV-1517B E-206 HV-1518B E-218A-D E-219
FV-1018 A-H
AC2
HV-1019A
D1 E-124A-C E-123A-B E-122 A-D
E-127A-E
D2 HV-1019B 010-P-003A-C
010-F-101 E-127F-K E-126 E-132 E-129
PARADIP REFINERY
FV-1518 A-H
OPERATING MANUAL
010-C-001
HV-1519A
BED-1 E-224A-C E-223A-B E-222 A-D
D1 D3 E-227A-E
BED-2
HV-1519B
010-F-201 E-227F-K E-226 E-232 E-229
BED-3
D4
E-127 A-E
D3
Checked By:
C-007
Page 174 of 592

D5 VR Quench
BED-4
HS-1025 VC31
Manish Kumar, CPNM

ENABLE AC3 AC11
VO4
LIC-1028
D4 AO11
BED-5 FV1124
VO31 VR TO DCU
VC31 VC4
E-127 F-K
E-126 E-117 E-151A/BC
HSFO Tank
FV-3004 A-L
D5
010-F-002 010-P-007 A-C E-227A-E VR TO DCU

PV 3115 STORAGE
VR Quench
VO2
VO4
VC31 AC3
010-P-025 A-C 2'’
VO1 FV1624
VC31 VO31
E-227 F-K VC4 E-226 E-217 E-251A/BC
Approved By:
Doc. No:
Vacuum Circulation
Revision: 07
PDR/AVU/OM

Doc. No:
 Increase coil outlet temperature to 3570C.

 When level appears in the side draws D-2, D-3 and D-4, drain condensate from the respective pump’s
casing drain, prime the pumps, start and establish pump around and refluxes.
 After achieving steady pump around & reflux flows and adequate level in draw trays open the draw
C/Vs of the respective strippers and bring stripper level to 50%.
 Gradually charge stripping steam to the strippers after draining condensate.
 Drain condensate through stripper bottom pump’s casing drain. Prime & start the pumps and route
products to the slop tanks.
 Start product air coolers as per the requirement.
 When hydrocarbon level builds up in 010-V-005, line up the 010-P-010A/B normal discharge, pump-
out crude over head liquid to 010-V-007 through Recontactor cooler (010-AC-008) and 010-E-35A/B.
 Start 010-P-011A/B and route boot water to SWS unit.
 Set the top pressure of 010-V-007 at 6kg/cm2 through PIC-2011
 Start 010-V-007 bottom pump 010-P-013A/B and route the unstabilized naptha to naptha/slop tanks
bypassing stabilizer, 010-C-004.
 Start OFF gas compressors as per the standard operating procedures.
 Take APH in line as per the standard operating procedures.
 Inform ARU for necessary action.
 Line up PIC-2001 (10-V-007 gas to 10-V-006).
 Make sure the compressor discharge line up to 010-V-007 through recontactor cooler 010-AC-008
and recontactor trim cooler 010-E-35A/B.
 When crude inlet temperature of desalter raised up to 1200C switch ON transformer power.
 Build up 60% level in 010-V-001 by taking SW/Service water make up C/Vs on line, Start 010-P-
001A/B and inject wash water (8% by volume) to the crude I/L of second stage desalter (10-V-102B)
through 010-E-113A/B and 010-E-116 for train-1.(vent out air before opening injection B/V)
 Set the delta pressure across the mixing valve @ 0.8Kg/cm2.
 Once interface level built in the desalter 010-V-102B (around 30-40%), start 010-P-103A/B/C and
inject water to first stage desalter, 010-V-102A.
 Route desalter effluent from to ETP through 010-E-113A/B and 010-E-152 under interface level
control of first stage desalter. Close Desalters bypass line B/V.
 Similarly commission 10-V-202A/V-202B.
 Pressurise the steam generators (E-149/150/151A-C/251A-C) by closing its vent valve and divert
steam to LP/MP headers of the 10-F-101/201.
 Start chemical dosing pumps, inject corrosion inhibitor and neutralising amine to 010-C-001 overhead
vapour line. Demulsifier to crude at the u/s of 2nd stage desalters,Anti foulant at crude O/L of second
stage desalter and trisodium phosphate to boiler feed water for WHB& steam generators.


Page 175 of 592

Doc. No:
NOTE:
Even in case of non-availability of off-gas compressor Stabiliser can run stand alone.
I) COMMISSIONING OF STABILISER
 Inform ARU
 Divert 010-P-013A/B discharge to stabilizer by isolating stabiliser bypass line B/V.
 Build up 60% level in 010-C-004 through 010-E-037A/B/C.
 Take reboiler 010-E-038 in line (displacing cold FLO by LAGO PA).Gradually increase bottom
temperature up to 1900C taking TIC-2013 on line.
 Start over head air coolers (010-AC-009) as per requirement.
 When 010-C-004 top temperature increases to 800C, liquid level builds up in 010-V-008.
 Start reflux pump 010-P-015A/B, slowly increase reflux quantity to bring down the top temperature
to 700C. As the top temperature decreases with increase in reflux quantity the top pressure increases.
 Maintain normal operating parameters by taking the respective control valve in line i.e. bottom
temperature (TIC-2013), top pressure (PV-2018) and top temperature (TIC-2015).
 Route 010-V-008 boot water to SWS unit under level control LIC-2012
 Sent naphtha sample to laboratory from stabilizer bottom for RVP checking.
 Route stabiliser bottom to naptha R/D tank through 010-E-37A/B/C.,010-AC-010 and 010-E-40A/B
under level control LIC-2007. As per the requirement hot feed can be routed to naptha HDT unit.
J) COMMISSIONING OF DE-ETHANISER :
 Make sure that Amine & Caustic circulation have been established in SR LPG unit.
 Ensure the line-up of de-ethaniser bottom to SR-LPG unit.
 Prime 010-P-016 (010-C-004 over head liquid to 010-C-005).Start the pump and build up 60% level
in 010-C-005, De ethaniser column.
 Take reboiler 010-E-043 in line after displacing cold FLO by LAGO PA, Increase 010-C-005 bottom
temperature to 850C by increasing LAGO PA flow to the reboiler.
 When de-ethaniser top temperature reaches 650C, Over head vapours passes through condenser 010-
E-042, gets condensed and collected in the receiver vessel 010-V-009.
 After building up @50% level in 010-V-009, start the total reflux pump, 010-P-018A/B for reflux
(Total reflux) and spill back under level control LIC-2016.
 Route 010-V-009 boot water to SWS unit.
 Start 010-P-002A/B/C and route sour LPG to SR LPG unit through 010-E-044
 Provision is given to route De-ethaniser bottom directly to off spec LPG bullets and to depropaniser
column along with depropaniser feed.

Page 176 of 592

Doc. No:
 Take 010-V-009 pressure control on Auto mode PV-2065A/B (split range) to route excess gases to
fuel gas treatment section along with 010-V-007 gases or directly to LP flare.
K) COMMISSIONING OF DEPROPANISER:
 Take sweet LPG from SR LPG unit and Build up 60% level in De propaniser 010-C-006 after ensuring
bottom and overhead circuit line up.
 Take reboiler 010–E-047 in line after displacing cold FLO by LAGO PA, Increase 010-C-006 bottom
temperature to 950C ( Taking TIC-2035) by increasing LAGO PA flow to the reboiler.
 When top temperature reaches 400C, the overhead vapours produced passes through condenser 010-
E-046, gets cooled and collected in 010-V-10 as C-3 LPG.
 Control the top pressure of 10-C-006 by taking PIC-2038 in line.
 Start 010-V-010 LPG bottom pump, 010-P-19A/B/C and send a part to 010-C-006 as reflux and
remaining to storage/Off spec LPG bullets.
 Route boot water to SWS unit.
 Start depropaniser bottom pump 010-P-20A/B and route C-4 LPG through LPG product cooler 010-
E-48 to storage/alkylation unit/off spec LPG bullets.
L) STABILISATION OF CDU:
 Try to operate the unit operating parameters closer to the design operating parameters to achieve
quality and quantity products.
 All control loops are to be kept in AUTO/CASCADE mode.
 All duty controls are to be taken in line to maintain product draw temperature.
 Take LP steam to super heating coils TICs of 010-F-101/201 and MP steam super heating coil TIC at
the O/L of 010-F-101 controls in line after ensuring its healthy status in PLC.
 Maximise PA to achieve better fractionation and to increase pre heat temperature.
 Maintain over flash @ 4% by volume of total crude thru put to maintain the quality of D-4 side draw
product and to minimise Diesel components falling down to AR.
 All safety inter locks are to be taken in line after ensuring healthy condition.
 After normalising the unit, send product samples to laboratory and accordingly route ON SPEC
products to OM&S/secondary units as per requirement.
 Visually check all static/rotary equipments, if any abnormalities noticed/observed take preventive
measures/corrective action in time to avoid any major incidents or loss of property.
7.3 VDU START UP PROCEDURE:

Major Steps involved

Page 177 of 592

Doc. No:
1. Tightness check with plant air

2. Vaccum test
3. Vacuum breaking and inertisation with N2
4. Steaming, FG/Nitrogen back up & Condensate draining. ( *This step to be completed during pre-
commissioning activity)
A) VDU cold circulation/Overhead circuit line up.
B) Establish cold circulation.
C) Burner light-up
D) Establish hot circulation.
E) Replacement of FLO by hot AR.
F) Vacuum pulling & Feed cut
G) VDU Stabilization and product routing
A) VDU cold circulation/Overhead circuit line up

Line up the VDU circulation through following loops (as per Line up sketch/valve operation status
given below)
E-127A-E
010-C-007 010-P-025A-C (Via start up 010-F-002 010-C-007
recycle line)

Page 178 of 592

Crude Tank
(201-TK-001 to 011) HV-1017A 2nd Bypass HV-1018A
E-107 E-117 E-131

010-V-102 A 010-V-102 B
1ST Bypass
B/L PV-1019A/B
E-102 E-103 E-104B E-108 E-128
HV-1017B E-106 HV-1018B E-118A-D E-119

Crude
HV-1517A HV-1518A
201-P-001 A-E PV-1022 A/B
010-V-003
Prepared By:
E-207 E-217 E-231
010-V-202 A 010-V-202 B
E-202 E-203 E-204B E-208 E-228

HV-1517B E-206 HV-1518B
CDU HOT CIRCULATION E-218A-D E-219
FV-1018 A-H
& HV-1019A
D1 E-124A-C E-123A-B E-122 A-D
VACUUM CIRCULATION E-127A-E
D2 HV-1019B 010-P-003A-C
010-F-101 E-127F-K E-126 E-132 E-129
PARADIP REFINERY
FV-1518 A-H
OPERATING MANUAL
010-C-001
HV-1519A
BED-1 E-224A-C E-223A-B E-222 A-D
D1 D3 E-227A-E
BED-2
010-F-201 HV-1519B
E-227F-K E-226 E-232 E-229
BED-3
D4
D3 E-127 A-E
Checked By:
Page 179 of 592

C-007
D5 VR Quench
BED-4
Manish Kumar, CPNM

HS-1025
ENABLE
LIC-1028
D4
BED-5
FV1124
VR TO DCU
E-127 F-K
E-126 E-117 E-151A/BC
D5
010-F-002 010-P-007 A-C

E-227A-E VR TO DCU
PV 3115 STORAGE
VR Quench
010-P-025 A-C 2'’
FV1624
E-227 F-K E-226 E-217 E-251A/BC
Approved By:
Doc. No:
Revision: 07
Vacuum Circulation
PDR/AVU/OM

Doc. No:
S. No Valve operation checklist Status
1 P-025 discharge to E-127 A shell side inlet isolation valve OPEN
2 E-127 E shell side outlet isolation valve OPEN
3 E-127 E tube side (crude) inlet isolation valve OPEN
4 E-127 A tube side (crude) outlet isolation valve OPEN
5 Vacuum Residue recycle to 010-F-002 ex E-127 A-E isolation valve (2nos) OPEN
1 P-025 discharge to E-227 A shell side inlet isolation valve OPEN
2 E-227 E shell side outlet isolation valve OPEN
3 E-227 E tube side (crude) inlet isolation valve OPEN
4 E-227 A tube side (crude) outlet isolation valve OPEN

Vacuum Residue recycle to 010-F-002 ex E-227 A-E isolation valve (2
10 OPEN
no’s)
 Ensure overhead circuit line up. For uncondensed vapours, up to 010-V-011 keeping its vent open to
atmosphere and furnace side B/V isolated.
 Condensate to 010-V-013.Interface routing to SWS unit through 010-P-28A/B and hot well oil to
DHDT through pump 10-P-27A/B via coalescer 010-V-015 to be lined up.
 Ensure water level in the barometric vessel, 010-V-13 and sour gas seal drum, 010-V-014.
 Make sure that amine circulation is established in low pressure scrubber 010-C-009.
 Ensure cooling water line up to Ejector condensers.
B) Establish VDU cold circulation
 Deblind 4 inch FLO line joining at the D/S B/V of VR quench line to 010-C-007.
 Charge FLO through 4 inch FLO line connected to VR quench line to 010-010-C-007 and build up
60% level.
 Once 010-C-007 level built up to 60%, take column bottom materials to pumps, Prime the pumps,
Start 010-P-025 A/B and establish cold circulation through 010-F-002 passes.
 While taking FLO through furnace passes, take flow through all passes one by one, Verify alarm
conditions and maintain equal flow in passes, within alarm limits.

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 After establishing steady flow in passes and maintaining 60% level in the column, stop receiving FLO
make up to 010-C-007.
 Stop cold circulation after 3-4 Hrs.Allow1-2 Hrs.to settle condensate. Drain condensate from all low
point drain bleeders.
C) VDU HEATER LIGHT UP:
Refer Chapter-15 for details.
D) VDU HOT CIRCULATION:
 After ensuring condensate removal, establish circulation by starting 010-P-025A/B/C pumps.

 Ensure flow through all passes of 010-F-002.
 Light up pilot burners as per BMS procedure. (Refer Chapter-15 for details).
 Take pass flow interlocks on line before burner light up.
 Increase COT to 150deC @15-20 deg C/Hr and hold temperature for two Hrs.
 Drain out condensate from all low point drains.
 When box temperature reaches 250deg C, charge LP steam to super heating coils and vent out steam
through silencer.
 Give clearance for hot bolting.
E) Replacement of FLO by hot AR.
 Increase COT to 1800C by taking main burners on line (FO/FG), at this temperature slowly displace
FLO by hot AR.
 Take AR (3450C) through 2inch bypass line of main feed I/L B/V to 010-F-002 from 010-P-007A/B/C
discharge.
 Displace FLO and AR mix material to DCU storage along with 010-E-127K O/L by taking FV-1097
in line.
 Check sample time to time and make sure that FLO is completely replaced by AR. Sample can be
collected from the U/S drain bleeder of FV-1097(Temporary sample cooler to be arranged or
permanent provision to be made.)
 Increase COT to 300deg C @ 15-200C/hr.
F) Vacuum pulling & Feed cut

Page 181 of 592

Doc. No:
 At 300 Deg C gradually open 010-P-007 discharge main block valve to 010-F-002 and continue AR
routing to DCU through 010-F-002 as per following :
010-E-127 A-E
010-F-002 010-C-007 010-P-025
/E-227 A-E
DCU (routing change

010-E-151 010-E-117/ 010-E-116/
to be carried out as
A/B/C & E-251
per valve operation E-217 E-216
A/B/C
checklist)
 Take CDU column level controller LIC-1025 cascading with FIC 3003 (Vacuum Furnace total feed
Flow) and slowly close FIC-1124 & FIC-1624.
 If required reduce 010-F-002 firing as there will be sudden rise in Vacuum COT after routing AR
completely through Vacuum Furnace.
 Increase Vacuum COT upto 350 Deg C @ 15-20 deg C /hr.
 Drain condensate from low point drain bleeders of the MP steam header to ejectors.
 Ensure vacuum column O/H circuit is line-up upto off gas KOD (010-V-016).
 Open the KOD vent line isolation valve.
 Start vacuum pulling at a very slow rate by commissioning second stage ejectors, first stage ejectors
and booster stage ejectors as per the standard operating procedure for taking ejectors on line.
 Close fuel gas/nitrogen back up isolation valves; maintain column top pressure @ 17mm/Hg.
 Drain condensate from superheated stripping steam header up to the U/S side of main isolation B/V s.
(near column).
 Charge stripping steam (both sides) very slowly after ensuring condensate removal from the super
heated stripping steam header.
 Increase the 010-F-002 COT to 400 deg C @ 15-20 deg C /hr.
 When flue gas temperature reaches @ 4000C take WHB-002 on line taking ID fan on line, keeping
APH bypassed.
 Route WHB steam to F-002 MP steam coils and vent out through silencer.

Page 182 of 592

Doc. No:
S.
CHECKLIST Status
No
VDU FEED CUT
1 010-P-007 discharge isolation valve to F-002 OPEN
VR R/D to E-126 ex E-127 A-K isolation valve (TI 1057 U/S)

2 OPEN
N.B-Ensure FV-1097 is lined up
3 Vacuum Residue recycle to 010-F-002 ex E-127 A-E isolation valve (2nos) CLOSE
4 E-127 F shell side (VR) inlet isolation valve OPEN
5 E-127 K shell side (VR) outlet isolation valve OPEN
6 AR to E-127 F Shell side inlet isolation valve CLOSE
7 AR ex E-127 K Shell side outlet isolation valve CLOSE
8 FV-1124 U/S & D/S isolation valve (AR Inlet to E-127 F) CLOSE
VR R/D to E-226 ex E-227 A-K isolation valve (TI 1557 U/S)

9 OPEN
N.B-Ensure FV-1597 is lined up
10 Vacuum Residue recycle to 010-F-002 ex E-227 A-E isolation valve (2nos) CLOSE
11 E-227 F shell side (VR) inlet isolation valve OPEN
12 E-227 K shell side (VR) outlet isolation valve OPEN
13 AR to E-227 F Shell side inlet isolation valve CLOSE

Page 183 of 592

Doc. No:
S.
CHECKLIST Status
No
14 AR ex E-227 K Shell side outlet isolation valve CLOSE
 When level in D-1 tray builds @40%-50%, start vacuum diesel pump 010-P-021A/B, establish steady
pump around flow to control top temperature, vacuum diesel reflux and product to slop tank.
 Similarly as and when level builds up in D-2, D-3 and D-4, start 010-P-022A/B/C for VGO, 010-P-
23A/B/C for HVGO for pump around/reflux/rundown.
 Start product R/D air coolers as per the requirement.
 When level builds up in D-5, start 010-P-024A/B and route its discharge to 010-F-002 feed I/L line as
per the requirement.
 Start 010-P-028A/B and 010-P-027A/B, route hot well interface water/oil to SWS unit and DHDT
storage.
G) VDU Stabilization and product routing:

 Maintain COT 4000C.
 Take all bypassed pre heat exchangers on line carefully to avoid thermal shock/leak.
 Charge turbulising steam to radiation tubes of all passes.
 Commission APH as per the standard procedure for taking APH in line.
 Take all controls in AUTO/CASCADE mode and all safety interlocks in line.
 Commission BFW and route MP steam from furnace O/L to main MP steam header of 010-F-002.
 Maintain operating parameters closer to design operating parameters to get quality and quantity
products.
 Take column top pressure C/V PV-3019 on line. Commission 010-F-002 LP burners after closing
010-V-011(vent gas knock out drum) vent line B/V.
 After ensuring product quality route ON SPEC products to storage/secondary units as per the
requirement.
 Start ammonia and corrosion inhibitor injection.
 Physically check for any leak/abnormality in all areas of vacuum section.

Page 184 of 592

Doc. No:
CHAPTER-8
NORMAL SHUTDOWN PROCEDURE

Page 185 of 592

Doc. No:
8.1 INTRODUCTION
In this section, procedure for planned shutdown (M&I) is discussed.
8.2 SHUT DOWN SEQUENCE

The shut down sequence indicated below will ensure a systematic and smooth shut down of the
unit.
1. Pre Shut Down activities
2. Reduction of feed rate to all units
3. Shutdown of vacuum section
4. Shutdown of atmospheric section
5. Shutdown SR LPG Treater and De-Propaniser.
6. Shutdown De-ethaniser and Stabilizer.
All the above steps are elaborated subsequently: -

8.2.1 PRE SHUT DOWN ACTIVITES
 Shut Down the unit preferable with Light Crude (50/50 Oman/Basrah), so switch over the crude
processing accordingly.
 CBD pumps 010-P-610/611/612/613/614 are in ready condition and underground CBD vessel
010-V-610/611/612/613/614 are emptied out in advance.
 All tools and tackles to be arranged in advance
 Blinds with tag marking to be arranged as per standard blind list and to be kept at appropriate
location.
 Ensure maximum ullage in slop tank.
 Bring down inventory of chemicals.
 Chemicals to be used during shut down (KMn0 4 for column washing, chemicals for alkali Boil
out, Lime powder for APH washing) to be arranged in advance.
 Arrangement of Scaffoldings for difficult approaches.
 Inform OM& S to make arrangements to supply adequate FLO.
8.2.2 REDUCTION OF FEED RATE TO ALL SECTIONS

 Inform RSM, CPP, DCU, DHDT, NHDT, ETP, Offsite Area, VGO HDT, Alkylation, ARU &
SWS.
 Reduce unit throughput to 50% of design crude charge rate (1060m3/hr), holding temperature
and pressures, maintaining product specifications and continuing product rundown to storage.
.
8.2.3 SHUTDOWN OF VACCUM SECTION

Page 186 of 592

Doc. No:
A. VDU T’PUT REDUCTION
 Ensure Crude throughput is reduced to 50% of design rate (686 m3/hr).

 Inform the OMS to divert Vacuum column products(Vac. Diesel, VGO, HVGO, VR) from
rundown (or) downstream units to heavy slops tank and line up for the same at AVU B/L
 Divert Recycle oil discharge through VR pump discharge to heavy slops
B. COT REDUCTION:
 Reduce COT @ 30º C/hr to 350º C.

 Stop velocity steam to furnace passes.
 Take 010-F-002 on force draft (Open the MSD, PV-3118 and stop the ID fans 010-K-
005A/B).
 Stop BFW flow to Steam Drum 010-V-022 by closing FV-3078 and also phosphate
injection.
 Divert Recycle oil discharge through VR pump discharge to DCU.
 Inform the OMS to divert Vacuum column products (Vac. Diesel, VGO, HVGO) from
rundown (or) downstream units to heavy slops tank and line up for the same at AVU B/L.
 Stop chemical dosing injection to 010-C-007
 Isolate (B/V in the oxidiser vent gas I/L to 010-C-009) oxidiser vents gas from SR LPG
Treatment unit and vent out the same from 011-V-008.
 Inform ARU-1, stop receiving Lean amine (close FV-4002) and bring down 010-C-009
level by pumping out rich amine.
C. PUTTING VDU ON HOT CIRCULATION:
 At 350º C, put VDU on hot circulation and route AR to DCU through VR circuit. The VDU
circulation to be lined up through following loops:

Page 187 of 592

Doc. No:
010-C-
007
010-F- 010-P-
002 025
The following operations to be carried out for hot circulation line up:
STEP-1:
a) Open the E-127 & E-227 shell side (VR) bypass isolation valve isolation valve in the
vacuum start up recycle line of both Trains ( line no: 250-P-010-1246-B4AV-IT & 250-
P-010-1746-B4AV-IT) ( Total no. valves:2)
b) Line up the downstream of AR circuit to E-126 from E-127K/227K (Total no. Of B/V: 2
X 2=4)
c) Ensure FV-1124 & FV-1624 (C/V for AR routing to E-127F/227F) are in closed condition
and respective c/v isolation valves are in open condition.
STEP-2:
a) Divert the 010-P-25A/B/C discharge to 010-F-002 by opening up VDU circulation B/V’s
ex E-127 & E-227 in the line no. 250-P-010-1310-B4AV-IT & 250-P-010-1810-B4AV-IT
(dedicated circulation lines from 10-E-127/227 VR O/L lines to 10-F-002). (Total no. Of
valves:1 X 2=2) and close FV-1097/1597, VR R/D C/V
b) Close the B/V in the VR I/L & O/L line to E-127 F & A & 227 F& A line no: 250-P-010-
3009-038P-IT/250-P-010-3209-038P-IT and 250-P-010-1270-038P-IT /250-P-010-1770-
038P-IT. (Total no. Of valves:2x2=4)
c) Now divert the flow of AR from 010-F-002 through VR R/D circuit to DCU storage by
changing selector switch HS-1025 (010-C-001 bottom level control) as a result of which
010-FIC-1124/1624 will open.

Page 188 of 592

Doc. No:
d) Close the 010-P-007 discharge isolation valve towards 010-F-002
N.B: All the above activities mentioned in step-2 to be carried out in parallel.
e) Open the steam venting valve of 010-E-150/151/251 to maximize the rate of cooling of
AR to DCU. ( if required)
f) Close VR quench C/V from panel (010-FIC-3008) once AR is diverted to VR R/D circuit
D. VACUUM COLUMN OVERHEAD SECTION & VACUUM BREAKING
 After putting VDU on hot circulation, start reducing 010-F-002 COT @ 300C/hr up to
2500C.
 Isolate ejectors in the order of :
1. Booster ejectors 010-EJ-001,
2. First stage ejectors 010-EJ-002
3. Second stage ejectors 010-EJ-003.
The operation to be carried out by following the steps given below:

a) Close Booster Ejector vapour inlet B/Vs: For 010-EJ-001A/B/C: B/Vs (3nos.) in the vapour
lines coming from 010-C-007 overhead (Line no.: 1600-P-010-3311-A2A6-IA, 2200-P-
010-3002-A2A6-IA, 1900-P-010-3093-A2A6-AI)
b) Close Vac. Column pressure C/V PV-3019
c) Close motive steam to ejector (First individual HVs of Booster Ejector, 1 st stage and 2nd
stage ejectors and finally close main steam C/V 010-HIC-3013)
d) Open the nitrogen back up valve & back up nitrogen to the column and maintain positive
pressure (0.5Kg/cm2).
e) Isolate stripping steam to 010-C-007; stripping steam C/V, FV-3007 and isolation valve
near to column. Vent out steam through 010-F-002 silencer.
f) Isolate cooling water to each ejectors condenser gradually (010-E-53-A-M, 010-E-54,010-

E-055) and drain /depressurize all condensers.
g) Isolate off gas (From 010-E-055) to sour gas system (010-V-014) through the B/V provided
in the line 200-P-010-3038-B2A6-NI.
h) Isolate the Vent Gas flame arrestor and individual B/V of all Vent gas burners.

Page 189 of 592

Doc. No:
E. DILUTION OF COLUMN CONTENT

 Around 2000 C Vacuum sections is ready for dilution with Gasoil. Keep minimum levels
in Vacuum column draw trays and at bottom to minimise the thermal shock while
diluting through gasoil.
 For dilution of column content let the Vac. Diesel, VGO & HVGO pumps continue to run
& increase internal refluxes to make the vacuum column bottom content lighter.
 Bring down 010-C-007 level to minimum operating range by gradually displacing column
bottom material along with AR by opening VR R/D C/V FV-1097/1597.
 Start introducing gasoil through Vacuum diesel/ VGO/HVGO ( gas oil can be taken from
the FLO line provided at Vac. Diesel/VGO/HVGO PA return strainer)
 Flush all instruments connected to Vacuum column.
 VDU circulation will continue with this diluted column bottom material for furnace coil
dilution. Also flush the recycle line to 010-F-002 (open Recycle oil C/V to 10-F-002, FV-
3013).
 Stop Vacuum Diesel/VGO/HVGO/Recycle oil pumps after emptying out respective Draw
trays, D1/D3/D4/D5.
 When vacuum column material is sufficiently diluted & the VDU furnace COT comes
down to 150 deg C, take FLO in column bottom through the dedicated line provided (100-
FLO-010-3106-A1AD-NI) and reduce the circulation rate.
 Start emptying out column bottom material (open FV-1097/1597 and line up VR to 010-
AC-015 through VGO circuit in the downstream of 010-E-150) to heavy slop tank/crude
tank (scheme for the routing proposed).
 Stop circulation (isolate VDU furnace passes C/V).
F. FURNACE COIL PURGING:
 Line up coil purging steam main header isolation B/V and XZV-3041A-L in the coil
purging steam line of 010-F-002 and start condensate draining from all low point drain
points till dry steam is observed.
 Keep one or two burners “ON” and ensure box temperature is 180-200 deg 0C
 Introduce coil purging steam to all passes one by one slowly through lining up/adjusting
isolation valve provided in each pass @ 1-2 t/hr (purging steam flow by monitoring the
total MP steam flow to unit through FT-9001.)
 Watch column pressure, preferable it should not cross 0.5Kg/Cm2 and also observe the
COT of each pass of 010-F-002
 Empty out the column bottom level by Pumping out the material to heavy slop tank/ crude
tank through 10-AC-015 by running 010-P-025B/C.
 After completion of coil purging, cut off firing to 010-F-002(FO/FG/Pilot) and isolate all
burners.

Page 190 of 592

Doc. No:
 Isolate the main FO/FG and pilot gas line to 010-F-002.

 Stop coil purging steam and charge stripping steam to C-007 by opening TV-3040 & FV
3007.
 When column top pressure start rising, isolate the Nitrogen back up to column.
 Keep both the FD fan running to bring down the box temperature
N.B: 010-F-002 coil purging to be carried out after flushing 010-P-007 normal discharge line to F-
002 during CDU column bottom material dilution. Connect steam hose at 010-P-007 discharge and
push up the line hold up to 010-C-007.
G. DRAINING & STEAMING:
COLUMN /OVERHEAD SECTION:

 Isolate the u/s B/V of inhibitor and Filming amine to 010-C-007 and open the drain points
of the chemical injection lines near the column.
 Open the all C-007 PSV u/s drain point.
 Open 010-C-007 top vent and depressurise column slowly. Keep vent B/V open
 Deblind transfer line CBD drain and drain the holdup material.
 Drain individual pump suction to CBD & isolate suction and discharge valves of all pumps.
Isolate individual pump casing vent line (2") & wedge gap towards column side.
 Drain all directly connected PA/Reflux /wash oil return lines by isolating respective C/V
or last exchanger D/S B/V of the respective circuit and opening the available LPDs within
the loop.
 Drain column bottom material to CBD/OWS.
 Keep the vent/drain of 010-V-013 deblinded.
 Deblind LP steam line to 010-V-011 /V-013/014
 Empty out hot well oil to CBD & water to SWS. Also empty out V-014 to OWS.
 Drain 010-V-011 to Amine drain (V-018) and after complete draining open the OWS B/V.
 Give clearance to M/M to open suction strainers of 010-P-021/022/023/024/025 for
condensate draining
 Open the Bypass of Vac. Column pressure C/V PV-3019
 Continue steaming through stripping steam.
 Back steam from 010-C-007 to all pump suctions 010-P-021/022/023/024/025 and drain
condensate from pump suctions
 Back steam from column to VR quench C/V 010-FIC-3008 and open the LPD in the line.
 Drain the condensate hold up from transfer line.
 Continue steaming for 24 hrs.

Page 191 of 592

Doc. No:
 Isolate all pump around filters u/s isolation valves and drain the material to CBD. Check
from OWS drain, when full bore steam comes from OWS drain, isolate CBD and allow
steam/condensate draining through OWS.
 Throttle column top vent valve and divert steam towards over head vapour line.
 Line up the vent and drain of 010-V-013/V-014/V-011 and also open the drain point in
treated off gas line to F-002 near the flame arrestor.
 Charge LP steam to V-011/013/14.
 Continue the steaming of the overhead section for 24 hours.
H. VAC. DIESEL CIRCUIT (PA, Reflux & R/D)
 Drain 010-P-021 A/B discharge circuit at 010-E-102/202 (tube side), 010-AC-014/16, 010-
E-39 A/B (shell), 010-STR-001 A/B, 010-STR-002 A/B via CBD line.
 Isolate and depressurise CW side of 010-E-039
 Introduce Steam from 010-P-021 A/B discharge line and 010-E-102/202/39 Vac. Diesel
inlet side, keeping all exchanger/cooler/filter OWS in open position and also introduce
steam to 010-STR-001A/B and STR-002A/B.
 Drain condensate from 010-P-021 A/B discharge line from low point drains of PA
C/V(FIC 3027), Reflux C/V (FIC 3029) , Tr. 1 & 2 flow dividing C/V (HV 1012) , hot
B/P C/V (QV 3003 A/B), R/D C/V(FIC 3058) & sample point at B/L.
 Check time to time for full bore steam from the low point drains, B/L sample point and
slop line low point drain.
 Line up Reflux /PA filters u/s valve, isolate d/s valves and check for full bore steam from
OWS drain.
 Give clearance for blinding at necessary locations.
I. VGO CIRCUIT (PA, Reflux & R/D)
 Drain 010-P-022 A/B/C discharge circuit at 010-E-122/222/118 A-F/218 A-F /108 (all
shell side) /010-AC-015 /010-STR-003 A/B via CBD line.
 Introduce Steam from 010-P-022 A/B/C discharge line casing vent, 010-E-122/222/118 A-
F/218 A-F /108 (all shell side) /010-AC-015 inlet keeping all exchanger OWS in open
position and also charge steam from 010-STR-003A/B.
 Drain condensate from 010-P-022 A/B/C discharge line from low point drains in PA/Hot
B/P C/Vs (QV-3004A/B), Tr. 1 & 2 flow dividing C/Vs (HV 3008 A/B), R/D C/V (FV
3032) & sample point at B/L. Check from time to time for full bore steam from the low

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point drains , B/L sample point and slop line U-loop LPD. Line up PA filters 010-STR-003
A/B u/s valve, isolate d/s valves and check for full bore steam from OWS drain.
 Give clearance for blinding as per standard blind list.
J. HVGO CIRCUIT (PA, Wash oil & R/D)
 Drain 010-P-023 A/B/C discharge circuit at 010-E-124 A-C(shell)/ 224 A-

C(shell)/149(tube)/150(tube)/010-STR-004 A-B/010-STR-005 A-B via CBD line.
 Isolate BFW inlet & outlet valves and keep the water side bleeders open before steaming.
 Introduce steam from 010-P-023 A/B/C discharge line casing vent, 010-E-124 A-C/ 224
A-C/149/150(HVGO I/L side) and also from 010-STR-004A/B and STR-005A/B
 Drain condensate from 010-P-023 A/B/C discharge line ,from low point drains in PA C/V
(FIC 3014) ,Reflux C/V (FIC 3016) , Hot B/P C/V (QV-3002A/B), R/D C/Vs (FIC
3063/3021A-B/3063), Tr. 1 & 2 flow dividing(HV 3007 A/B) & sample point at B/L.
Check from time to time for full bore steam from the low point drains ,B/L sample point
and slop line U-loop LPD's.
 Line up HVGO reflux filters 010-STR-005 A-B /PA filters 010-STR-004 A-B filters u/s
valve, isolate d/s valves and check for full bore steam from OWS drain.
K. RECYCLE OIL:
 Drain 010-P-024 A/B discharge circuit at all available points via CBD line
 Introduce steam from 010-P-024 A/B discharge line casing vent and flush the lines viz.
recycle to 010-C-007, vacuum recycle to 010-F-002 and line to VR circuit.
 Drain condensate from 010-P-024 A/B discharge line from low point drains in recycle oil
to furnace C/V (FIC 3013), Recycle oil line to VR pump discharge C/V (FV 3064), and
recycle oil to vac. Column C/V (FV 3012) & sample point at B/L. Check from time to time
for full bore steam from the low point drains.
L.VACUUM RESIDUE CIRCUIT:

After sufficient dilution with FLO ,isolate the B/L R/D valve & drain the material from the discharge
circuit of 010-P-025 A/B/C to CBD of 010-E-127 A-K/010-E-227 A-K /010-E-117/126/010-E-217/226
(all shell side) and 010-E-151 A-C/251 A-C (all tube side) .
 Isolate BFW inlet & outlet valves of 010-E-151 A-C/251 A-C and keep water side bleeders
open before steaming.

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 Introduce steam from 010-P-025 A/B/C discharge line casing vent and VR side I/L of
010-E-127A-K/227 A-K /117/126/217/226/151A-C/251A-C,keeping exchanger CBD's in
open position. Flush the r/d line upto B/L.
 Drain condensate from 010-P-025 A/B/C discharge line ,from OWS drains in 010-E-127
A-K /227 A-K /117/126/217/226/ 151 A-C/251 A-C & sample point at B/L.
 Check from time to time for full bore steam from the OWS drain lines, B/L sample point,
and slop line LPD.
M. VACUUM FURNACE (F-002) ISOLATION AND MAN ENTRY
 After 24 hours of coil and column steaming stop coil purging steam.
 After completion of COT reduction & coil purging, isolate all individual burners.
 Isolate the main FG line and depressurise the FG ring through gas burners in running
condition. Then isolate all individual FG burner valves. Put blind in Main FG line.
 Similarly depressurise the pilot gas line through pilot burners & then put blind in pilot gas
line.
 Isolate FG, Pilot Gas main isolation valves, Give clearance for blinding, After blinding job
is completed purge both lines by nitrogen.
 Flush all FO burners thoroughly. Put the blind in FO supply and return lines after flushing
the FO ring with FLO and steam. (Detach oil/steam flexible hoses in burners before
steaming)
 FD fan to run continue for furnace box cooling.
 Ensure fire box purging by doing Gas test.
 Put blinds in atomising steam /soot blowing steam /velocity steam/box purging steam lines.
 Once the furnace box temperature reaches ambient temperature, stop the FD fan.
 Give clearance for positive isolation as per the standard blind list after ensuring isolation.
 Open all peep holes and man ways.
 After ensuring Oxygen (gas test) in furnace box give clearance for man entry.
 After checking by explosive meter, give clearance for furnace box man entry.
N. VDU COLUMN /COLUMN O/H WATER WASHING AND HANDOVER
 Stop steaming through V-011/013/014.

 Minimize the stripping steam charge rate and blind the sour water line from V-013 to 010-
P-028.

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 Line up service water to 010-P-028 suction and charge water to 010-C-007 by running the
pump.
 Continue steaming through stripping steam at reduced rate for hot water washing.
 Bring down water to all draw trays up to column bottom.
 Drain full bore water from column bottom and all PA/Run down pump suction strainers.
 Ensure hot water is coming out from all the drain points and continue hot water washing
for 08 hours.
 After 8 hrs gradually reduce stripping steam to column.
 Close the stripping steam to column and continue cold water washing till column
temperature comes down to normal temperature.
 Ensure all the vents and drains are full open.
 Stop cold water washing and drain out the water from the column.
 Start KMnO4 washing for column passivation.
 Constantly monitor the color change of drain out water (KMnO4 solution: Pink to brown)
and continue cold water washing for another 4 hours.
 After ensuring complete water draining, give clearance for positive isolation as per
standard blind list followed by opening of manholes.
8.2.4 SHUT DOWN OF ATM. COLUMN
A. CDU T’PUT & COT REDUCTION:
 CDU shut down activity to be carried out in parallel with VDU hot circulation.
 CDU unit is running with 50% of design throughput (1060m3/hr)
 Reduce COT @ 30º C/hr to 300º C.
 Take 010-F-101/201 on force draft (Open the MSD, PV-1098 and stop the ID fans 010-K-
002A/B).
 Stop BFW flow to Steam Drum 010-V-024 by closing FV-1131 and also phosphate
injection
 Bring down all the stripers level (010-C-002/003/008) to minimum operating level by
maximizing the pumping rate of on- spec product.
 As COT reduces gradually, the product is expected to go Off-spec.
 Check the product color/draw temperature and route off spec product (Side cut naphtha,
Kero, AGO) to light slop tank after informing Off-site in charge.
 Take all the PA and the stripper I/L C/V in manual mode and maximize IR flow.
 At COT of 300 0C isolate stripping steam to column & side strippers. Vent out steam
through 010-F-101/201 silencer.

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 As draw tray level decreases, close Stripper I/L C/V and stop PA and R/D pumps.
 Line up start up reflux line (100-P-010-1309-A2AQ-NI) from 010-P-010 discharge to CDU
column for maintaining top temperature if required.
 Stop all product R/D air coolers.
 Stop 010-AC-007 fans as per requirement.
 Stop Off gas compressor and route unstabilised naphtha to light slop bypassing the
stabilizer ( from u/s of E-37C, through the line 200-P-010-1482-B2AQ-NI)
 Stop stabilizer, De-ethaniser and De-propaniser sections.
B. STOPING CHEMICAL & DESALTER WASH WATER INJECTION
 Stop filming/neutralising amine, corrosion inhibitor, phosphate (injection to steam

generators), antifouling agent, and demulsifier injection.
 Stop water injection to desalter.
 Switch off desalter and de-energies the desalters.
 Isolate chemical area filters; drain & give clearance for opening.
 When chemical tanks are empty stop the dosing pumps. Drain residual quantity.
 Take water in these tanks. Run the bottom pumps & water flush respective lines to OWS
 Overflow all the chemical tanks with water 2-3 times.
C.PUTTING CDU ON HOT CIRCULATION

STEP-1:
1. Take Desalter Pressure C/V, PV-1019/1022 and all Pass I/L C/V of F-101/201 in manual mode
and minimize the crude intake to the unit( Ensure all Furnace pass flows are healthy).
2. Open the isolation valve (near 010-V-003) in the start up recycle line to 010-V-003 (Line no:
450-P-010-3114-B2AP-IT).
3. Ensure the cold circulation B/V at B/L is closed (in line: 450-P-010-1280-B2AP-IT)
4. Open the Crude side B/P B/V of 010-E-117/217 & 010-E-126/226
STEP-2:
1. Gradually route Column bottom material to 010-V-003 (Open the 1st isolation valve in start-up
recycle line; 450-P-010-3114-B2AP-IT) and simultaneously close the isolation valve towards
DCU side (Line no: 450-P-211-1127-B2AP-IT).
2. Establish the hot circulation and inform OMS to keep running at least one crude Booster pump
in minimum circulation.

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3. Start 010-AC-015 and partially lined up AR through HVGO circuit (Scheme proposed) so that
circulation to be carried out through HVGO and VR circuit (through HVGO R/D A/C-
Proposed scheme) simultaneously
8.2.5 SHUTTING DOWN DE-PROPANISER, DE-ETHANISER & STABILISER:
 As COT starts reducing, 010-C-001 top pressure and temperature decreases resulting decrease
in 010-V-005 level.
 Stop all the running Air coolers including 010-AC-007.
 Keep minimum positive pressure at the 010-C-001 top by reducing the top pressure set value.
 Empty out 010-V-005/010-V-007 by running 010-P-010A/B & 010-P-013 via AC-008 - > V-
007 -> 010-C-004.
 Start sour water pump, 010-P-011 and empty out boot water of 010-V-005 to SWS
 Empty out stabilizer O/H receiver 010-V-008 to 010-C-005 by running 010-P-016
 Empty out stabilizer bottom to Slop/naphtha tank under system/nitrogen pressure.
 Run 010-P-018A/B (De-ethaniser overhead pump) and bring down minimum level in 010-V-
009.
 Empty out De-ethaniser bottom to off-spec LPG by running 010-P-002
 Empty out De-propaniser O/H receiver to off-spec LPG by running 010-P-019
 Empty out De-propaniser bottom (010-P-020A/B/C discharge) to off spec LPG through 010-
FV-2014 and close 010-FV-2013.
 Maintain slightly positive pressure by floating with FLP in 010-C-004/005/006, till the start
of steam out operation for handing over.
A. EMPTYING OUT OF CRUDE CKT IN PRE HEAT TRAINS:
 Isolate the crude B/L main block valve and bypass the desalters for both Train-1&2.
 Charge steam at B/L crude inlet line and at 2nd stage Desalter crude O/L of both trains.
 Push out the crude of Preheat Train-1 and Preheat Train-2 to 010-V-003.
 Start 010-P-003 and empty out 010-V-003 by pushing material to 010-C-001.
 Now charge steam to Preheat Train-3 at 010-P-003 discharge and push out the material to 010-
C-001.
 Start 010-P-007 and pump out 010-C-001 bottom material to crude tank.
 Charge steam at all above mentioned point and drain individual preheat exchanger’s crude
side one by one to OWS and open the respective exchangers high point vent.
B. DESALTER EMPTYING OUT:

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 Pressurise all the four desalters with Nitrogen.

 Drain water interface of all Desalter to OWS. Once crude appears in the drain line, close OWS
draining and empty out Desalter to ETP (IZ-0160 logic to be bypassed, XZV-1061/LV-1002
to be kept open).
 Take service water in 010-V-001 by opening LV-1007B and start 010-P-001 to fill all the
desalter with water.
 Drain Desalter to OWS.
C. 10-F-101/201 COIL PURGING:
1. Line up coil purging steam main header isolation B/Vs and XZV-1001A-H/XZV-1501A-H in the coil
purging steam line of 010-F-101/201 and start condensate draining from all low point drain till dry
steam is observed.
2. Keep one or two burners “ON” and ensure box temperature is 180-200 deg 0C
3. Introduce coil purging steam to all passes one by one slowly through lining up/adjusting isolation valve
provided in each pass @ 1-2 t/hr (purging steam flow to be controlled by monitoring the total MP steam
flow to unit through FT-9001.)
4. Keep close watch on column pressure.
5. When the bottom level increase, start 010-P-007 and pump out the bottom material to crude tank
(through cold circulation start up recycle line)
6. Keep the pilot burner on.
7. Keeps FD fan running to bring down the box temperature.
D. Draining of 010-C-001 /C-002/C-003/C-008/V-003:

1. De-blind the CBD line of all vessels, columns, Exchanger, pumps and all vents cap/end blind are to be
opened.
2. Deblind transfer line CBD drain and drain the holdup material.
3. Bring down the level of 010-V-003 by emptying out to 010-C-001 with help 010-P-003.
4. Increase the top pressure of 010-C-001 to 1kg/cm2g (with help of FG)
5. Drain the remaining bottom material of V-003/C-001/C-002/C-003/C-008 to CBD.
6. Drain the Desalters PSV relief line to 010-C-001 by connecting hose in the PSV downstream drain
points
7. Drain 010-V-003 vapour line to 010-C-001 at PV-1021 downstream LPD
8. Drain 010-C-001 over flash line to OWS.
9. Drain 010-AC-007/V-005 hydrocarbon to CBD.
10. Drain 010-V-005 boot water line near 010-P-011.
11. Isolate 010-V-005 (column O/H) from the 010-V-006.
12. Drain 010-P-007 vent line to C-001 near the pump.

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13. Isolate the discharge B/V and open suction strainer of TPA/Side cut naphtha/Kero PA/ Kero
RD/LAGO PA/LAGO RD/ HAGO PA/ HAGO RD pumps and drain the respective line contents.
14. Drain all column interconnected PA/Reflux return line by isolating respective C/V or last exchanger
D/S B/V of respective circuit and opening the available LPDs within the loop.
15. Isolate the column from the stabilizer circuit (including the off gas compressor)
STEAMING OF COLUMNS AND STRIPPERS:
 During steaming CBD drain B/V to be kept closed and condensate is to be drained in OWS
 Open Kero, LAGO & HAGO strippers’ level C/V bypasses, so that at the time of steaming, these
lines are also steamed.
 Increase the coil purging steam flow and raise the column pressure. (Ensure furnace box
temperature is around 200 deg C to avoid condensation inside furnace coils).
 Gradually decrease the fuel gas make up to 010-V-005.
 Once column pressure rise to 1kg/cm2g, isolate the FG to 010-V-005 and open the top vent of 010-
C-001 slowly.
 Vent out steam from all strippers, pre-flash vessel and column overhead line.
 Drain condensate of transfer line to OWS.
 Remove the condensate by opening the pump suctions and available LPDs
 When full bore steam observed from column top, gradually reduce the coil purging steam and
continue steaming through stripping steam(LP) of 010-C-001/002/003/008 (Bypassing the furnace
steam heaters through TV-1134/1634)
 Charge LP steam to preflash vessel, 010-V-003 (Deblind 010-V-003 overhead vent and slowly
isolate the PV-1021).
 Steaming to continue for 24 hrs and ensure full bore steam from all pump suction strainers, vents,
PA C/V d/s LPD's & minimum circulation C/V d/s LPD's.
WATER WASHING (HOT & COLD):

For hot water washing the following steps are to be taken:
 Line up water to 010-C-001 through dedicated service water line (150-WS-010- 9467-A2AW-NI)
provided at 010-P-010A/B suction and gradually charge water in 010-C-001
 Continue steaming through stripping steam lines in controlled manner. Ensure steam flow through
all the vents/suction strainers.
 Drain full bore water from column bottom, all PA/Run down pump suction strainers.
 Ensure hot water is coming out from all the drain points and continue hot water washing for 12
hours.

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 Gradually reduce stripping steam to column.

 Close the stripping steam to column and continue cold water washing till column temperature
comes down to normal temperature.
 Ensure all the vents and drains are full open.
 Stop cold water washing and drain out the water from the column & strippers.
 Isolate all the strippers (C-002/003/008) from 010-C-001.
 Start KMnO4 washing for column passivation.
 Constantly monitor the colour change of drain out water (KMnO 4 solution: from pink to brown)
and continue cold water washing for another 4 hours.
 After ensure complete water draining, give clearance for positive isolation and opening of
manholes.
E. EMPTYING OUT OF PA & R/D CIRCUITS:
I. TPA/SIDE CUT NAPHTHA CIRCUIT:
 Drain 010-P-004 A/B/C (TPA pumps) discharge circuit at 010-E-104/204- A/B/C/D

(shell), & 010-P-014A/B/C (SIDE CUT NAPHTHA discharge circuit) at 010-E-037 A/B
(shell) via CBD line.
 Introduce Steam from 010-P-004 & 010-P-014 discharge line casing vent , 010-E-104/204 A-D
TPA inlet, 010-E-037 sidecut naphtha inlet(keep the O/L B/V closed and U/S flange wedge opened)
keeping all exchanger CBD's in open position.
 Drain condensate from 010-P-004/014 discharge line from low point drains in TPA C/V( 010-
QV-1002A/B), top reflux C/V(010-FV-1037), TPA hot B/P C/V( 010-QV-1002A/B), TPA
Train1/2 split flow C/V(010-HV-1004A/B) , side cut naphtha R/D C/V (010-FV-1092) & sample
point at B/L.
 Check for full bore steam from the low point drains, B/L sample point and slop line LPD and after
that only give clearance for blinding at necessary locations.
II. KERO CIRCUIT (Reflux, PA & R/D):

 Drain 010-P-005 A/B discharge circuit at 010-E-131/231/106/206 (shell side) and 010-P-008A/B
discharge at 010-AC-004 & 010-E-017A/B (shell side) via CBD line. Isolate CW inlet & outlet
valves of 010-E-017 and keep the water side bleeders open before steaming.
 Introduce Steam from 010-P-005 & 010-P-008 discharge line casing vent, 010-E-131/231/106
/206/17A-B and 010-AC-004 Kero I/L side .keeping all exchanger CBD's in open position.
 Drain condensate from 010-P-005 & 010-P-008 discharge line from low point drains in 010-FV-
1022A/B, 010-FIC-1025, 010-FV-1039, 010-HV-1020A/B and 010-QV-1004A/B and sample

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point at B/L. Check in regular interval for full bore steam from the low point drains, B/L sample
point and slop line LPD and after the confirmation give clearance for blinding at necessary
locations.
III. LAGO/HAGO (AGO) CIRCUIT (Reflux, PA, R/D ) :
 For LAGO PA: Drain 010-P-006 A/B discharge circuit at 010-E-38/43/47 (tube), 010-E-
119/219(shell) via CBD line.
 For HAGO PA: Drain 010-P-030 A/B discharge circuit at 010-E-123/132(shell) via CBD line.
 For Combined (AGO) R/D: Drain 010-P-009/29 discharge circuit at 010-E-
129/229/128/228/107/207/116/216/103/203 (shell), 010-AC-005 via CBD line.
 Before steaming, ensure isolation of slop & R/D isolation valves at B/L.
 For flushing purpose introduce MP Steam at casing vent of 010-P-006 and LAGO inlet of 010-E-
038/43/47/119/219 for LAGO PA circuit, 010-P-030 and HAGO inlet of 010-E-123/132 /223/232
for HAGO P/A circuit.
 For flushing purpose of AGO R/D circuit introduce MP steam at discharge casing vent of 010-P-
009/29 and AGO(HAGO/LAGO) I/L of 010-E-129/229/128/228/107/207/116/216/103/203/010-
AC- 005 ,keeping all exchanger CBD's in open position.
 Drain condensate from low point drains through C/Vs FV 1040/QV1006A-B/HV 2007A-B/FIC
1014/FIC 1015/HV 1015A-B/QV 1008A-B/FIC 1042/FIC 1068/PIC 1197/TIC 1082 & sample
point at B/L. Check for full bore steam from the low point drains, B/L sample point and slop line
LPD.
 Give clearance for blinding as per standard Blind list.
8.2.6 FURNACE ISOLATION AND MAN ENTRY:

 After 24 hours of coil and column steaming stop coil purging steam.
 After completion of COT reduction & coil purging, isolate all individual burners.
 Isolate the main FG line and depressurise the FG ring through gas burners in running condition.
Then isolate all individual FG burner valves. Put blind in Main FG line.
 Similarly depressurise the pilot gas line through pilot burners & then put the blind in pilot gas line.
 Isolate FG, PG main isolation valves, Give clearance for blinding, and after blinding job is
completed purge both lines by nitrogen.
 Flush all FO burners thoroughly. Put the blind in FO supply and return lines after flushing the FO
ring with FLO and steam. (Detach oil/steam flexible hoses in burners before steaming)
 Continue running FD fan for furnace box cooling.
 Put blinds in atomising steam /soot blowing steam /velocity steam/box purging steam lines.
 Ensure fire box purging by doing Gas test.

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 Once the furnace box temperature reaches ambient temperature, stop the FD fan.
 Give clearance for positive isolation as per the standard blind list after ensuring isolation.
 Open all peep holes and man ways.
 After ensuring Oxygen (gas test) in furnace box give clearance for man entry.
 After checking by explosive meter, give clearance for furnace box man entry.
Steaming of 010-C-004/C-005/C-006:
 Deblind all vents and CBD/OWS drains of 010-AC-008, E-035,V-007, P-013,P-014,E-037, C-

004, E-038,AC-009, V-008,AC-010, C-005, V-009, C-006, V-010,E-043, E-044, P-002, E-047,E-
048 and P-020.
 Deblind the LP steam line to 010-C-004/005/006, V-007/008/009/010.
 Deblind the depressurizing line to LP flare header of the following, P-
002/013/014/015/016/018/019/020, AC-008/009.
 Drain all the vessels/Pumps/Columns/Air coolers to CBD.
 Charge LP steam to stabilizer (2-3 threads) after draining condensate.
 Watch temperature and pressure profile of the column.
 If the pressure shoots up open depressurizing B/V fully and release the gases to flare.
 Gradually increase steam.
 Open the top vent bleeder carefully and isolate the depressurizing line B/V.
 Increase the opening of steam B/V till steam appears from the top vent with sufficient pressure.
 Drain condensate from the stabilizer bottom.
 Vent out steam from the rebolier and drain condensate from bottom.
 Bleed out steam from the nitrogen line drain bleeder at the downstream of NRV.
 Bleed out steam from C-004 PSV upstream bleeders.
 Back steam to C-004 feed (unstabilized naptha), steam out E-037 (including the bypass line) and
drain condensate from the LPDs available.
 Charge steam from 010-P-014 discharge and bleed out seam near E-037C I/L.
 By pass FV-2002, back steam to Pump 010-P-015A/B discharge line and drain condensate from
the drain bleeder at the discharge.
 Vent out steam from AC-009, E-036 (including the bypass line).
 Charge steam to 010-V-008, bleed out steam from top vent, PSV u/s PV-2018A/2018B CV u/s
drain point, LV-2012 u/s and drain condensate from 010-P-015/P-016 suction strainer.
 Similarly charge steam to C-005/C-006/V-009/V-010 and vent /drain from following points:
o C-005/C-006/V-009/V-010 top vent
o C-005/C-006/V-009/V-010 PSV u/s bleeder.

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o At E-043/042/047/046
o PV-2025A/B , LV-2042 , FV-2012, PV-2038A/B , LV-2022 u/s drain point
o 010-P-002/018/019 suction strainer.
o Nitrogen make line to C-005/006 NRV downstream bleeder.
 Charge steam 010-P-19/P-002 /020 discharge header and carry out steaming up to B/L.
Steaming of 010-C-010/V-016/V-017 (Off gas system):

 Deblind all related CBD drain/ vent and LP steam line.
 Charge steam to 010-V-016 and C-010 and open the B/P of off gas C/V V-007/009 to 010-V-016.
 Carry out venting and draining from following points:
o V-016/V-017/ C-010 top vent
o From NRV downstream of off gas line from naptha hydrotreater.
o V-016/017 & C-010 PSV u/s bleeder
o V-016/V-017/ C-010 bottom drain.
o P-033A/B suction strainer.
o Lean amine to C-010 B/L drain point ( Open the bypass of FV-4001)
o PV-4005 u/s drain
 Charge steam at 10-P-033 discharge and carry out steaming up to B/L.

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CHAPTER-9
EMERGENCY SHUTDOWN & HANDLING

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9.1 INTRODUCTION:
Emergency in the operating plant can be caused due to failure of utilities like Power, Steam, Instrument
Air, fuel Oil or failure of equipment or by a serious leak/fire. During some of the emergency situations
the unit can be operated for a limited duration with appropriate timely action, while in other cases an
immediate shut down may be necessary to avoid any damage to the equipment and injury to the
operating personnel.
General Guidelines:
General guidelines listed below should always be kept in mind during emergency.
 High pressure, level and temperature beyond design limits for vessels, columns, pump, exchangers
and furnaces must be avoided.
 Furnaces process coil should never run dry while furnace firing is ‘ON’.
 In the ejector, flow of the motive steam must be ensured prior to opening of off gas line B/V.
Conversely if the steam to ejector is failing, ensure the off gas vent B/V of LP Gas KOD (010-V-
011) is closed.
 Furnaces firing to be controlled to avoid temperature shoot up in transfer line.
 Heavy oil circuits such as AR, Vacuum Diesel, VGO, HVGO, Recycle Oil & VR must be flushed
with FLO to avoid congealing of lines during emergency S/D of unit.
 In case of furnace shut down, fuel oil circulation should be kept ‘ON’ but ensure individual burner
B/V must be closed after flushing with steam.
 Stripping steam lines connected to the columns must be isolated in case of steam failure to avoid
any chance of hydrocarbon backing up into steam line.
 Product run down B/Vs must be closed at unit B/L to avoid any chance of Hydrocarbon reverse
flow from offsite & other units.
 The following pumps are provided with Auto Start facility:
TAG No. Description

010-P-004 A/B/C Top pump around pumps
010-P-035 A/B VGO seal fluid pumps
010-P-036 A/B AGO seal fluid pumps
010-P-027 A/B Hot well oil pumps
010-P-301 A/B AVU LP flare KOD pumps

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 Emergency power supply to Equipments/motors :
Sl. No. Description

1. LP flares KOD pumps (010-P-301 A/B)
2. Fire water booster pump (010-P-501 A-D)
3. UPS supply to off gas Compressor (010-K-003A/B) Motor Panel
4. Unit 010/011 critical lighting (010-CLDB-1/2)
5. Cathodic protection for rectifier Panel (010-CATHODIC PR1/2-
CP)Aviation lighting (010-ALDB1)
6. Emergency lighting (010-ELDB-01/02/03/04)
7. Aviation lighting (010-ALDB1, 010-ELDB1/2/3/4).
 Motors provided with re-accelerated facility in the event of a power dip:
SL. No TAG No. Description

1. 010-PM-003A/B/C Flashed Crude Pumps.
2. 010-PM-004A/B/C TPA Pumps
3. 010-PM-005A/B Kero PA Pumps
4. 010-PM-006A/B LAGO PA Pumps
5. 010-PM-007A/B/C AR Pumps
6. 010-PM-021A/B Vacuum diesel Pumps
7. 010-PM-022A/B/C VGO Pumps
8. 010-PM-023A/B/C HVGO Pumps
9. 010-PM-025 B/C VR Pumps
10. 010-PM-030A/B HAGO PA Pumps
11. 010-PM-004A/B/C TPA Pumps
12. 010-PM-005A/B Kero PA Pumps
13. 010-PM-006A/B LAGO PA Pumps
14. 010-PM-015A/B Stabiliser Reflux Pumps
15. 010-PM-018A/B De-Ethaniser Reflux Pumps
16. 010-PM-015A/B C3 LPG Pumps
17. 010-KM-001A/B Crude Charge Heaters ID fans
18. 010-KM-002A/B Crude Charge Heaters FD fans
19. 010-KM-004A/B Vacuum Heater ID fans
20. 010-KM-005A/B Vacuum Heater FD fans
21. 010-PM-301A/B LP Flare KOD pumps

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SL. No TAG No. Description

22. 010-AC-009 A/B/C-M01/02 Stabiliser Overhead coolers
NOTE:
Emergency procedure basically provides broad guidelines. In actual emergency, deviation
may become necessary depending on the type of emergency & situation. In such cases, shift
in charge’s decision with discussion of unit in charge will be final.
TYPE OF EMERGENCIES:
9.2 POWER FAILURE: Power failure can be outlined under two categories:
 Partial power failure

 Total power failure
PARTIAL POWER FAILURE
Partial Power Failure can be arises due to following reasons:
A. TRANSFORMER FAILURE
It is restricted to a section of the unit and should not affect the unit much but for stopping of a few
L.T. motors which can be started immediately to restore normalcy.
B. FAILURE OF BUS SECTION

Bus section is grouped in pair and the motors in that section will be affected due to simultaneous
failure of both buses. One bus failure will cause the stoppage of one set of motors; spare motors
can be started to restore normalcy.
C. MOTOR CONTROL CENTER FAILURE (MCC FAILURE)

This will affect motors in that particular MCC. As per the arrangement, any main and spare motor
for a particular service is energized from different MCC. Hence, spare motors can be immediately
started to restore normalcy.
D. POWER DIP
Power Dip could be due to excessive over loading of transformers. This will result in stoppage of
few LT motors in the unit, which will have to be restarted immediately. A power dip of 2 - 3 seconds
is enough to trip a motor.

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E. FAILURE OF 220V AC SUPPLY.

This will cut off supply to lighting system in unit. The power supply to DDCS should be continuing
with battery backup. If battery back-up also fails, then power supply to control system would also
fails and there will be no control action possible and no indication shall be available in DCS. In
case of failure of battery backup, same to be informed to the controlling officer/unit incharge for
unit safe shut-down.
F. FAILURE OF 110V D.C

This will cut off all security devices (ESD) of the unit and will call for an emergency shutdown.
G. LOAD SHEDDING
In case of CPP is unable to generate the required power for the refinery due to some problem in
CPP operation, load shedding shall be operated. In the load shedding scheme some non critical area
like Adm. Building, Roads lighting, Township & OM&S power is to be cut off first. At present
load shedding scheme AVU thru’ put will be reduced to 50% of design capacity. Even if CPP
cannot sustain with reduced T’put of AVU, power of this unit is cut off as per load shedding
priority.
TOTAL POWER FAILURE
Power failure can affect all process units which may occur with the failure of all the bus sections
due to trip of power generating machines in CPP and will call for an emergency shutdown. The
various scenarios due to power failure and actions to be taken are given below:
Major effects in the Unit:

 No regular lighting will be available in control room
 In the event of a complete power failure the unit will shut down with loss of crude flow,
products disposal, pump around, refluxes, overhead distillate product pumps and all fin fan
coolers.
Action to be taken:
Sl. Action Responsibility Remarks

No
Communicate with CPP and if Power clearance not received
1. within short period of time, take decision to proceed for unit S/D Panel
and inform to RSM & Unit Incharge

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No
Ensure, Emergency lamps provided in the control room should
2. Panel
get switched ‘ON’ automatically.
3. Ensure all the safety interlock is activated as per logic Panel/Field
Ensure CDU/VDU furnace main stack damper is 100% open;
4. Panel/Field
both furnaces FG/FO S/D valves are closed.
5. Ensure CDU/VDU furnace FG/FO shut down valves are closed. Panel/Field
6. Close individual control valves of FG/FO line from DCS. Panel
Ensure individual furnace flue gas damper and MSD is fully
7. Field
open in the field ( in case of VDU Furnace only MSD)
Isolate the B/Vs of individual FG & Pilot Gas burner at the
8. Field
firing P/F.
In vacuum furnace also isolate individual B/V of Vent Gas
9. Field
Burners
10. Close ejector motive steam main C/V HIC-3013. Panel
Open Nitrogen B/V to 010-C-007 to bring slightly positive
11. Field
pressure in the vacuum column
12. Ensure off gas line to atmospheric vent at 010-V-11 is closed Field
13. Isolate the B/V across flame arrestors in vent gas line to burner. Field
Close 010-C-007 stripping steam C/V & B/V after ensuring
14. Panel/Field
positive pressure in the column.
15. Ensure LP & MP steam silencer vent XZV is open. Field
FO circulation to be established depending on the availability
16. Panel/Field
of FO pump (offsite area).
MP steam supply to Furnace convection coil (F-002) to be
17. Field
isolated.
Close Off Gas compressor (010-K-003) suction and discharge
18. Field
isolation B/V
Control the pressure of 010-C-001 by taking 010-PV-1072 in
19. Panel
manual mode.
If required 010-PV-1072 flare side B/P B/V to be opened or
20. C/V main isolation B/V to be throttled for pressure control by Field
co-coordinating with panel in charge.
Isolate the LPG reprocessing B/V and wild Naphtha from
21. Field
DHDT B/V in case of reprocessing was going on.
22. Close brine effluent, LV-1002/1502 manually. Panel

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No
Close C/Vs and B/Vs of Stripping Steam to columns and
23. Panel/Field
strippers
010-C-001/002/003/008 stripper feed I/L C/V (010-LV-1028,
24. 010-LV-1014, 010-LV-1016 & 010-LV-1018) to be closed Panel
manually
All control valves of products run down to storage/hot feed to
25. secondary units to be closed manually from the DCS and also Panel/Field
close B/L isolation valve of respective product.
26. Internal reflux (I/R) C/V to the column to be closed manually. Panel
Close 010-C-004/005/006 reboiler heating C/V (010-FV-2019
A/B, 010-FV-2022 A/B & 010-FV-2025 A/B) and take the
27. Panel
over head pressure controller of these columns in manual
mode.
In case of pressure overshoot of the above columns, use HZV-
28. 2008(010-V-008), HZV-2013 (010-V-009) and HZV-2012 Panel
(010-V-010) to depressurize the respective column.
Close BFW flow C/V and B/V to all steam generators (010-E-
29. 149/150/151A-C/251A-C/WHB-001/WHB-002) and also to Panel/Field
De-super heaters (010-DS-001/002).
Close discharge B/Vs of all product/PA pumps which were
30. Field
running. (Except the Auto Start Pumps)
Close discharge B/V of Desalter wash water
31. injection/circulation pumps and chemical injection pumps Field
which were running.
Close B/V of desalter water injection to 010-V-102B/202B
32. Field
near mixing valve and at the I /L of E-102/202
33. Isolate all the chemical dosing Field
Field
 Close B/V of Demulsifier injection/antifouling injection.
34.  Close LV-1002 and U/S isolation valve on brine effluent to
ETP.
Panel/Field
35. Close the B/V of sour water to O/H Air cooler (010-C-001) Field
Close pump discharge & open warm-up fully to release
36. Field
pressure.
37. Frequently check HE’s / equipment, for possible leakage. Field

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No
38. Change over seal fluid V19/V20 make up to FLO Field
Keep all HVs open & draw pump warn up valve full open to
39. Panel
release pressure (due to thermal expansion) back to column.
Notes:
 If start up clearance is not available shortly then 10-F-101/102/002 coil inlet C/Vs to be isolated
and coil hold up to be emptied with coil purging steam.
 Flush all heavy product lines/pumps if FLO is available.
 Line up circulation in CDU and wait for the power clearance.
9.3 STEAM FAILURE:
Unit is receiving three types of steams HP, MP & LP. Following points to be remembered before taking
any decision during emergency:
 HP steam is used for driving 010-P-025A turbine, so incase of failure of HP steam the standby
VR pump (motor driven) to be taken in line.
 In case of MP steam failure, oil burners will “cut off” due to activation of “low low differential
pressure” interlock.COT can be maintained by maximizing fuel gas firing.
 During normal unit operation 30.0T/hr MP steam is generated from steam generators and WHB,
34 T/hr LP steam is generated from LP steam generators, stripping steam requirement for CDU
operation alone is around 31 T/hr.
Major effects in the unit:
 There will be no steam to ejectors and hence loss of vacuum in 010-C-007

 There will be no atomizing steam to the oil burners.
 Stripping steam to 010-C-001/002/003/008/007 will fail.
 Supply of steam to super heater coils of 010-F-101/102/002 will fail.
 VR steam turbine driven pump will trip.
 There will be failure of turbulising velocity steam to furnace 010-F-002 passes.
 There will not be any quench steam to mechanical seals of the pumps.

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 Fire fighting steam supply to manifold will not be there.

 Heater box purging steam and emergency steam to furnace coils will fail.
 Steam to tracing network will fail.
ACTION TO BE TAKEN
Sl. No Action Responsibility Remarks

In case of total steam failure, VDU to be put in hot
1 Panel/Field
circulation in as described in shutdown chapter
CDU operation can be survived in standalone mode with help of LP steam generated from 010-E-
151A-C / 251A-C ( AR to be routed in VR circuit) by taking following action:
3 Reduce the unit throughput to 50%. Panel

4 Route the AR to DCU through VR circuit Field/Panel
Cut off fuel oil firing in both the charge heaters (010-
5 Field/Panel
F-101/201). Heaters to be operated on FG only
6 Optimize the stripping steam consumption Panel
Minimize the consumption of tracing steam by
7 Field
isolating steam tracers wherever possible
Steam to steam air pre-heater to be closed
8 Field
completely.
Check the R/D product quality and take action
9 Field/Panel
accordingly
9.4 COOLING WATER FAILURE:
AVU receives cooling water from CT-3. Cooling water failure can occur when all the operating pumps
in cooling water block (CT-3) fail to supply water. This is a rare phenomenon and can happen during
total power failure.
Major effects in the unit:
 Machinery lube oil system normally receiving cooling water will tend to overheat and Bearings
could damage the running equipments.
 Loss of vacuum in vacuum column.

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 Loss of cooling water will lose the condensing ability on Stabilizer overheads, with resultant
loss of reflux and column pressure control.
 Loss of product trim cooling will result in higher run down temperatures.
 Loss of liquid level in hot well drum due to vaporisation of water/hydrocarbons.
ACTION TO BE TAKEN:
Emergency shutdown of the plant to be taken in the same way as mentioned in total power
failure case ( except in this case all running pump to be stopped manually)
9.5 INSTRUMENT AIR FAILURE:
Instrument air is supplied to the unit at a pressure of about 7.0 kg/cm2 g. normally with instrument Air
failure CPP will also go for an emergency shutdown. Steam, power and other utilities will not be
available. Initiate emergency shutdown action when instrument Air pressure comes down to 3.0 kg/cm2
g.
Following points to be remembered before taking any action during instrument air failure:
 In case of Instrument Air failure all C/V and XZV will go to fail safe position.
 Unit to be shut down safely with the help of available resources.
 If the instrument air failure is due to a big leak inside AVU B/L, instrument air B/L block valve
to be isolated immediately so that CPP/other unit can be saved from an emergency shutdown
due to instrument air failure.
 Generally, valves on systems that eventually supply a heat source fail closed (FC) and those
that contribute to heat removal fail open (FO). (FAIL SAFE POSITION)
The effects with the corresponding action to be taken are summarised as follows:
(N.B: Emergency action will be taken in the field with proper communication with panel in charge in
case of Instrument Air Failure)
Sl.
EFFECTS ACTION TO BE TAKEN
No.
Shut down valves on both fuel gas/fuel oil
Both CDU&VDU heaters will be shutdown
1 including the pilot will close to cut off fuel
as per the logic.
supply to burners.

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Sl.
EFFECTS ACTION TO BE TAKEN
No.
 Desalter pressure controller PV-
1019/1022 will get full open. Desalter pressure and post Desalter
 Furnace feed flow control valves will get exchanger train pressure to be monitored.
2
full open. If required throttle 010-P-003 discharge to
 Pre-Desalter and post Desalter HIC’s will maintain the pressures.
get full open.
Pre flash Vessel (010-V-003) pressure Keep 010-V-003 pressure under control
3 controller 010-PV-1021 will come to fail by opening the B/P block valve of PV-
close position 1021
Crude column overhead receiver (010-V-
Keep 010-C-001 pressure under control by
4 005) controller 010-PV-1072 will come to
opening the B/P valve of 010-PV-1072B.
fail close position.
Check amperage of all PA pumps 010-P-
010-C-001: All PA C/V including TPA will
5 004/005/006/030 and throttle the discharge
be in completely open condition
accordingly.
Stripping steam control valves at 10-C- Close stripping steam block valves of 010-
6
001/C-002/C-003/C-008 will close. C-001 and all strippers.
Take emergency shutdown of vacuum
Vacuum section shutdown due to firing
7 section as per the procedure mentioned in
cutoff in furnace.
total power failure case.
If shut down is for longer duration, pump
8 All run down product control valve close out the strippers by opening the bypass of
product run down control valves.
Stabilizer section Stabiliser pressure to be monitored. If
Feed C/V will close. Fuel gas ex 010-V-004 stabiliser pressure increases, release the
9
C/V will close. Re-boiler will be by-passed. pressure to FG header by opening the by-
Reflux C/V will full open. pass of PV-2018A mounted on 010-V-008.
Desalter Isolate desalter brine outlet Level control
10  Water inlet valve closes. valves & also water injection B/V
 Brine outlet valve closes. Stop chemical injection.
NOTE:
If the failure is for longer duration, say more than one hour, flush the heavy oil lines with flushing oil and keep
the units bottled up under positive pressure.
9.6 FUEL FAILURE:

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Both the crude charge heater are designed for dual firing (for both fuel oil and fuel gas). The duty of
heaters can be achived by firing fuel gas or fuel oil or a mixture of both fuels.
Effects:
 In case of FO failure, Furnaces coil outlet temperatures will come down abruptly.
 Incase failure of FG furnace will be tripped due to Low Low pilot gas pressure and Fuel gas make
up for 010-C-001 pressure control will not be available.
ACTION TO BE TAKEN
For Fuel oil Failure:
Sl. No Action Responsibility Remarks
Sustain the unit normal operation by maximising gas firing
1 Panel/Field
(reducing the unit throughput if required).
Isolate B/V of individual FO burners after ensuring flushing
of the same through Interlock logic. (As per logic in FO low
2 low pressure individual burners FO supply XZV will get Panel/Field
closed and flushing steam XZV of the same burner will
open automatically for flushing).
FO circulation to be established depending on the
3 Panel/Field
availability of FO pump (off site area).
For Fuel gas Failure:

SL.No Action Responsibility Remarks
On low low pressure of fuel gas , the main
1 Interlock action
burner will cut off as per Interlock logic
FG to both Main
burner as well as Pilot
Burner is taken from
2 Consequently pilot gas will also cut off. Interlock action
010-V-004 O/L
through a common
header
Reduce crude charge rate to 50% of design and
3 route CDU & VDU products to light slop & Panel/Field
heavy slop tank respectively
Shut down the unit as per normal shutdown
4 Panel/Field
procedure

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SL.No Action Responsibility Remarks

Establish CDU & VDU circulation as per
5 Panel/Field
normal shut down procedure
9.7 FEED FAILURE:

Crude oil to the unit is supplied from crude tanks 201-TK-001-011 through booster pumps 201-P-
001A/B/C/D/E from Unit-201.
Effect:
 Desalter pressure will come down
 Pre-flash vessel level will come down.
 CDU furnace firing will tripped in low low pass flow/total furnace flow but pilot burner will be on
 Subsequently VDU furnace firing will tripped due to low low pass flow but pilot burner will be on.
ACTION TO BE TAKEN
Sl.
Action Responsibility Remarks
No
CRUDE DISTILATION UNIT (CDU)
Stripping steam to all columns and strippers to be
1 Panel/Field
closed
Isolation valves of individual burners (FO & FG) at
2 firing P/F to be closed after ensuring proper flushing of Field
FO burners.
3 Establish FO circulation. Panel/Field
Keep continue the flow of all P/A reflux of CDU till
4 Field
top temperature/pressure is under control
5 Run down/ IR flow of CDU to be stopped Field
Desalter wash water injection and all chemical dosing
6 Panel/Field
to Desalter/010-C-001/007/004 to be stopped
7 All R/D air coolers and compressor to be stopped. Panel/Field
Bring down the 010-C-001 column bottom level in
8 Panel
operating range by routing AR to DCU storage
Line up CDU hot circulation and establish hot
8 Field/Panel
circulation as per normal procedure.
VACUUM DISTILATTION UNIT (VDU)
1 Isolate the steam ejector as per standard procedure Field

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Sl.
Action Responsibility Remarks
No
Line up nitrogen back up to 010-C-007 and isolate
2 stripping steam to column after ensuring positive Field
pressure in the column
Isolation valves of individual burners (FO/FG/Vent
Gas) at firing P/F to be closed after ensuring proper
3 Field
flushing of FO burners. Stop turbulising steam to all
passes
4 Establish FO circulation. Panel/Field
Stop all product pumps and flush all the R/D lines with
5 Field
FLO to slop tank
6 Stop all the chemical injection Field
Bring safe operation level in the column by routing VR
7 Panel/Field
to DCU through VGO A/C
8 Stop all the R/D air cooler Field
9 Line up circulation and establish hot circulation Field/Panel
9.8 HEATER TUBE FAILURE :
This type of emergency can be broadly categorized into two types:

 Pin hole leak
 Tube rupture
Effect:
 In case of pin hole leak, hydrocarbon from coil will catch fire which can be visible from the Peep
hole
 In case of tube rupture, there is chance of major fire inside the box and may leads to explosion.
ACTION TO BE TAKEN:
Sl.No Action Responsibility Remarks

Plant shutdown to be taken by activating the emergency
1 Panel/Field
push button either from field or Panel
2 Inform F&S and RSM

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Sl.No Action Responsibility Remarks

3 Ensure FD & ID fan are stopped. Field
4 Box purging steam to be charged. Field
Introduce coil purging steam very slowly after ensuring
condensate draining from the header (Before charging
5 Panel/Field
coil purging steam ensure no flame is present inside the
furnace and Box temp. is under control).
6 Monitoring the column top pressure and bottom level Panel
In case of vacuum Furnace (in addition to above
steps) turbulising steam and stripping steam charging to
7 the column to be kept on in controlling manner to Panel/Field
maintain positive pressure in the column. If required
nitrogen back up to be lined up to column.
Prepare the unit for H/O to maintenance as per normal
8 Panel/Field.
shutdown procedure.
9.9 FURNACE FAILURE/TRIP
VACUUM FURNACE:
During normal unit operation If Vacuum furnace trips the following actions are to be taken.
1. In case of failure of Vacuum Furnace, reduce CDU throughput to 60% & route AR to DCU through
010-E-127 A-E
010-F-002 010-C-007 010-P-025
/E-227 A-E
DCU (routing change

to be carried out as 010-E-151 A/B/C 010-E-117/ 010-E-116/
per valve operation & E-251 A/B/C E-217 E-216
checklist)
2. Isolate all individual burners B/Vs at the firing platform.(FO,FG and OFF gas burners)
3. Ensure all pilot burners are in line.

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4. Reduce CDU through put to 50% to avoid level building up in 010-C-001.

5. Maintain CDU furnace COT as per the nature of crude being processed to avoid lighter hydrocarbon
falling down to RCO.
6. Isolate Ejectors, Start nitrogen/fuel gas back up to 010-C-007.
7. Gradually close stripping steam to the column (close PV-3007 and the isolation B/V near the column)
8. Force the inter lock logic and vent out super-heated LP steam through (open XZV-3003) silencer.
9. Stop turbulising steam injection to passes.
10. Pump out the draw tray material to the respective tanks keeping minimum level in draw trays. Stop the
pumps and line the product routing to heavy slop tank.
11. Stop reflux and wash oil and recycle oil.
12. Continue PA circulation as per requirement.
13. Maintain Column pressure slightly positive (0.5kg/cm2g).
14. Open vent gas knock out drum vent line B/V valve.
15. Stop hot well drum bottom pumps for interface and hot well oil (010-P-027/P-028)
16. If the flue gas temperature is less (<4000C) by pass waste heat boiler and air pre heater. Isolate MP
steam to 010-F-002 from WHB and open vent line B/V.
17. If the Furnace trip is recovered in short period light up the furnace and start the vacuum section as per
normal start up procedure.
CDU FURNACE TRIP:
As per trip logic if any one of the CDU furnaces, either 010-F-101 or 010-F-201 trips the other furnace will
also trip. In such condition the following actions are to be taken and both sections are to be brought for a
safe shut down followed by circulation.
1. Close the isolation B/Vs of all individual burners at the firing platform (fuel gas/fuel oil).
2. Take LIC-1010, 010-V-003 level, on manual mode and give controller output zero which will regulate
the control valve at the crude pump discharge, thereby restricting crude flow to unit. Inform the same
to crude pump house in charge.
3. Stop 010-P-007 and 010-P-003 pumps.
4. Vacuum furnace firing will cut off as per low low pass flow trip logic.
5. Shut down vacuum section as per standard procedure.
6. Ensure all pilot burners of CDU and VDU furnaces are in line.
7. If the flue gas temperature is less than 4000C by pass WHB and APH.
8. Isolate MP and LP steam from the steam generators and waste heat boiler to furnaces.
9. Close stripping steam control valves and B/Vs near the columns and strippers and vent out steam
through silencer.
10. Pump out the products to the product tanks keeping minimum level in the strippers.

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11. Stop off gas compressors.

12. Shut down stabilizer, deethaniser, depropanizer and SR LPG sections as per normal shut down
procedure.
13. Stop chemical injections; switch off the power to Desalters.
14. If the furnace trip problem is recovered in a short period, Line up CDU for hot circulation, establish
circulation and light up the burners as per standard procedure.
15. Line up for VDU circulation, establish circulation and light up burners in 010-F-002 as per standard
procedure.

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CHAPTER-10
SAMPLING, LABORATORY ANALYSIS

&
QUALITY CONTROL

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10.1 Following are the list of sampling and test to be performed for AVU:
Each
Sample Name Type of analysis Method D W M
shift
010-E-149 Blowdown Sample PH,TDS 1
010-E-150 Blowdown Sample PH,TDS Note: 2
010-E-151 A/B/C Blowdown
PH,TDS Note: 2
Sample
010-E-251 A/B/C Blowdown
PH,TDS Note: 2
Sample
Crude Heater Steam Drum
PH,TDS 1
(010-V-024)
Vacuum Heater Steam Drum
PH,TDS 1
(010-V-022)
Crude column Ovh.
PH,Cl,Fe, Cu 1
(010-V-005)-Sour Water
Naphtha Stabiliser Ovh.
PH,Cl,Fe, Cu Note: 2
Hot Well
PH,Cl,Fe, Cu 1
AR Recovery @ 360 deg C 1
AR Distillation (Vac) Note: 2
AR Density 1
AR Flash Point 1
ASTM
AVU Diesel to DHDT Distillation 1
D 86
AVU Diesel to DHDT Flash Point 1
AVU Diesel to DHDT Pour Point Note: 2
AVU Diesel to DHDT Sp Gr 1
AVU Diesel to DHDT Recovery 1
Crude at B/L BS&W 1
Crude at B/L Sp Gr 1
Crude at B/L Sulphur 1
Crude at B/L Salt Content 1
Crude at outlet of V-102 B Salt Content 3 /week
Crude at outlet of V-102 B BS&W 3 /week
Crude at outlet of V-202 B Salt Content 3 /week
Crude at outlet of V-202 B BS&W 3 /week
Crude Heater flue gas Orsat 1
Vacuum Heater flue gas Orsat 1
Desalter Effluent (Train-1) PH 1
Desalter Effluent (Train-2) PH 1

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Each
shift
Fuel gas ex AVU Composition 1
Fuel gas ex AVU H2S 1
LP Gas ex LP Scrubber
H2S 1
(010-C-009)
ASTM
HAGO Distillation 1
D 86
HAGO Sp Gr 1
HAGO Flash Point 1
HVGO Distillation (Vac) 1
HVGO Pour Point 1
HVGO Sp Gr 1
HVGO Color 1
ASTM
Kerosene Distillation 1
D 86
Kerosene Flash Point 1
Kerosene Sp Gr 1
Kerosene Freezing Point 1
Kerosene Smoke Point 1
ASTM
LAGO Distillation 1
D 86
LAGO Sp Gr 1
LAGO Flash Point 1
Sour LPG H2S Note: 2
Sour LPG Weathering 1
ASTM
VGO Distillation 1
D 86
VGO Sp Gr 1
VGO Pour Point Note: 2
ASTM
Naphtha Distillation 1
D 86
Naphtha Sp Gr 1
Naphtha RVP 1
Naphtha Sulphur 1
Neutralizing Amine Strength Note: 1 Note: 1 Note: 1
Corrossion Inhibitor Solution Strength Note: 1 Note: 1 Note: 1
Phosphate Solution Strength Note: 1 Note: 1 Note: 1
Recycle Oil Distillation (Vac) Note: 2
Recycle Oil Sp Gr Note: 2
Recycle Oil CCR Note: 2
Vacuum Diesel Pour Point 1

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Each
shift
Vacuum Diesel Sp Gr 1
Metal Content
VGO & HVGO Combined Sample 1
(Ni ,Vanadium)
VR Penetration 1
VR Sp Gr 1
VR CCR 1
VR Flash Point Note: 2
Depropaniser (010-C-006) top
Composition 1
product
Depropaniser (010-C-006) Bottom
Composition 1
product
D: Daily, W: Weekly & M: Monthly
Note-1: As per batch preparation Note-2: As per request
10.2 SIGNIFICANCE OF LABORATORY TEST
1) Salt Content
Salt content in crude oil is a result of production practices on the oil fields and the handling of the crude in
the tankers bringing it to Refinery. Even small amount of salt is critical to CDU operations because of the
constant accumulation of salt in critical equipments such as exchangers, heaters etc. In addition to checking
up of the equipment, certain metallic salt break down and liberate corrosive acids during the processing
operation. Setting, heating, chemical treating and mixing with water all reduce salt content.
2) Weathering Test
This test indicates the presence of higher boiling constituents in LPG. In test method 100 ml sample is
collected in weathering tube and allow liquid to weather at specified conditions and temperature is observed
when 95% of initial quantity has evaporated.
3) Copper Corrosion
Copper corrosion test gives an indication of the corrosiveness of the product to the metallic parts of the
system in which the product is used. It has the following grades of nomenclature to denote degree of
corrosion.
1a, 1b
2a, 2b, 2c, 2d, 2e
3a, 3b
4a, 4b, 4c

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4) Specific gravity & API gravity

Specific gravity is the ratio of the weight of a unit volume of oil to the weight of the same volume of water
both at a standard temperature (usually 60 F)
To avoid confusion of standards by instrument manufacturers, a special gravity scale has been adopted by
the American petroleum institute for expression of the gravities of petroleum products. API gravity is
measured in degrees API. The relation between API gravity & specific gravity is
141.5
Degrees API = --------- - 131.5
Sp. Gr.
5) Vapor pressure
The pressure, under which liquid and vapor can co-exist at equilibrium, is the saturation vapor pressure or,
in brief, the vapor pressure of the liquid.
6) Reid Vapor Pressure (RVP)
The RVP is considered the best single criterion of freedom from vapor lock in spark ignition automotives.
Vapor pressures of volatile non-viscous petroleum products like gasolene are measured by RVP method.
This test is conducted at 100 F. The true vapor pressure is higher than RVP by about 5 to 9 percent.
7) Boiling point
When the vapor pressure of liquid equals external pressure on the liquid, liquid starts boiling. The
temperature at which this process occurs is called boiling point. A pure liquid boils at a constant temperature
at a certain pressure. But mixtures boil at a range of temperatures at a constant pressure, because of the
variation in their boiling points in pure state.
8) Initial boiling point (IBP)
It is the temperature at which first drop of liquid boils out when a liquid mixture is distilled.
9) Final boiling point (FBP)
It is the temperature at which last drop of liquid boils out when a liquid mixture is distilled.
10) ASTM distillation
It is a method of distillation evolved by American society for testing materials (ASTM) for lighter
petroleum fractions. In this method, 100cc of oil is distilled at a uniform rate of 5cc per min. The
distillate is condensed in a brass tube surrounded by cracked ice. The temperature of the vapor when the
first drop of condensate drips from the condenser (in not less than 5 or more than 10 min ) is recorded as
the initial boiling point (IBP) . The vapor temperature is also recorded as each successive 10 % is collected.
The maximum temperature is recorded as the end point.

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11) Flash point

It is the temperature at which the vapor of a petroleum product heated under definite standard conditions
forms an explosive mixture with the surrounding air and ignites when a flame is brought up to it.
12) Ignition point
It is the temperature at which a product heated under definite conditions ignites when a flame is brought up
to it and burns for at least five seconds. It is always higher than the flash point. The heavier a petroleum
product the larger is this difference.
13) Self ignition point
It is the temperature at which a heated product in contact with the air ignites spontaneously without any
external source of flame. The heavy petroleum residues have lower self ignition points (around 300 to 350
C) than the lighter petroleum fractions. This is also called 'Auto Ignition Point'.
14) Pour point
It is the temperature below 5 F at which a liquid cooled under standard conditions ceases to flow.
15) Cloud point
It is the temperature at which a distinct cloudiness or haziness appears in the bottom of a jar containing
liquid when cooled under standard conditions.
16) Octane number
It the percentage (by volume) of iso-octane in a mixture with n-heptane, which is equivalent in its anti-
knock characteristics in a single cylinder engine to the fuel being tested under standard conditions. The
octane no. of iso-octane is taken as 100 and that of n-heptane as zero.
17) Cetane number
It is the index of ignitability of diesel fuel. It is defined as the percentage (by volume) of cetane (n-hexa
decane, C16H34) in a mixture with alpha-methyl naphthalene (C16H34), which possesses the same
ignitability in a single cylinder engine under standard testing conditions as the fuel being tested.
18) Over flash
It is the excess amount flashed in the column over and above required distillate yield for providing internal
reflux at the bottom section of the fractionator for better fractionation. Generally, it is 3 to 5 % on the feed.
19) GAP
GAP defines the relative degree of separation between adjacent fractions. It is determined by subtracting
the 95 vol. % ASTM temperature of a fraction from the 5 vol. % ASTM temperature of the adjacent heavy
fraction. Generally, 15 C GAP is considered for crude column design.

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10.3 HYDROCARBON SAMPLING PROCEDURES:
A) SAMPLING OF LIQUIDS AT OR LOWER THAN 560C.
1. Samples are to be collected in the clean& dried sample bottles.

2. Open the second isolation B/V (near OWS).
3. Gradually open the first isolation by a few threads (near the process line) and drain out the line
content to OWS.
4. Now collect the sample in the sample bottle and rinse out two/three times and collect sufficient
quantity of the sample.
5. Close the first isolation B/V, second isolation B/Vs and ensure no liquid is coming out of the
sampling line.
6. Close the bottle properly and tie up the sample tag mentioning name of the sample, source, time
and date.
Sample Point SC-1 Type
SL.
Tag No P&ID Number Process supply Line No Process Fluid/location
No
PDRP4210-270-8110-25-
1 010-SP-506 450-P-010-1003-B1AP-IT Crude inlet to E-102
010-1001

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SL.
No
PDRP4210-270-8110-25- 150-WP-010-1008-
2 010-SP-108 Desalter Effluent Train 1
010-1008 B4AV-NI
PDRP4210-270-8110-25- 150-WP-010-1029-
3 010-SP-109 Desalter Effluent Train 2
010-1008 B4AV-NI
PDRP4210-270-8110-25- 350-WCR-010-1005- WCR of Desalter effluent

4 010-SP-501
010-1008 A2AW-NI water cooler (E-152) Train1
PDRP4210-270-8110-25- 150-P-010-1133-B1AP-
5 010-SP-110 Kerosene to KTU/Storage
010-1024 NI
PDRP4210-270-8110-25- 250-WCR-010-1000- WCR of Kerosene product

6 010-SP-111
010-1024 A2AP-NI trim cooler
PDRP4210-270-8110-25- 300-P-010-1135-B1AP-
7 010-SP-502 Hot AGO to DHDT
010-1024 PP
PDRP4210-270-8110-25- 250-P-010-1136-B1AP-
8 010-SP-503 Cold AGO to Storage
010-1024 NI
PDRP4210-270-8110-25-
9 010-SP-504 450-P-010-1002-B1AP-IT Crude inlet to E-202
010-1101
PDRP4210-270-8110-25- 350-WCR-010-1505- WCR of Desalter effluent

10 010-SP-505
010-1108 A2AW-NI water cooler (E-252) Train2
PDRP4210-270-8110-25- 250-WCR-010-2001- WCR of Recontractor trim

11 010-SP-217
010-2002 A2AW-NI cooler (E-035)
PDRP4210-270-8110-25- 250-WCR-010-2005- WCR of Stabilised Naphtha

12 010-SP-218
010-2005 A2AW-NI trim cooler (E-040)
PDRP4210-270-8110-25- 50-AM-010-3001-A4AR- Amine drain of Vent Gas

13 010-SP-518
010-3001 NI KOD (010-V-011)
PDRP4210-270-8110-25- Vacuum Diesel PA after

14 010-SP-347 350-P-010-3077-B2AP-IT
010-3015 PA trim cooler (E-039)
PDRP4210-270-8110-25- 300-WCR-010-3002- WCR of Vacuum Diesel

15 010-SP-348
010-3015 A2AP-NI PA trim cooler (E-039)

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SL.
No
PDRP4210-270-8110-25- 100-WCR-010-6063- WCR of AGO seal fluid
16 010-SP-515
010-6013 A2AW-NI cooler (E-057)
PDRP4210-270-8110-25- 100-WCR-010-6065- WCR of VGO seal fluid

17 010-SP-516
010-6014 A2AW-NI cooler (E-058)
B) SAMPLING LIQUIDS ABOVE 550C AND CONGELEANING SERVICE
1. Open condensate drain B/V, charge steam and drain out condensate.
2. Open sampling line B/V at the O/L of the water cooler and charge steam by opening second
isolation B/V at the I/L of the water cooler and flush out the sample line thoroughly.
3. Close flushing steam and condensate drain B/Vs.
4. Open CWS B/V to the sample cooler.
5. Now open the First isolation B/V of the sampling line and drain out the initial material to OWS.
6. Collect the sample in a clean, dry sample bottle/ ladel and tie up the sample tag as stated above.
7. Isolate the first isolation B/V and flush out the sample cooler hold up material to OWS by
charging Flushing steam.
8. Once flushing is completed close steam line B/V, condensate drain B/V, the second isolation B/V
of the sampling line and cooling water supply line B/V to the sample cooler.
Note: VR sample is to be collected in ladle.

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SL. Process supply Line

Tag No P&ID Number Process Fluid/location
No No
010-SP- PDRP4210-270-8110-25- 400-P-010-1069-
1 VGO line before E-118
112 010-1011 B2AP-IT
010-SP- PDRP4210-270-8110-25- 250-P-010-1073-

2 HAGO PA line at i/l of E-123
507 010-1012 B2FP-IT
010-SP- PDRP4210-270-8110-25- 250-P-010-1070-

3 HAGO PA line at o/l of E-123
508 010-1012 B4AV-IT
010-SP- PDRP4210-270-8110-25- 250-P-010-1072-

509 010-1012 B2AP-IT
010-SP- PDRP4210-270-8110-25- 400-P-010-1023-

5 VGO line at o/l E-118
113 010-1030 B2AP-IT
010-SP- PDRP4210-270-8110-25- 250-P-010-3009- VR pump discharge (P-025) to

6
114 010-1034 D38P-IT Train 1
010-SP- PDRP4210-270-8110-25- 400-P-010-1569-

115 010-1111 B2AP-IT
010-SP- PDRP4210-270-8110-25- 250-P-010-1112-

8 HAGO PA line at i/l of E-223
510 010-1112 B2FP-IT
010-SP- PDRP4210-270-8110-25- 250-P-010-1570-

511 010-1112 B4AV-IT
010-SP- PDRP4210-270-8110-25- 250-P-010-1187-

512 010-1112 B2AP-IT
010-SP- PDRP4210-270-8110-25- 400-P-010-1523-

116 010-1130 B2AP-IT
010-SP- PDRP4210-270-8110-25- 250-P-010-3209- VR pump discharge (P-025) to

12
117 010-1134 D38P-IT Train 2
010-SP- PDRP4210-270-8110-25- 150-P-010-3017- Recycle oil Pump Discharge (P-

13
349 010-3005 D0LV-IT 024)

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SL. Process supply Line

No No
010-SP- PDRP4210-270-8110-25- 100-P-010-3035- HVGO at o/l of E-150
14
350 010-3008 B2AP-IT (HVGO/LP steam Generator)
010-SP- PDRP4210-270-8110-25- 300-P-010-1024- VGO product to VGO

15
351 010-3016 B2AP-IT HDT/storage
010-SP- PDRP4210-270-8110-25- 100-P-010-1006-

16 Vacuum Diesel to DHDT/storage
517 010-3017 B2AP-IT
010-SP- PDRP4210-270-8110-25- 300-P-010-3013-

17 VR to DCU/Storage
352 010-3018 B2AP-IT
C) SAMPLING LIQUID ABOVE 550C AND NON CONGEALING SERVICE

The sampling procedure is the same as above. No requirement of steam flushing and sample can
be collected in the sample bottle.

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Sl.
No
PDRP4210-270-8110-25-
1 010-SP-130 200-P-010-1276-B2AP-IH AGO product ex E-107
010-1002
PDRP4210-270-8110-25-
2 010-SP-131 250-P-010-1018-B2AP-IH Kero PA ex Ex-106
010-1002
PDRP4210-270-8110-25-
3 010-SP-132 200-P-010-1016-B2AP-PP AGO product ex E-103
010-1002
PDRP4210-270-8110-25-
4 010-SP-133 200-P-010-1277-B2AP-IH AGO product i/l E-103
010-1002
PDRP4210-270-8110-25- Try line of Desalter 010-

5 010-SP-134 010-A-101
010-1004 A-102A
Crude from 1st Stage
PDRP4210-270-8110-25-
6 010-SP-135 010-A-101 Desalter O/L, 010-A-
010-1004
102A
PDRP4210-270-8110-25- Desalter Bottom 010-A-
7 010-SP-136 010-A-101
010-1004 102A

8 010-SP-137 010-A-101
010-1005 102B

9 010-SP-138 010-A-101
010-1005 A-102B
Crude from 2nd Stage
PDRP4210-270-8110-25-
10 010-SP-139 010-A-101 Desalter O/L, 010-A-
010-1005
202B
PDRP4210-270-8110-25-
11 010-SP-141 250-P-010-1035-B2AP-IH Kero PA i/l to E-131
010-1009
PDRP4210-270-8110-25-
12 010-SP-142 250-P-010-1027-B2AP-IH Kero PA ex E-131
010-1009
PDRP4210-270-8110-25-
13 010-SP-143 250-P-010-2043-B2AP-IH LAGO PA i/l to E-119
010-1009
PDRP4210-270-8110-25-
14 010-SP-144 250-P-010-1042-B2AP-IH LAGO PA ex E-119
010-1009

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Doc. No:
Sl.
No
PDRP4210-270-8110-25-
010-1009
PDRP4210-270-8110-25-
16 010-SP-146 300-P-010-1038-B1AP-IH Desalted crude ex E-117
010-1009
PDRP4210-270-8110-25-
17 010-SP-147 200-P-010-1184-B2AP-IH AGO product i/l to E-129
010-1012
PDRP4210-270-8110-25-
010-1012
PDRP4210-270-8110-25-
19 010-SP-154 250-P-010-1089-B2AP-IH Kero PA ex Ex-206
010-1102
PDRP4210-270-8110-25-
010-1102
PDRP4210-270-8110-25-
21 010-SP-156 200-P-010-1177-B2AP-PP AGO product ex E-203
010-1102
PDRP4210-270-8110-25-
22 010-SP-157 200-P-010-1777-B2AP-IH AGO product i/l E-203
010-1102

23 010-SP-158 010-A-201
010-1104 A-202A

24 010-SP-159 010-A-201
010-1104 202A
Crude from 1st Stage
PDRP4210-270-8110-25-
25 010-SP-160 010-A-201 Desalter O/L, 010-A-
010-1104
202A
26 010-SP-161 010-A-201
010-1105 202B

27 010-SP-162 010-A-201
010-1105 A-202B
Crude from 2nd Stage
PDRP4210-270-8110-25-
28 010-SP-163 010-A-201 Desalter O/L, 010-A-
010-1105
202B

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Sl.
No
PDRP4210-270-8110-25-
29 010-SP-165 250-P-010-1103-B2AP-IH Kero PA i/l to E-231
010-1109
PDRP4210-270-8110-25-
30 010-SP-166 250-P-010-1527-B2AP-IH Kero PA ex E-231
010-1109
PDRP4210-270-8110-25-
31 010-SP-167 250-P-010-2122-B2AP-IH LAGO PA i/l to E-219
010-1109
PDRP4210-270-8110-25-
32 010-SP-168 250-P-010-1107-B2AP-IH LAGO PA ex E-219
010-1109
PDRP4210-270-8110-25-
010-1109
PDRP4210-270-8110-25-
34 010-SP-170 300-P-010-1538-B1AP-IH Desalted crude ex E-217
010-1109
PDRP4210-270-8110-25-
010-1112
PDRP4210-270-8110-25-
36 010-SP-173 200-P-010-1074-B2AP-IH AGO product i/l to E-229
010-1112
PDRP4210-270-8110-25- Suspected condensate of

37 010-SP-357 100-CL-010-9102-A2AS-PP
010-9615 AVU
PDRP4210-270-8110-25- Suspected condensate

38 010-SP-358 80-CL-010-1002-A2AS-PP
010-9615 from unit 026/027
Blowdown of E-149
PDRP4210-270-8110-25-
39 010-SP-359 50-BD-010-3000-B2AS-IH (HVGO/MP steam
010-3007
Generation)
PDRP4210-270-8110-25- Saturated MP steam ex E-
40 010-SP-360 100-SM-010-3004-B1AS-IH
010-3007 149
Blowdown of E-150
PDRP4210-270-8110-25-
41 010-SP-361 50-BD-010-3001-B2AS-IH (HVGO/LP steam
010-3008
Generation)
PDRP4210-270-8110-25- Saturated LP steam ex E-
42 010-SP-362 200-SL-010-3005-A1AS-IH
010-3008 150

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Doc. No:
Sl.
No
PDRP4210-270-8110-25- Blow down of E-251 A
43 010-SP-364 50-BD-010-3005-B2AS-IH
010-3019 (VR/LP steam generator)
PDRP4210-270-8110-25-
44 010-SP-365 300-SL-010-3025-A1AS-IH LP Steam ex E-251 A
010-3019
PDRP4210-270-8110-25- Blow down of E-151 A

45 010-SP-366 50-BD-010-3002-B2AS-IH
PDRP4210-270-8110-25-
46 010-SP-367 300-SL-010-3026-A1AS-IH LP Steam ex E-151 A
010-3020
PDRP4210-270-8110-25- Blow down of E-251 B

47 010-SP-368 50-BD-010-3006-B2AS-IH
PDRP4210-270-8110-25-
48 010-SP-369 200-SL-010-3027-A1AS-IH LP Steam ex E-251 B
010-3023
PDRP4210-270-8110-25- Blow down of E-251 C

49 010-SP-370 50-BD-010-3007-B2AS-IH
PDRP4210-270-8110-25-
50 010-SP-371 200-SL-010-3049-A1AS-IH LP Steam ex E-251 C
010-3024
PDRP4210-270-8110-25- Blow down of E-151 B

51 010-SP-372 50-BD-010-3003-B2AS-IH
PDRP4210-270-8110-25-
52 010-SP-373 200-SL-010-3028-A1AS-IH LP Steam ex E-151 B
010-3025
PDRP4210-270-8110-25- Blow down of E-151 C

53 010-SP-374 50-BD-010-3004-B2AS-IH
PDRP4210-270-8110-25-
54 010-SP-375 200-SL-010-3046-A1AS-IH LP Steam ex E-151 C
010-3026
D) SAMPLING OF HIGHLY VOLATILE LIQUID AND SOUR WATER, BELOW 55 0C

AND ABOVE 550C
1. Place the sampling Bomb in position and fix it properly on the process line flanges.
2. Open I/L and O/L side B/Vs of the bomb.

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3. Open low pressure side B/V at the O/L of the bomb and gradually open second isolation B/V and
first isolation B/Vs at the I/L side of the bomb (high pressure side) and allow the sample to pass
through the bomb for a few minutes and collect the sample
4. Once sample is collected in the bomb, close I/L & O/L B/Vs of the bomb, isolate low pressure
and high pressure sides B/Vs.
5. Now disconnect the bomb and tie up the Laboratory tag.
6. For hot liquids, Charge cooling water to the sample cooler before collecting the sample. Sampling
procedure is as same as sampling of high volatile liquid and sour water below 56 0C.
Sample Point SC-4 Type (Sampling for highly volatile liquids and sour water below 55 OC)
Sl. Process supply Line

No No
010-SP- PDRP4210-270-8110-25- 100-WP-010-1162- Sour Water line of P-011
1
120 010-1027 A4AR-NI discharge
010-SP- PDRP4210-270-8110-25- 200-P-010-2017-B2AQ- Unstabilized Naphtha line of P-

2
219 010-2003 NI 013 discharge

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No No
010-SP- PDRP4210-270-8110-25- 100-P-010-2014-A2AQ- Off Gas from Recontact Drum
3
220 010-2003 NI (V-007)
010-SP- PDRP4210-270-8110-25- 250-P-010-2115-A2AQ- Naphtha stabiliser O/H receiver

4
221 010-2006 NI pump P-015/016 suction
010-SP- PDRP4210-270-8110-25- 100-P-010-2069-B1AP- Sour LPG line after (E-044) to SR

5
222 010-2008 NI LPG Trt.
010-SP- PDRP4210-270-8110-25- 80-P-010-2092-B1AP- C4 to Alkylation/storage (after E-

6
223 010-2011 NI 048)
010-SP- PDRP4210-270-8110-25- 50-P-010-2118-B1GP- C3 to storage (after P-019

7
224 010-2013 NI discharge)
010-SP- PDRP4210-270-8110-25- 100-P-010-2148-B1GP- Off spec LPG from LPG bullets

8
624 010-1035 IH for reprocessing
010-SP- PDRP4210-270-8110-25- 80-P-010-3057-B2AP-

9 Hot well oil (Coalescer o/l)
355 010-3010 NI
010-SP- PDRP4210-270-8110-25- 150-P-010-3049-B4AR- Sour Water from Hot Well (P-028

10
356 010-3011 NI discharge)
010-SP- PDRP4210-270-8110-25- 50-AM-010-4020- Lean Amine to Amine Absorber

11
225 010-4001 B2AL-NI (C-010)
010-SP- PDRP4210-270-8110-25- 200-FG-010-4004- Treated Fuel Gas from KOD (V-

12
226 010-4002 A2AD-NI 017)
010-SP- PDRP4210-270-8110-25- 50-AM-010-4010- Rich Amine to ARU (from C-

13
227 010-4003 A4AR-NI 009)
010-SP- PDRP4210-270-8110-25- 80-AM-010-4007- Lean Amine to Amine Scrubber

14
228 010-4003 B2AL-NI (C-009)
Sample Point SC-5 Type (Sampling for highly volatile liquids and sour water above 55 0C)

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No No
010-SP- PDRP4210-270-8110-25- 500-P-010-1025-A2AQ-
1 TPA line at the i/l of E-104
125 010-1002 IH
010-SP- PDRP4210-270-8110-25- 500-P-010-1014-A2AQ-

2 TPA line at the o/l of E-104
126 010-1002 IH
010-SP- PDRP4210-270-8110-25- 200-P-010-2020-B2AQ- CDU O/H liquid pump P-010

3
127 010-1027 NI discharge
010-SP- PDRP4210-270-8110-25- 500-P-010-1157-A2AQ-

4 TPA line at the i/l of E-204
128 010-1102 IH
010-SP- PDRP4210-270-8110-25- 500-P-010-1156-A2AQ-

5 TPA line at the o/l of E-204
129 010-1102 IH
010-SP- PDRP4210-270-8110-25- 80-AM-010-4004- Rich Amine to ARU (from C-

6
229 010-4001 A4AR-NI 010)
010-SP- PDRP4210-270-8110-25- 350-P-010-2041-A1AP- Naphtha product at the o/l of E-

7
513 010-1035 IH 037
010-SP- PDRP4210-270-8110-25- 150-P-010-1321-B2AQ- Side cut Naphtha line at P-014

8
514 010-1035 IH discharge

Page 238 of 592

Doc. No:
CHAPTER-11
TROUBLE SHOOTING

Page 239 of 592

Doc. No:
11. TROUBLESHOOTING
Sl. Operational
Possible cause Operation Response
No Symptom
1. Check the opening of 010-TV-1002/010-TV-1502 from field,

if it is malfunctioning get it attended through I/M.
2. Carry out temperature survey of Preheat Train-1 exchangers,
if any deviations/abnormality is
observed , sort out the same ( The reason may be: 1 st Preheat
Exchanger Bypass open, Exchanger fouling, Product/PA draw
temp. low )
Low Desalting 3. Check the Desalting wash water injection temperature, if any
temperature deviation observed, sort out the same. ( The reason may be:
Malfunctioning of TV- 1025/1525, Low Draw temperature of
AGO (LAGO + HAGO), Fouling / Bypass open of 10-E-
113/116)
Check the followings and sort out if any deviation observed :

Poor Desalting 1. 010-PIC-1099/1022 malfunctioning
01
( High salt content in Low desalting 2. Crude B/L pressure low (010-PT-1118)
Desalted crude, High pressure 3. Passing of Desalter PSVs.
Oil ppm in de-salter 4.1st Preheat Exchangers Pressure drop profile.
effluent, Water
carryover with Check the following and sort out if any deviation is observed :
Desalted crude) 1. De-Emulsifier dosing pump strokes (Either too little or too much
De-Emulsifier added to the untreated crude may increase the
De-Emulsifier amount of salt in the treated oil.)
Dosing rate 2. If for any reason the type of De-Emulsifier chemical has changed,
then recalculate De-Emulsifier dosing rate.
Mixing Valve Check the mixing valve pressure drop in field/panel and ensure it is
Delta Pressure not too high or not too low than normal (0.8 – 1.3 Kg/Cm2)
Wash water Check the interface level from the try line and adjust wash water
injection rate injection rate accordingly.

Page 240 of 592

Doc. No:
Sl. Operational
No Symptom
1. Check for the 10-P-003 (running pump) low discharge pressure and
if any abnormality observed, take necessary accordingly.
1. Check the OP of 10-LIC-1010 / Crude Booster pump
discharge control valve opening and get it attended if any
Liquid carry over from High level in abnormality observed.
flash drum overhead to Flash Drum 2. Check the opening of 10-PV-1021 from field and get it attended
02. 10-C- 001. (10- V-003) if any abnormality observed.
3. Check the opening of 10-F-101/201 feed pass C/V. If any
abnormality is observed, take necessary actions.
1. Check De-salter interface level (Try line checking) and if
required reduce wash water injection rate.
2. Contact BOOT and check whether water carry over is from
Water carry over Crude tank and if so take action accordingly (Reduce the
from De-salter throughput if required and if slop processing is going on through
Pressure surge in crude tank, inform OMS to stop the slop processing).
03. 010-V-003
Malfunctioning of Check the opening of 10-PV-1021 from field and get it attended if
10-PIC-1021 any abnormality is observed.
1. Carry out the pressure and temperature survey of preheat

Exchanger Trains
Preheat Exchanger 2. Increase the wash water injection rate (at E-102 Crude side)
tube side fouling 3. Increase the antifouling Dosing rate
Low preheat 4. Ensure no exchanger Bypass valve is open
temperature ( coil inlet
04.
temperature)
Low Product/PA Optimize the product draw temperature by adjusting column operating
Draw temperature. parameters
1. Adjust the Burner flame height as required

2. Identify the defective burners for handing over to M/M for
cleaning.
1.Burner Problem 3. Adjust the combustion air flow as per the excess air in flue gas
2.Excess analysis/excess oxygen sensor.
combustion air 4. Carry out the Fuel gas sample to check whether ammonium
3.High Draft salt formation is there.
05. Poor Furnace efficiency
4.Low air preheat 5. Adjust the ID fan load to control the Draft if necessary.
temperature 6. Increase the steam flow rate in SAPH in case of low air pre-
heat temperature.

Page 241 of 592

Doc. No:
Sl. Operational
No Symptom
1. Check for the 10-P-007 (running pump) low discharge pressure

and if any abnormality observed, take necessary accordingly.
1.Malfunctioning 2. Check the opening of 10-F-002 feed pass C/V opening. if any
of instruments abnormality observed take necessary accordingly
2.Desalter safety 3. Check the column level from level Gauge in the field.
valve passing 4. Check the stripping steam flow rate.
10-C-001 Bottom level
06. 3.Continuous 5. Check Desalter PSV for passing.
increasing
liquid carry over 6. Check whether any product draw
from 10-V-003 temperature/draw rate is low.
1. Malfunctioning 1. Check the opening of PV-1072A/B from the field.

10-C-001 Top pressure of 10-PIC-1072 2. Maximize Kero/LAGO/HAGO PA rate to optimize PA
07.
high 2. TPA quantity flow rate if required.
high 3. Adjust stripping steam rate to column & strippers.
Check for water carry over with crude from De-salter/Crude tank
and if so take necessary action as describe for water carry over.
08. Pressure surge in 10- Water carry over Check stripping steam flow rate/Control valve opening and also
C-001 stripping steam temp.
Check the draw trays for low level
1. Increase the ejector motive steam flow.

2. Check cooling water pressure and flow to ejector condenser
Increase in Top Flooding in the 3. Check the vacuum feed quality (AR recovery).
pressure of Vacuum column 4. Check the vacuum Diesel top reflux flow and temperature.
column 5. Check for any leak in overhead circuit
09.
6. Check the performance of all LP burners.
7. Adjust the stripping steam and turbulising steam flow rate
8. Check Barometric vessel 010-V-013 interface
Level
9. Check suction pressure of ejectors for any abnormality.

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Doc. No:
Sl. Operational
No Symptom
1. Check all the safety relief valves connected to flares for
any passing
2. If flaring is from column over head system, start more no. of
air cooler if possible.
10. Flaring Product loss 3. Check the cooling water flow and pressure in trim cooler.
4. Check whether bypass of flare control valves in C-04/C-05 and
C-06 are open or not.
5. Check whether any PSV bypass valves are in open condition or
not.
Leakage in O/H air

Monitor all O/H receiver boot water sample pH and adjust
11. cooler and Trim
Due to corrosion neutralizing amine to maintain the pH @ 6.5 – 7.0
cooler.
1. Incomplete
combustion due 1. Adjust the combustion air flow
to improper 2. Check for any condensate carry over from fuel gas knock out
12. fuel/air ratio. drum
Smoke from Furnace
2. Problem in 3. Adjust the differential pressure of steam to fuel oil
stack
Fuel oil/Gas 4. Check the atomizing steam temperature.
quality
13. ID suction temperature Low flue gas stack 1. Check for any leak in APH
low temperature 2. Check for APH air bypass C/V opening and air temperature
1. Increase stripping steam flow in respective stripper

Low IBP 2. Decrease PA flow
Kero/LAGO/ HAGO 1.Decrease product draw temperature and product

14. Product off spec/give draw rate
High FBP
up 2.Increase IR flow rate
1. Increase over flash rate

2. Increase HAGO internal reflux 3.Reduce
HAGO colored
product draw rate

Page 243 of 592

Doc. No:
Sl. Operational
No Symptom
1.Reduce stripping steam flow rate to kero stripper

Kero/ATF
freezing point 2.Decrease column draw temperature
high 3.Reduce Kero draw rate/draw temperature
1. Maximize the draw rate of LAGO/HAGO.

High RCO 2.Optimise over flash rate
Vacuum feed lighter 3. Increase the CDU furnace COT, if margin available
15. recovery
4. Increase CDU column stripping steam flow
1. Increase stabilizer bottom 2.temperature/bottom heating.

Presence of lighter 3.Decrease stabilizer top pressure 4.Adjust the
16. Naphtha RVP High
component stabilizer reflux rate
High bottom 1.Check Bottom temperature indication 2.Increase VR

VR pump vapor locking temperature/Coke quench flow
17
formation 3. Increase turbulizing steam flow.
1. Adjust side cut draw rate keeping freezing point in range

High Sulphur in
18 High Sulphur content in KEROSENE cut in 2. Adjust kerosene draw rates and inform KTU panel
Kerosene accordingly.
crude blend
3. Reduce kerosene draw temperatures

Page 244 of 592

Doc. No:
CHAPTER – 12
SAFETY SYSTEMS/FIRE FIGHTING
SYSTEMS/MSDS

Page 245 of 592

Doc. No:
12. FIRE PROTECTION PHILOSOPHY FOR PARADIP REFINERY
The Fire Protection system of Paradip Refinery is designed in accordance with OISD 116 and other
international specification (NFPA & API) and PDRP Project standards.
The aim of the fire protection philosophy is to minimize loss of life or serious injury, contain and
prevent the spread of a fire, extinguish it in the early stages if possible and thus minimize the damage
and financial loss caused by such an incident. To achieve these aims the following design guidelines
are followed and equipment supplied:
1. The plant layout is such that an incident in one area of operation will not spread to adjacent
plot areas due solely to the proximity of the plots to one another. The layout is based on the
Oil Industry Safety Directorate document OISD-STD-118.
2. Emergency isolation valves are incorporated into the design to limit the volume of material
released in the event of a fire.
3. Any outbreak of fire or significant build-up of gas (flammable/combustible or toxic) is
alarmed automatically to the appropriate personnel and facilities are available for site
operatives to initiate a manual alarm from any location on the plant.
4. Adequate fixed and mobile firefighting facilities are available.
5. Adequate training in the use of firefighting equipment is given to the site operatives.
The firefighting systems on site and the required firewater quantities are designed on the basis of
two significant fire scenarios occurring at one time.
BASIS FOR FIRE WATER REQUIREMENT & STORAGE FACILITY IN PARADIP

REFINERY:
For the purpose of quantifying the firewater requirements, two major concurrent incidents in
different locations shall be considered. The fire water demand for these two incidents is calculated
to be 7000 m3/hr.
The maximum water required for this site has been calculated by the method detailed in OISD 116
Annexure -1 Clause 2.5 Alternate 1. In this clause it is specified that the water required to a process
area, with a 30 meter separation round it, shall be calculated by applying water to the process area
at 1 L/min/m2 plus a supplementary hose stream allowance of 600m3/hr. This is to be applied to the
two largest process areas on the assumption that they both require the full calculated rate of firewater
simultaneously.

Page 246 of 592

Doc. No:
For Paradip Refinery project the two largest process areas are Unit 30 (DCU) and Unit 10 (AVU) process
plots.
The water rates calculated based on:
3113 + 600 m3/hr = 3713 m3/hr for the AVU

and
2670 + 600 m3/hr = 3270 m3/hr for the DCU
Giving total 6983 m3/hr (say 7000m3/hr) of Fire Water.

Quantity of Storage Water required = Maximum demand x 4 hours = 7000 x 4 = 28,000 m3 Water
stored in 2 nos. of Tanks 37.5m diameter x 15.5 m high; capacity 2 x 14,000 m3
Fire water shall be stored in two (2) above ground atmospheric tanks each 37.5m diameter and
16.1m high. The combined tanks` storage capacity shall be capable of providing 100% flow for 4
hours. i.e. each tank sized at 14,000 m3.
The two storage tanks shall be interconnected and suitably valved such that the firewater pump
suctions can be taken from either storage tank without interruption to the firewater supply to the fire
main network.
In the event of a major prolonged incident when all the stored firewater in both tanks is exhausted
then it shall be possible to use raw water from the Refinery raw water system for firefighting
purposes. This shall be achieved by providing raw water directly to the firewater tanks via the raw
water transfer pumps.
The following fire protection measures are envisaged for Atmospheric Vacuum Plant.
- Fire Fighting system with Hydrant, Hose Box and Hose Reel, etc.
- Water Spray System for Columns, Pumps & Vessel handling volatile materials
- Water Spray System on Air Fin Cooler
- Fire Proofing for Equipment and Steel Structure
- First Aid Fire Protection ( Portable Fire Extinguishers)
- Gas Detection System
- Fire Alarm System
- CCTV
- Safety Shower and Eye Washer
- Utility Hose Station

Page 247 of 592

Doc. No:
- Paging and Communication System
Brief Details facilities in Atmospheric Vacuum Unit & SR LPG Unit are listed below:
- Double headed hydrants (4”size ) : 29

- Manual Water monitors (500-1000 GPM) : 12
- Remote Operated Water Monitors-HVLRM (500-1000 GPM) : 04
- Dry risers ` : 09
- Fire hose pipe 15 m length with 63mm dia. : 58
- Hose reel, 35 m of 25 mm bore hose. : 17
- Hose Cabinet with accessories. : 31
12.2 FIRE FIGHTING, FIRE ALARM & GAS DETECTION SYSTEM
A. Fire Fighting System

Fire Fighting System covered is as under:
A. FIRE HYDRANT, FIRE MONITORS & HVLRM SYSTEM
A 24 inch fire water ring is provided around the AVU unit with hydrants and monitors. Hydrants are
located in every 30M interval as per OISD-116 keeping in view the fire hazards at different sections
of the premises to be protected and to give most effective service. Within the unit fire hydrants, fire
monitors and HVLRM are located in strategic location.
Coverage:
Fire Hydrants: The horizontal range and coverage of hydrants with hose connections shall not be
considered more than 45 M.
Fire monitors: The monitor jet range shall be a minimum of 30 m.
High Volume Long Range (HVLR) water Monitor:
-Horizontal water throw: 80 – 90 meters

-Horizontal foam throw: 75 – 85 meters

Page 248 of 592

Doc. No:
Following are the list of Fire Hydrants, Fire Monitors & HVLRM in AVU & SR LPG unit:
List of Fire Hydrants in AVU & SR LPG Unit
Sl.No. Tag Number Description

1 010-HY-001/002 North side of ISBL at 010-V-611
2 010-HY-003/004 North side of ISBL at 010-P-203A-C
3 010-HY-005/006 North side of ISBL at 010-V-202A
4 010-HY-007/008 North side of ISBL at 010-V-610
5 010-HY-009/010 North side of ISBL at 010-V-102 B
6 010-HY-011/012 Near to 010-V-301
7 010-HY-013/014 Near to 010-V-016
8 010-HY-015/016 Near to 010-V-018 & 010-V-614
9 010-HY-017/018 Near to 010-K-003 A/B
10 010-HY-019/020 Near to 010-P-018 A/B
11 010-HY-021/022 South side of 010-E-151 A
12 010-HY-023/024 Near to 010-P-014 A/B
13 010-HY-025/026 Near to 010-E-127 F/G
14 010-HY-027/028 Near to 010-E-122 A/B
15 010-HY-029/030 Near to 010-E-117
16 010-HY-031/032 Near to 010-P-003 A
17 010-HY-033/034 Near to 010-P-003 C
18 010-HY-035/036 North-West side of chemical injection Package
19 010-HY-037/038 South side of Chemical Injection Package
20 010-HY-039/040 Near to 010-P-016 A
21 010-HY-041/042 West Side of Crude Column
22 010-HY-043/044 Near to 010-P-501A/B/C/D
23 010-HY-045/046 West Side of Crude Heater Area
24 010-HY-047/048 South Side of Crude Column
25 010-HY-051/052 Near to 010-V-613
26 010-HY-053/054 Near to 010-P-025 A
27 010-HY-055/056 North East Side of Vacuum Heater.
28 010-HY-059/060 In between Vacuum & Crude Heater
29 010-HY-061/062 North East Side of Crude Heater.
Note:
The Hydrants located at the periphery of AVU plot are not listed in above table.

Page 249 of 592

Doc. No:
List of Fire monitors in AVU & SR LPG Unit
Sl. No. Tag No Location/Area

1 010-FFM-001 Near to 010-P-016 A
2 010-FFM-002 At ground level of 010-AC-007
3 010-FFM-003 Near to 010-P-014 A
4 010-FFM-004 Near to Off Gas Compressor Area
5 010-FFM-005 Near to 010-P-018 B
6 010-FFM-006 Near to 010-V-018 & 010-V-614
7 010-FFM-007 Near to Flare KOD (010-V-301)
8 010-FFM-008 Near to 010-V-102 B
9 010-FFM-009 Near to 010-V-202 A
10 010-FFM-010 Near to 010-E-127 F/G
12 010-FFM-011 North Side of Vacuum Heater Area
Note:
The Monitors located at the periphery of AVU plot are not listed in above table.
List of HVLRM in AVU & SR LPG Unit
Sl. No. Tag No Location/Area Elevation in metres
1 010-EFM-001 At Vacuum Column Transfer Line 38.3
2 010-EFM-002 At Vacuum Column (010-C-007) 35
3 010-EFM-003 North West Side of Crude Column (010-C- 001) 20
4 010-EFM-004 At Crude Column (010-C-001) 39

Page 250 of 592

Doc. No:
B. DELUGE & WATER SPRAY SYSTEM
Where monitors are unable to provide the required cover, fixed water deluge shall be provided
designed in accordance with OISD 116 and NFPA 15.
Deluge systems shall be automatically initiated where located over critical equipment and otherwise
manually operated. Automatic operation shall be initiated by rate of rise or fixed temperature heat
detection pneumatic systems utilizing frangible bulbs (Quartz bulb).
As per OISD-116 requirements, equipment in Process Areas to be water spray protected

includes:
1. Pumps handling products above auto-ignition temperature, irrespective of its
location (below pipe racks or in open area).
2. Pumps handling petroleum products Class `A` under pipe racks
3. Un-insulated vessels having capacity greater than 50 m3 and containing class
A or B flammable liquid
4. Vessels inaccessible to fire tender/ mobile equipment, fire hydrants (monitors)
5. Air fin coolers in hydrocarbon service located above pipe racks/ elevated location
For columns over 45 meters high, spray rings to protect the area above 45 meters shall be installed, manually
operated and fed via a booster pump.
List of Deluge Valves in AVU & SR LPG Unit
DV skid
Sl.No. Tag Number Equipment Catering Type
Number
Atms. Residue Pump (010-P-007 A-C) Automatic (QB

1 DVS - 1 DV-01
Top pump around Pump (010-P-004 A-C) Detection
Automatic (QB
2 DV-03 VGO Product Cooler (010-AC-015 A-H)
Detection
Automatic (QB
3 DV-04 VGO Product Cooler (010-AC-015 A-H)
Detection
Kerosene Product Cooler(010-AC-004)
DVS-2 AGO Product Cooler (010-AC-005 A-C) Automatic (QB
4 DV-05
Stabilised Naphtha Cooler (010-AC-010 A- Detection
B
Recontactor Cooler (010-AC-008 A-B)
Automatic (QB
5 DV-06 Naphtha Stabiliser Overhead Cooler (010-
Detection
AC-009 A-C)

Page 251 of 592

Doc. No:
DV skid
Sl.No. Tag Number Equipment Catering Type
Number
C3 LPG Pump (010-P-019 A-C) Automatic (QB
6 DV-20
C4 LPG Pump (010-P-020 A-C) Detection
Automatic (QB
7 DV-07 Off Gas Compressor (010-K-003 A-B)
Detection
Deethaniser Bottom Pump (010-P-002 A-C)
Automatic (QB
8 DV-18 Deethaniser Overhead Pump (010-P-018 A-
DVS-3 Detection
B)
9 MV-1 Recontactor Drum (010-V-007) Manual
Naphtha Stabilizer Overhead Receiver (010-
10 MV-2 Manual
V-008)
Vacuum Diesel Product Cooler (010-AC- Automatic (QB
11 DV-08
014) Detection
DVS-4
Crude Column Overhead Receiver (010-V-
12 MV-3 Manual
005)
Crude Column Overhead Condenser (010- Automatic (QB
13 DVS-5 DV-13
AC-007 A-H) Detection
Automatic (QB
14 DVS-6 DV-10 Vacuum Column (010-C-007)
Detection
LAGO PA Pump (010-P-006 A-B)
Automatic (QB
15 DV-02 HAGO PA Pump (010-P-030 A-B)
Detection
Kerosene PA Pump (010-P-005 A-B)
Automatic (QB
16 DV-14 Diesel PA Cooler (010-AC-016 A-C)
Detection
DVS-7 HVGO Pump (010-P-023 A-C) Automatic (QB
17 DV-15
VR Pump (010-P-025 A-C) Detection
VGO Pump(010-P-022 A-C) Automatic (QB
18 DV-16
Recycle Oil Pump (010-P-024 A-B) Detection
LAGO Product Pump (010-P-009 A-B)
Automatic (QB
19 DV-17 HAGO Product Pump (010-P-029 A-B)
Detection
Kerosene Product Pump (010-P-008 A-B)
Automatic (QB
20 DVS-8 DV-09 Crude Column (010-C-001)
Detection
Automatic (QB
21 DVS-10 DV-19 LPG Product Pump (011-P-006 A-B)
Detection

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Spray Details of Crude & Vacuum Column
1st 2nd 3rd 4th 5th 6th

7th Ring
Crude Column (010-C-001) Ring Ring Ring Ring Ring Ring
Elevation 71.9 66.82 64.38 60.14 57 52.26 47.82
Ring Size, mm 50 80 80 80 80 80 100
Nos of Nozzles 12 17 17 17 17 17 17
Flow Per Nozzle 48.5 60.3 60.3 60.3 75.7 75.7 75.7
Min Pressure, kg/cm2 1.4 1.4 1.4 1.4 1.4 1.4 1.4
Total Flow 582 1025.1 1025.1 1025.1 1286.9 1286.9 1286.9
Vacuum Column (010-C- 1st Ring 2nd 3rd 4th 5th 6th
007) Ring Ring Ring Ring Ring
Elevation 67.26 61.4 55.85 53.4 50.15 48.05
Ring Size, mm 50 100 80 80 80 100
Nos of Nozzles 11 19 19 19 24 24
Flow Per Nozzle 60.3 93.5 75.7 48.5 48.5 75.7
Min Pressure, kg/cm2 1.4 1.4 1.4 1.4 1.4 1.4
Total Flow 663.3 1776.5 1438.3 921.5 1164 1816.8
Firewater booster Pumps at AVU

Spray rings of CDU & VDU column are connected with booster pump. Booster pump details are
given below.
Fire Water Pump Data

Pump Tag Name = 010-P-501 A-D
Pump Capacity = 315 m3/hr
Differential Press = 5.1 kg/cm2

Page 253 of 592

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C. FIRST AID FIRE PROTECTION (FIRE EXTINGUISHERS)
Fire Extinguishers shall be located strategically through the plant in conspicuous and easily accessible
places. Necessary Portable extinguishers will be located as below.
Qty.(in
Criteria
SL. No. F. Equipment Name nos.)
10 kg Dry Chemical Type Ground Level inside process units 46
50 kg Dry Chemical Type At the elevated location 11
D. HOSE REEL PROTECTION

Hose reels shall be provided throughout high risk areas in the Facility where there is a possibility of
a hydrocarbon release. They shall consist of 35 m of 1.25" hard booster hose equipped with a
combination of straight stream/fog nozzle and shut-off valve. The supply piping shall be 2" and the
hoses a firm type, rubber covered and rubber lined, wound on a storage drum and able to be put into
service without completely unwinding the hose from the reel. In AVU there are 17 Hose reel
provided in strategic location.
E. DRY RISERS
Dry risers shall be provided to supply firewater (or foam solution) to landing valves in multi- storey
structures/ buildings. They shall comply with the requirements of NFPA 14 and any relevant Project
Specifications.
Risers shall be installed near stairways (both main and emergency access routes). Riser inlets and
outlets shall be fitted with standard hose connections and low point drains incorporated in the piping.
List of dry risers in AVU and SR-LPG units

SL.
Location/Area
No Tag No Structure No.
1 DR-001 STR-010-001 Train 1 Preheat Exchangers platform (010- E-104/122/117/118/128)
2 DR-002 STR-010-002 Train 2 Preheat Exchangers platform (010- E-204/222/217/218/228)
3 DR-003A STR-010-003 010-V-016 & 010-V-017
4 DR-003B STR-010-005 010-E-048, 010-E-046 & 010-V-010
5 DR-004A 010-V-007, 010-V-008, 010-V-009, 010-E-035, 010-E-036, 010-E-
STR-010-006
6 DR-004B 038, 010-E-040 & 010-E-042
7 DR-005 STR-010-008 Ejector & Ejector Condenser Platform

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SL.
Location/Area
No Tag No Structure No.
8 DR-006 STR-010-007 CDU Stripper Area
011-E-001, 011-E-002, 011-V-005, 011-V-
9 DR-003C STR-011-01
01 011-V-006
F. FIRE WATER NETWORK DESIGN BASIS
The fire water system had to be designed to meet the fire water flow requirement for fighting two fires
simultaneously requiring largest water demand as following:
According to OISD-116, the fire water demand for AVU UNIT (including SR LPG) protection can be
estimated.
Case-1
Total Unit Area : 51973.4 m2
(276.7m X 202.1m) - (95.7m X 41.25m): Total Plot Area –Area of Substation 332S
Consider Water Rate @ 1 lpm / m2 on area basis : 3118.4 m3 / hr Water for

supplementary hose stream (including 2HVLRM) : 600 m3 / hr Total Water
Rate : 3718.4 m3 / hr
Case-2
Consider 10m by 10m portion of process unit on fire. Provide water cover over an area of 30m by 30m at the
rate of 10.0 lpm / sq. m
Water Rate (900 m2 by 10.0 lpm / m2) : 540 m3 / hr Water for

supplementary hose stream (including 2HVLRM) : 600 m3 / hr Total Water
Rate : 1140 m3 / hr
Case-3
Water required for portion of unit area provided with fixed spray system in AVU unit
Area to be protected by water spraying : 5138 m2 (Air cooler Area

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+ Pump Area + CDU&VDU column Area) : (3288.7+926.2+923)

Water Application Rate : 10.0 lpm /m2
Cooling Water required : 3082.8 m3 /hr
Water for supplementary hose stream (including 2HVLRM) : 600 m3 /hr
Total Water Rate : 3682.8 m3 /hr
Considering the maximum water demand under Case-1, 2 & 3
Design Water Demand: 3718.4 m3 / hr.
The fire water main shall be sized by network calculation under the condition that the fire water can flow
through all sections of fire water main with no portion being out of service.
12.3 Fire and Gas Detection System
A. MANUAL ALARM CALL POINTS (MCP), FIRE SOUNDERS & FIRE BEACONS
A manual alarm call point (MCP) shall be located at each exit / near stair case from all buildings.
Manual Call Points at the unit peripheral roads shall be located at maximum interval distances of
61m. Manual Call Points within the units shall be located at Max. 60m travel distance from the
nearest MCP. While considering 60m travel distance the elevation also should be considered (i.e.
for locating MCP at some working platform/technological structure), the total distance travelled to
reach the nearest MCP should be within 60m.In process plots and tank storage areas, Manual Call
Points of flameproof design shall be Activation of Manual Call Points shall raise alarms within the
respective Control Room and at both Fire Stations. In addition to that, respective plant area fire
sounders and beacons shall be activated.
The break glass has a push button kept in pressed condition by a glass sheet fitted in the front of
the box. A nickel plate brass hammer, duly chained to box with stainless steel chain is provided
with each box for breaking the glass.
List of Manual Call points (MCP) in AVU & SR LPG
Sl. No. MCP No. Location of MCP

Manual Call Points in AVU (010)

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1 010-AFMCP-0101 Near to 010-V-611
2 010-AFMCP-0106 Near to 010-E-202
3 010-AFMCP-0201 Near to 010-P-203 C
4 010-AFMCP-0202 Near to 010-E-223 A/B
5 010-AFMCP-0210 Near to 010-E-251 A
6 010-AFMCP-0301 Near to 010-V-610
7 010-AFMCP-0305 Near to 010-E-104 A
8 010-AFMCP-0401 Near to 010-P-102 B
9 010-AFMCP-0402 Near to 010-E-151 A
10 010-AFMCP-0501 Near to 010-P-301 B
11 010-AFMCP-0502 Near to 010-E-017 B
12 010-AFMCP-0505 Near to 010-V-016
13 010-AFMCP-0506 Near to 010-V-016
14 010-AFMCP-0507 Near to 010-V-016
15 010-AFMCP-0601 Near to 010-P-021 A
16 010-AFMCP-0701 Near to 010-P-014 A
17 010-AFMCP-0706 Near to Chemical Injection Package (010-TK-005)
18 010-AFMCP-0801 Near to 010-V-020
19 010-AFMCP-0806 Near to 010-P-001 B
20 010-AFMCP-0901 Near to 010-K-003 A
21 010-AFMCP-0904 Near to 010-V-006
22 010-AFMCP-1001 Near to 010-P-011 A
23 010-AFMCP-1002 Below 010-AC-009 C
24 010-AFMCP-1101 Near to 010-P-013 A
25 010-AFMCP-1112 Near to 010-V-007
26 010-AFMCP-1113 Near to 010-E-038
27 010-AFMCP-1114 Near to 010-V-009
28 010-AFMCP-1115 Near to 010-E-038
29 010-AFMCP-1201 Near to Vacuum column
30 010-AFMCP-1301 Near to VDU Heater Area (010-F-002)
33 010-AFMCP-1401 Near to 010-E-039 B
34 010-AFMCP-1411 At Vacuum column

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35 010-AFMCP-1412 Near to 010-P-024 A
36 010-AFMCP-1413 Near to 010-E-039 B
37 010-AFMCP-1501 Near to 010-P-029 A
38 010-AFMCP-1601 Near to CDU Heater Area (010-F-101/201)
42 010-AFMCP-1701 Near to 010-C-003
43 010-AFMCP-1702 Near to 010-C-008
44 010-AFMCP-2001 Near to 010-P-007 B
45 010-AFMCP-2201 Below 010-AC-004
Manual Call Points in SR-LPG (011)
1 011-AFMCP-0101 Near to 011-K-001 B
2 011-AFMCP-0102 Near to 011-V-001
3 011-AFMCP-0103 Near to 011-P-010 A
4 011-AFMCP-0104 Near to 011-C-002
List of Fire Beacons in AVU & SR LPG
Sl. No. AFB (Beacons) Number Location of Beacon

Fire Beacons in AVU (010)
1 010-AFB-0104 Near to 010-E-231
2 010-AFB-0107 Near to 010-E-231
3 010-AFB-0208 Near to 010-P-203 A
4 010-AFB-0303 Near to 010-E-131
5 010-AFB-0306 Near to 010-E-131
6 010-AFB-0504 Near to 010-AC-615
7 010-AFB-0608 Near to 010-P-021 B
8 010-AFB-0711 Near to 010-P-003 C
9 010-AFB-0812 Near to 010-V-001
10 010-AFB-0907 Near to 010-K-003 A
11 010-AFB-1014 Near to 010-AC-009 C
12 010-AFB-1109 Near to 010-V-007

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13 010-AFB-1203 Near to Vacuum Column

14 010-AFB-1304 Near to Vacuum Heater (010-F-002)
15 010-AFB-1409 Near to 010-E-039 A
16 010-AFB-1509 Near to 010-P-029 A
17 010-AFB-1605 Near to Crude Heater (010-F-101/201) 18
18 010-AFB-1704 Near to 010-C-003
19 010-AFB-2005 Near to Stripper Area 20
20 010-AFB-2106 Near to 010-AC-015 D
Fire Beacons in SR-LPG (011)
1 011-AFB-0107 Near to 011-C-001
List of Flame Detectors in AVU & SR LPG
Sl. No. Flame Detector No. Location of Flame Detectors

Flame Detectors in AVU (010)
1 010-AFDF-0211 Near to 010-V-202 B
2 010-AFDF-0510 Near to 010-P-301 B
3 010-AFDF-0511 At 010-C-010
4 010-AFDF-0512 Near to 010-P-033 A
5 010-AFDF-0603 Near to 010-P-023 C
6 010-AFDF-0604 Near to 010-P-025 A
7 010-AFDF-0702 Near to 010-P-003 C
8 010-AFDF-0703 Near to 010-P-003 A
9 010-AFDF-0704 Near to 010-P-014 C
10 010-AFDF-0705 Near to 010-P-014 A
11 010-AFDF-0713 Near to 010-V-004
12 010-AFDF-0802 Near to 010-P-036 B
13 010-AFDF-0803 Near to 010-P-005 B
14 010-AFDF-0804 Near to 010-AC-016 C
15 010-AFDF-0805 Near to 010-P-030 A
16 010-AFDF-0902 Near to 010-K-003 B
17 010-AFDF-1003 Near to 010-P-004 C
18 010-AFDF-1004 Near to 010-P-010 B
19 010-AFDF-1005 Near to 010-P-007 A
20 010-AFDF-1016 Near to 010-P-011 A

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21 010-AFDF-1116 Near to 010-P-018 B
22 010-AFDF-1117 Near to 010-C-005
23 010-AFDF-1118 Near to 010-C-006
24 010-AFDF-1119 Near to 010-P-020 C
25 010-AFDF-1120 Near to 010-P-13 A
26 010-AFDF-1127 Near to 010-P-016 A
27 010-AFDF-1128 Near to 010-C-004
28 010-AFDF-1129 Near to 010-P-15 B
29 010-AFDF-1308 Near to Vacuum Heater (010-F-002)
30 010-AFDF-1309 Near to Vacuum Heater (010-F-002)
31 010-AFDF-1402 Near to 010-P-028 B
32 010-AFDF-1403 Near to 010-E-039 A
33 010-AFDF-1414 At Vacuum Column 010-C-007
34 010-AFDF-1415 Near to 010-C-009
35 010-AFDF-1416 Near to 010-P-031 B
36 010-AFDF-1502 Near to 010-P-008 B
37 010-AFDF-1503 Near to 010-P-029 A
38 010-AFDF-1511 Near to 010-V-612
39 010-AFDF-1608 Near to Crude Heater (010-F101/201)
40 010-AFDF-1609 Near to Crude Heater (010-F101/201)
41 010-AFDF-1706 Near to 010-C-002
42 010-AFDF-1707 Near to 010-C-001
43 010-AFDF-1708 Near to 010-C-002
44 010-AFDF-1709 Near to 010-C-003
45 010-AFDF-1904 Near to 010-AC-016 A
46 010-AFDF-2004 Below 010-AC-007
47 010-AFDF-2104 Near to 010-AC-015 A
48 010-AFDF-2105 Near to 010-AC-015 D
49 010-AFDF-2204 Near to 010-AC-004
Flame Detectors in SR-LPG (011)
1 011-AFDF-0113 Near to 011-C-002
2 011-AFDF-0114 Near to 011-P-006 A
3 011-AFDF-0112 Near to 011-C-001
4 011-AFDF-0110 Near to 011-P-008 B

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5 011-AFDF-0111 Near to 010-P-010 B
List of Fire Sounder in AVU & SR LPG
Sl. No. AFA (Fire Sounder Number) Location of Fire Sounder

Fire Sounders in AVU (010)
1 010-AFA-0104 Near to 010-E-228
2 010-AFA-0107 Near to 010-E-228
3 010-AFA-0208 Near to 010-E-231
4 010-AFA-0303 Near to 010-E-131
5 010-AFA-0306 Near to 010-E-131
6 010-AFA-0504 Near to 010-AC-616
7 010-AFA-0608 Near to 010-P-003 C
8 010-AFA-0711 Near to 010-P-003 C
9 010-AFA-0812 Near to 010-V-001
10 010-AFA-0907 Near to 010-K-003 A
11 010-AFA-1014 Near to 010-AC-009 C
12 010-AFA-1109 Near to 010-E-042
13 010-AFA-1203 Near to Vacuum Column
14 010-AFA-1304 Near to Vacuum Column
15 010-AFA-1409 Near to 010-E-039 A
16 010-AFA-1509 Near to 010-P-029 A
17 010-AFA-1605 Near to Crude Heater (010-F-101/201)
18 010-AFA-1704 Near to 010-C-008
19 010-AFA-2005 Near to Stripper Area 20
20 010-AFA-2106 Near to 010-AC-015 D
Fire Sounders in SR-LPG (011)
1 011-AFA-0107 Near to 011-C-001
GAS DETECTION SYSTEM

Gas detectors shall be installed at critical locations throughout the plant areas to detect the presence
of flammable/combustible gas or hydrocarbon vapors and toxic gas. The Gas Detection System
(GDS) shall sound sounders and flash either yellow or blue beacons automatically depending on the

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type of leakage (flammable / toxic), the annunciation shall be unit wide based on any detector in
alarm (i.e. 1oo1).
List of Combustible Gas detector (HC) in AVU & SR LPG
Sl. No. AGDC Number Location of AGDC

Gas Detectors in AVU (010)
1 010-AGDC-0102 A Near to 010-E-227 F
2 010-AGDC-0102 B Near to 010-V-611
3 010-AGDC-0103 A Near to 010-V-611
4 010-AGDC-0103 B Near to 010-P-203 C
5 010-AGDC-0202 A Near to 010-P-203 C
6 010-AGDC-0202 B Near to 010-P-202 A
7 010-AGDC-0302 A Near to 010-V-610
8 010-AGDC-0302 B Near to 010-P-103 C
9 010-AGDC-0402A Near to 010-V-102 B
10 010-AGDC-0402B Near to 010-V-102 A
11 010-AGDC-0502 A Near to 010-V-301
12 010-AGDC-0502 B Near to 010-V-017
13 010-AGDC-0508 Near to 010-V-301
14 010-AGDC-0509 Near to 010-P-301 A
15 010-AGDC-0513 Near to 010-P-033 A
16 010-AGDC-0602 A Near to Vacuum Column Battery Limit
17 010-AGDC-0602 B Near to Chemical Injection Package
18 010-AGDC-0605 Near to 010-P-025 A
19 010-AGDC-0606 Near to 010-P-023 A
20 010-AGDC-0607 Near to 010-P-021 A
21 010-AGDC-0610 Near to 010-P-021 B
22 010-AGDC-0611 Near to 010-P-023 C
23 010-AGDC-0612 Near to 010-P-023 B
24 010-AGDC-0613 Near to 010-P-025 C
25 010-AGDC-0614 Near to 010-P-025 B
26 010-AGDC-0706 Near to 010-P-014 A
27 010-AGDC-0707 Near to 010-P-014 B
28 010-AGDC-0708 Near to 010-P-014 C
29 010-AGDC-0709 Near to 010-P-003 A

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30 010-AGDC-0710 Near to 010-P-003 B
31 010-AGDC-0714 Near to 010-P-003 C
32 010-AGDC-0715 Near to 010-P-35 B
33 010-AGDC-0807 Near to 010-P-024 B
34 010-AGDC-0808 Near to 010-E-054
35 010-AGDC-0809 Near to 010-P-005 B
36 010-AGDC-0810 Near to 010-P-006 A
37 010-AGDC-0811 Near to 010-P-030 A
38 010-AGDC-0814 Near to 010-P-022 A
39 010-AGDC-0815 Near to 010-P-036 B
40 010-AGDC-0816 Near to 010-P-022 B
41 010-AGDC-0817 Near to 010-P-024 A
42 010-AGDC-0818 Near to 010-P-005 A
43 010-AGDC-0819 Near to 010-P-006 B
44 010-AGDC-0820 Near to 010-P-030 B
45 010-AGDC-0821 Near to 010-P-030 A
46 010-AGDC-0904 Near to 010-K-003 A
47 010-AGDC-0905 Near to 010-K-003 B
48 010-AGDC-0906 Near to 010-K-003 B
49 010-AGDC-1002 B Near to Stripper Area
50 010-AGDC-1002A Near to 010-AC-014
51 010-AGDC-1006 Near to 010-P-004 C
52 010-AGDC-1007 Near to 010-P-010 B
53 010-AGDC-1008 Near to 010-P-011 B
54 010-AGDC-1011 Near to 010-P-011 A
55 010-AGDC-1012 Near to 010-P-007 C
56 010-AGDC-1013 Near to 010-P-007 A
57 010-AGDC-1017 Near to 010-P-010 A
58 010-AGDC-1018 Near to 010-P-004 B
59 010-AGDC-1019 Near to 010-P-004 A
60 010-AGDC-1020 Near to 010-P-007 B
61 010-AGDC-1021 Near to 010-P-007 A
62 010-AGDC-1102 A Near to access way of 010-P-020 & 010-P-013
63 010-AGDC-1102 B Near to Substation 332-S

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64 010-AGDC-1103 A Near to Substation 332-S
65 010-AGDC-1103B Near to 010-AC-014
66 010-AGDC-1106 Near to 010-C-005
67 010-AGDC-1107 Near to 010-C-005
68 010-AGDC-1108 Near to 010-C-006
69 010-AGDC-1121 Near to 010-P-018 B
70 010-AGDC-1122 Near to 010-P-002 B
71 010-AGDC-1123 Near to 010-P-002 A
72 010-AGDC-1124 Near to 010-P-020 B
73 010-AGDC-1125 Near to 010-P-020 A
74 010-AGDC-1126 Near to 010-P-013 A
75 010-AGDC-1130 Near to 010-P-016 C
76 010-AGDC-1131 Near to 010-P-016 B
77 010-AGDC-1132 Near to 010-P-015 A
78 010-AGDC-1134 Near to 010-P-019 A
79 010-AGDC-1135 Near to 010-P-019 B
80 010-AGDC-1202 A Near to Vacuum Column Battery Limit
81 010-AGDC-1202 B Near to Vacuum Column Battery Limit
82 010-AGDC-1302 A Near to Vacuum Heater Area (010-F-002)
83 010-AGDC-1302 B Near to Vacuum Heater Area (010-F-002)
88 010-AGDC-1307 Near to Vacuum Heater Area (010-F-002)
89 010-AGDC-1404 Near to 010-P-027 A
90 010-AGDC-1405 Near to 010-P-027 B
91 010-AGDC-1406 Near to 010-P-027 A
92 010-AGDC-1408 Near to 010-E-053
93 010-AGDC-1417 Near to 010-V-013
94 010-AGDC-1504 Near to 010-V-612
95 010-AGDC-1506 Near to 010-P-008 B
96 010-AGDC-1507 Near to 010-P-009 A
97 010-AGDC-1508 Near to 010-P-029 A

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98 010-AGDC-1512 Near to 010-P-008 A
99 010-AGDC-1513 Near to 010-P-009 B
100 010-AGDC-1514 Near to 010-P-029 B
101 010-AGDC-1515 Near to 010-P-029 A
102 010-AGDC-1603 A Near to Crude Heater Area (010-F-101/201
103 010-AGDC-1603 B Near to Crude Heater Area (010-F-101/202
108 010-AGDC-1608 Near to Crude Heater Area (010-F-101/207
109 010-AGDC-1703 A Near to Crude Column & Stripper Area
110 010-AGDC-1703 B Near to Crude Column
111 010-AGDC-806 Near to 010-P-022 C
Gas Detectors in SR-LPG (011)
1 011-AGDC-0120 Near to 011-P-006 A
2 011-AGDC-0119 Near to 011-P-007 A
3 011-AGDC-0102 B Near to 011-K-001
4 011-AGDC-0103 A Near to 011-K-001
5 011-AGDC-0118 Near to 011-V-001
6 011-AGDC-0103 B Near to 011-P-010 A
7 011-AGDC-0117 Near to 011-P-010 A
8 011-AGDC-0116 Near to 011-P-008 B
9 011-AGDC-0102 A Near to Battery limit
List of Gas Beacons in AVU & SR LPG
Sl. No. AGB (Beacons) No. Location of Beacons

Gas Beacons in AVU (010)
1 010-AGB-0105 Near to 010-E-231
2 010-AGB-0209 Near to 010-P-203 A
3 010-AGB-0304 Near to 010-E-131
4 010-AGB-0408 Near to 010-V-102 B
5 010-AGB-0503 Near to 010-AC-615

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Sl. No. AGB (Beacons) No. Location of Beacons

6 010-AGB-0609 Near to 010-P-021 B
7 010-AGB-0712 Near to 010-P-003 C
8 010-AGB-0813 Near to 010-V-001
9 010-AGB-0908 Near to 010-K-003 A
10 010-AGB-1015 Near to 010-AC-009 C
11 010-AGB-1110 Near to 010-V-007
12 010-AGB-1111 Near to 010-V-007
13 010-AGB-1204 Near to Vacuum Column
14 010-AGB-1305 Near to Vacuum Heater (010-F-002)
15 010-AGB-1410 Near to 010-E-039 A
16 010-AGB-1510 Near to 010-P-029 A
17 010-AGB-1606 Near to Crude Heater (010-F-101/201)
18 010-AGB-1705 Near to 010-C-003
19 010-AGB-1903 Near to 010-AC-016 A
20 010-AGB-2003 Near to 010-P-029 A
21 010-AGB-2103 Near to 010-AC-015 G
22 010-AGB-2203 Near to 010-AC-004
Gas Beacons in AVU (010)
1 011-AGB-0108 Near to 011-C-001
List of Gas Sounder in AVU & SR LPG
Sl.No. AGA (Gas Sounder) No. Location of Gas Sounder

Gas Sounder in AVU (010)
1 010-AGA-0105 Near to 010-E-228
2 010-AGA-0209 Near to 010-E-231
3 010-AGA-0304 Near to 010-E-131
4 010-AGA-0408 Near to 010-P-103 A
5 010-AGA-0503 Near to 010-AC-616
6 010-AGA-0609 Near to 010-P-021 B
7 010-AGA-0712 Near to 010-P-003 C
8 010-AGA-0813 Near to 010-V-001
9 010-AGA-0908 Near to 010-K-003 A
10 010-AGA-1015 Near to 010-AC-009 C
11 010-AGA-1110 Near to 010-E-042

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Sl.No. AGA (Gas Sounder) No. Location of Gas Sounder

12 010-AGA-1204 Near to Vacumm Column
13 010-AGA-1305 Near to Vacumm Heater (010-F-002)
14 010-AGA-1410 Near to 010-E-039 A
15 010-AGA-1510 Near to 010-P-029 A
16 010-AGA-1606 Near to Crude Heater (010-F-101/201)
17 010-AGA-1705 Near to 010-C-008
18 010-AGA-1903 Near to 010-P-025 B
19 010-AGA-2003 Near to 010-P-029 A
20 010-AGA-2103 Near to 010-AC-015 G
21 010-AGA-2203 Near to 010-AC-004
Gas Sounder in SR-LPG (011)
1 011-AGA-0108 Near to 011-C-001
List of Gas Sounder in AVU & SR LPG
Sl.No. AGDT No. Location of AGDT

1 010-AGDT-1104 Near to 010-E-043
2 Near P-011A
3 Near P-011B
4 Near P-028A/B
Gas detector specification Principle

of sensor:
HC = Infrared type and non-selective based
H2S = Electrochemical type detector
Measuring/detection range:
HC = 0-100% LEL (High Alarm: 20% LEL, Very High Alarm: 40%LEL)
H2S = 0-100 PPM (High Alarm: 10ppm, Very high Alarm: 15ppm)
B. CLOSED CIRCUIT TELEVISION SYSTEM (CCTV)

CCTV monitoring system shall be provided in process area for the surveillance of the equipment in plants. CCTV
control unit shall be located in the Control Room Building. The cameras shall be installed at the strategic locations
of the plant as attached in CCTV System Plan. All the cameras shall have Pan & Tilt control unit with a viewing

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angle varying between 00 to 3500 & till angle of -900 to 900 and with zooming facility. Each camera shall
be equipped with a sunshield to prevent direct sun radiation into the lens and camera housing.
List of CCTV Cameras in AVU & SR LPG
Sl.No. Tag No. Area/Location Elevation

1 010-CPX-001 Near Crude Flash Drum 10m
2 010-CPX-002 Near Chemical Dosing Package 10m
3 010-CPX-003 Near to Ejector condenser 10m
4 010-CPX-004 Near Vacuum Column 10m
5 010-CPX-005 Near CDU Sour Water Pump Area 10m
6 010-CPX-006 Near to De-Propaniser Column 10m
7 010-CPX-007 SR-LPG Column 10m
C. UTILITY HOSE STATION

Utility hose stations are provided for Steam, Air, Water, Nitrogen etc. as indicated in the P&ID. Following
are the total nos. of utility stations located across the AVU & SR LPG unit.
Service Nos. of Utility Station

LP Steam 175
Service Water 154
Plant Air 175
Nitrogen 9
For Low Pressure Steam, a hose of 1”size x 15 M long is provided. It has M.O.C. of PTEE with smooth bore
and outer cover of SS304 wire braided. The hose is connected by flange to the hose point.
For service water and plant air a hose of 1” size x 15 M long is provided. It has M.O.C. of rubber – compound
lining with the smooth bore. The hose is connected by means of adapter provided on hose to quick release
coupler.
Hose stations for Nitrogen are provided with special type of quick release coupling to avoid any type of
inadvertent misuse/connection.
12.4 PAGING AND COMMUNICATION SYSTEM
Paging System consists of one central exchange located in Rack Room of Control Room Building, master
call station in the Control Room Building, field call station, loud speakers, rotating beacons and power

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supply system.
As a minimum the following facilities shall be provided in the system

-Master call station (MCS) in control room
-Paging of AVU/SR-LPG UNIT with facilities like all call, group call, priority call
-Communication from any field station to MCS
List of Call Stations in AVU & SR LPG Unit
Sl.No. Tag Number Location of Call Station Elevation

1 010/PUX/001 Chemical Injection Package 1.35m
2 010/PUX/002 Near to 010-E-118 C/D 10m
3 010/PUX/003 Near to 010-E-039 A/B 1.35m
4 010/PUX/004 Near to Crude Heater 1.35m
5 010/PUX/005 Near to 010-E-151 A 1.35m
6 010/PUX/006 Near to Crude Column 1.35m
7 010/PUX/007 Near to 010-E-037 C 1.35m
8 010/PUX/008 Near 011-P-001 B 1.35m
List of Speakers in AVU & SR LPG Unit
Sl. No. Tag Number Location of Speakers Elevation

1 010/PSX/0001 North side of Heat Exchanger Train 2 pipe rack 10m
2 010/PSX/0002 South side of Heat Exchanger Train 2 pipe rack 10m
3 010/PSX/0003 Pipe Rack of the Vacuum Column 10m
4 010/PSX/0004 Pipe Rack of the Vacuum Column 10m
5 010/PSX/0005 Ejector Platform 10m
6 010/PSX/0006 Pipe Rack of Crude Heater area 10m
7 010/PSX/0007 At the south side of 010-AC-007 10m
8 010/PSX/0008 Pipe Rack of Crude Column 10m
9 010/PSX/0009 South side of Heat Exchanger Train 1 pipe rack 10m
10 010/PSX/0010 Middle of the heat exchanges Train 1 pipe rack 10m
11 010/PSX/0011 North side of Heat Exchanger Train 1 pipe rack 10m
12 010/PSX/0012 Near to North side of 010-AC-015 10m
13 010/PSX/0013 Near to 010-AC-615 10m
14 010/PSX/0014 Near to 010-AC-004 10m
15 010/PSX/0015 Near to 010-AC-009 10m

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Sl. No. Tag Number Location of Speakers Elevation

16 010/PSX/0016 Near to 010-AC-014 10m
17 010/PSX/0017 North Side of SS 332 S 10m
18 010/PSX/0018 West Side of Crude Furnace (010-F101/201) 10m
19 010/PSX/0019 South Side of SS 332 S 10m
20 010/PSX/0020 Near to 010-E-048 10m
21 010/PSX/0021 Near to 010-P-019 A/B/C 10m
List of Speaker with Beacons in AVU & SR LPG Unit
Sl. No. Tag Numnber Location of Speakers with Beacon Elevation

1 010/PXS/0001 Heat Exchange Train 2 Platform 10m
2 010/PXS/0002 North side of Heat Exchanger Train 2 pipe rack 10m
3 010/PXS/0003 South side of Heat Exchanger Train 2 pipe rack 10m
4 010/PXS/0004 Noth Side of 010-AC-016 Pipe Rack 10m
5 010/PXS/0005 South Side of 010-AC-016 Pipe Rack 10m
6 010/PXS/0006 Near to the Vacuum Column Transfer Line 10m
7 010/PXS/0007 Near to Vacuum Colum Pipe Rack 10m
8 010/PXS/0008 Near to 010-P-005 B Pipe Rack 10m
9 010/PXS/0009 Heat Exchange Train 1 Platform 10m
10 010/PXS/0010 North side of Heat Exchanger Train 1 pipe rack 10m
11 010/PXS/0011 Near to 010-P-004 C Pipe Rack 12 10m
12 010/PXS/0012 Near to 010-AC-010 10m
13 010/PXS/0013 Near to 010-AC-014 10m
14 010/PXS/0014 Near 010-E-037 A/B/C 10m
12.5 SAFETY SHOWER AND EYE WASHER
Safety shower and eye wash is provided / installed at the various places inside of process area where either
acid / caustic or other chemicals are being handled or toxic chemicals may be present. Water will be fed from
Drinking Water Line. Discharge from safety shower & eye washer shall be connected to the CRWS header.
List of Safety Showers in AVU & SR LPG
Sl. No. Tag No. Location of Safety Shower

Safety Showers in AVU (010)
1 010-SS-001 Near to chemical Injection Package

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2 010-SS-002 Near to 010-P-033 A/B & 010-V-018

3 010-SS-003 Near to 010-P-015 A/B/C
4 010-SS-004 Near to 010-C-009 & 010-P-031 A/B
5 010-SS-005 Near to 010-V-014
6 010-SS-006 Near to 1st train Desalter Package
7 010-SS-006 Near to 010-F-002 (tag no. Repeating)
8 010-SS-007 Near to 2nd train Desalter Package
9 010-SS-008 Near to 010-F-101
Safety Showers in SR-LPG (011)
1 011-SS-001 Near to 011-C-001
12.6 ESCAPE ROUTES

Escape routes in AVU & SR LPG unit is shown in PDRP4210-8150-46-010-0002 REV A1. Snap
shot is shown here for reference.

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12.7 MATERIAL SAFETY DATA SHEETS

Generic Chemical Name – De-Emulsifier
Trade Name – VPC-6514

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1. Identification of substance
Product details
Trade name: VPC-6514
Manufacturer/supplier
Vasu Chemicals LLP,
Vasu Center, Military Road, Tel: +9122/6144 9500
Marol, Andheri (E), Mumbai – 400 059. Fax:+9122/29209624
Information Department:
Contact: Mrs. Renuka Pandit
2. Composition/ Data on components

Chemical characterization
Description:
Active Components:
Organic solvent and solute
3. Hazard Identification:
Information Pertaining to particular dangers for man and environment:
Skin: Causes skin irritation.
Eyes: May cause Serious eye irritation
Inhalation: May cause respiratory irritation
Ingestion: May cause irritation
4. First Aid Measures

General information:
All treatments should be based on observed signs and symptoms of distress in the patient. Consideration
should be given to the possibility that overexposure to materials other than this product may have
occurred.
After inhalation:
Remove victim to fresh air and keep at rest in a position comfortable for breathing. If breathing is difficult,
give oxygen. If not breathing, give artificial respiration. Call a physician if symptoms develop or persist.
After skin contact:
Take off immediately all contaminated clothing. Rinse skin with water/shower. Get medical attention if
irritation develops and persists. Wash clothing separately before reuse.
After eye contact:

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Immediately flush eyes with plenty of water for at least 15 minutes. Remove contact lenses, if present and
easy to do. Continue rinsing. Get medical attention if irritation develops and persists.
After ingestion:
Rinse mouth. If vomiting occurs, keep head low so that stomach content doesn't get into the lungs. Get
medical advice/attention if you feel unwell.
(Contd. On Page 2)
5. Fire- Fighting measures

Flammability:
Flammable
Suitable extinguishing agents:
Alcohol resistant foam. Water fog. Dry chemical powder. Carbon dioxide (CO2). Do not use
Water jet as an extinguisher, as this will Spread the fire.
Protective equipment:
Self -Contained breathing apparatus and full protective clothing must be worn in case of fire.
6. Accidental release measures

Person - Related safety precautions:
Keep unnecessary personnel away. Keep people away from and upwind of spill/leak. Eliminate all
sources of ignition. Do not breathe mist or vapor. Wear appropriate protective equipment and clothing
during clean-up. Do not touch damaged containers or spilled material unless wearing appropriate
protective clothing. Ventilate closed spaces before entering them. Ensure adequate ventilation. Local
authorities should be advised if significant spillages cannot be contained.
Measures for environmental protection:

Avoid discharge into drains, water courses or onto the ground. Environmental manager must be informed
of all major release.
7. Handling and storage

Handling
Information for safe handling:
Obtain special instructions before use. Do not handle until all safety precautions have been read and
understood. Do not handle, store or open near an open flame, sources of heat or sources of ignition. When
using do not smoke. Explosion-proof general and local exhaust ventilation is recommended. Take
precautionary measures against static discharges. All equipment used when handling the product must be
grounded. Use non-sparking tools and explosion-proof equipment. Do not breathe mist or vapor. Avoid
contact with eyes, skin, and clothing. Ensure adequate ventilation. Wear appropriate personal protective

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equipment. Wash hands thoroughly after handling. Observe good industrial hygiene practices. Avoid release to
the environment.
Storage
Requirements to be met by storerooms and receptacles:
Store locked up. Keep away from heat/sparks/open flames/hot surfaces. - No smoking.
Further information about storage conditions:
Keep container tightly closed. Store in a well-ventilated place. Keep cool.
Information about protection against explosions and fires
Store away from incompatible materials
(Contd. On Page 3)
8. Exposure controls and personal protection:

Personal protective equipment
Eye /face Protection:
Wear safety Goggles.
Hand protection:
Wear appropriate chemical resistant gloves.
Respiratory protection:
If engineering controls do not maintain airborne concentrations below recommended
Exposure limits (where applicable) or to an acceptable level (in Countries where exposure
Limits have not been established), an approved respirator must be worn.
Body Protection:
Wear overall safety shoes, helmet, gloves, and chemical splash goggles .
9. Physical and chemical properties

Physical state : Liquid
Specific Gravity: 0.79 – 0.94
pH value ( Neat ) : 8.00 – 12.00
10. Stability and reactivity

Stable under recommended storage conditions.

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Materials to be avoided:
Strong oxidizing agents
Dang erous products of decomposition.
Not known
11. Toxicological information

Primary irritant effect:
Inhalation: May cause irritation to the respiratory system. May cause drowsiness or dizziness.
Skin contact: Irritating to skin. Frequent or prolonged contact may defat and dry the skin,
Leading to discomfort and dermatitis.
Eye co ntact: Causes serious eye irritation.
Ingestion: May Cause Irritation and malaise.
Skin corrosion/irritation: Causes skin irritation.
Serious eye damage/eye irritation: Causes serious eye irritation.
(Contd. On Page 4)
Respiratory or skin sensitization

Respiratory sensitization: No data available.
Skin sensitization: No data available.
Germ cell mutagenicity: No data available to indicate product or any components present at greater
than 0.1% are mutagenic or genotoxic. Carcinogenicity: Suspected of causing cancer.
12. Ecological information

Ecotoxicity data:
Persistence and degradability: No data is available on the degradability of this product.
Bioaccumulative potential: No data available for this product. Partition
coefficient n-octanol / water (log Kow): Data not available Mobility in soil:
No data available.
Other adverse effects: No other adverse environmental effects (e.g. ozone depletion, photochemical
ozone creation potential, endocrine disruption, global warming potential) are expected from this
component.

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13. Disposal considerations

Product
Recommendation:
Whatever cannot be saved for recovery or recycling should be managed in an appropriate
And approved waste disposal facility and should be according to State and local disposal regulations.
Un-cleaned packaging
Recommendation:
According to State and local disposal regulations.
14. Transport Information:

Not regulated
15. Regulations.
Risk phrases:
R 41: Risk of serious damage to Eyes.
Safety phrases:
S 26: In case of contact with eyes, rinse immediately with plenty of water and seek medical advice.
(Contd. On Page 5)
16. Other Information:

Disclaimer of liability: The information in this MSDS was obtained from sources, which we believe are
reliable. However, the information is provided without any warranty, express or implied, regarding its
correctness. The conditions or methods of handling, storage, use or disposal of the product are beyond our
control and may be beyond our knowledge. For this and other reasons, we do not assume responsibility
and expressly disclaim liability for loss, damage or expense arising out of or in any way connected with the
handling, storage, use or disposal of the product. This MSDS was prepared and is to be used only for this
product. If the product is used as a component in another product, this MSDS information may not be
applicable.

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Generic Chemical Name – Neutralizing Amine

Product details
Vasu Chemicals LLP,

Description:
Active Components:
Amine formulation
3. Hazard Identification :
Information pertaining to particular dangers for man and environment:
Skin: Harmful in contact with skin. Causes skin irritation. May cause an allergic
skin reaction.
Eyes: Causes eye damage
Inhalation: Harmful by inhalation. May give off gas, vapor or dust that is very irritating or corrosive
to the respiratory system
Ingestion: Harmful if swallowed. May cause burns to mouth, throat and stomach.

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occurred.
After inhalation:
Get medical attention immediately. Move exposed person to fresh air. If not breathing, if breathing is
irregular or if respiratory arrest occurs, provide artificial respiration or oxygen by trained personnel. If
unconscious, place in recovery position and get medical attention immediately. Maintain an open airway.
After skin contact:
Get medical attention immediately. Flush contaminated skin with plenty of water. Remove contaminated
clothing and shoes. Continue to rinse for at least 10 minutes. Chemical burns must be treated promptly by
a physician after eye contact:
Get medical attention immediately. Immediately flush eyes with plenty of water, occasionally lifting the
upper and lower eyelids. Check for and remove any contact lenses. Chemical burns must be treated
promptly by a physician.
(Contd. On Page 2)
After ingestion:
Get medical attention immediately. Wash out mouth with water. If material has been swallowed and the
exposed person is conscious, give small quantities of water to drink. Do not induce vomiting unless directed
to do so by medical personnel. Chemical burns must be treated promptly by a physician. Never give
anything by mouth to an unconscious person.
5. Fire- Fighting measures

Flammability:
Non -Flammable
Use an extinguishing agent suitable for the surrounding fire.
Self -contained breathing apparatus and full protective clothing must be worn in case of fire.

Person - related safety precautions:
Ensure adequate ventilation. Use appropriate protective equipment. Do not breathe

dust/fume/gas/mist/vapors/spray. Remove sources of ignition. Take precautionary measures against static
discharges All equipment used when handling the product must be grounded Avoid contact with skin, eyes
and clothing.

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Prevent from entering sewers, waterways, or low areas.

Handling
Use only with adequate ventilation. Put on appropriate personal protective equipment (see section 8). Wear
appropriate respirator when ventilation is inadequate. Eating, drinking and smoking should be prohibited in
areas where this material is handled, stored and processed. Do not get in eyes or on skin or clothing. Do not
breathe vapor or mist. Empty containers retain product residue and can be hazardous. Do not reuse container.
Workers should wash hands and face before eating, drinking and smoking.
Storage
Store in the original container or an approved alternative made from a compatible material. Keep
container in a well-ventilated area.
Keep tightly closed when not in use. Use appropriate containment to avoid environmental contamination.
Store away from acids. Do not store in unlabeled containers.
(Contd. On Page 3)

Eye/face protection:
Goggles, face shield or other full-face protection should be worn if there is a risk of direct exposure
to aerosols or splashes. Hand protection:
Use chemical resistant, impervious gloves
If during normal use the material presents a respiratory hazard, use only with adequate ventilation or
wear appropriate respirator. Respirator selection must be based on known or anticipated exposure
levels, the hazards of the product and the safe working limits of the selected respirator Body
Protection:
Personal protective equipment for the body should be selected based on the task being performed and the
risks involved and should be approved by a specialist before handling this product.

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Specific Gravity: 0.85 – 1.05
pH value (10 % in 3:1 IPA/DI water ) : 9.5 – 13.5

Acids.
Dangerous products of decomposition.
Under normal conditions of storage and use, hazardous decomposition products should not be produced.

Inhalation: Data not available
Skin contact: Data not available
Eye contact: Causes serious eye damage.
Ingestion: Data not available
Skin corrosion/irritation: Causes skin irritation.
Serious eye damage/eye irritation: Causes serious eye irritation.
(Contd. On Page 4)
Respiratory or skin sensitization

Respiratory sensitization: No data available.
Skin sensitization: May cause an allergic skin reaction.
Germ cell mutagenicity: Data not available
Carcinogenicity: Data not available

Ecotoxicity data :
Persistence and degradability: No data is available on the degradability of this product.
Bioaccumulative potential: No data available for this product. Partition
coefficient n-octanol / water (log Kow): Data not available Mobility in soil:
No data available.

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Other adverse effects: No other adverse environmental effects (e.g. ozone depletion, photochemical
ozone creation potential, endocrine disruption, global warming potential) are expected from this
component.

Product
Recommendation:
Whatever cannot be saved for recovery or recycling should be managed in an appropriate
and approved waste disposal facility and should be according to State and local disposal regulations.
Un-cleaned packaging
Recommendation:
According to State and local disposal regulations.
14. Transport Information :

Not regulated
15. Regulations.
Risk phrases:
R 41: risk of serious damage to eyes.
Safety phrases:
Not available
(Contd. On Page 5)


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applicable.
Generic Chemical Name – Corrosion Inhibitor

Product details
Vasu Chemicals LLP,

Description:
Active Components:

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Blend of amines and aromatic solvents
3. Hazard Identification :
Information pertaining to particular dangers for man and environment:
Skin: Harmful in contact with skin. Causes skin irritation. May cause an allergic skin
reaction.
Eyes: Causes serious eye irritation.
Inhalation: Harmful if inhaled.
Ingestion: Harmful if swallowed. Droplets of the product aspirated into the lungs through
ingestion or vomiting may cause a serious chemical pneumonia.

occurred.
After inhalation:
Remove victim to fresh air and keep at rest in a position comfortable for breathing. Oxygen or artificial
respiration if needed. Call a poison center or doctor/physician if you feel unwell After skin contact:
Remove contaminated clothing immediately and wash skin with soap and water. In case of eczema or
other skin disorders: Seek medical attention and take along these instructions.
Wash contaminated clothing before reuse.
After eye contact:

Immediately flush eyes with plenty of water for at least 15 minutes. Remove contact lenses, if present and
easy to do. Continue rinsing. Get medical attention if irritation develops and persists.
(Contd. On Page 2)
After ingestion:
Call a physician or poison control center immediately. Rinse mouth. Do not induce vomiting. If vomiting
occurs, keep head low so that stomach content doesn't get into the lungs.

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5. Fire- fighting measures

Flammability:
Flammable
Water fog. Foam. Dry chemical powder. Carbon dioxide (CO2). Do NOT spray pool fires directly with
water. A solid stream of water directed into hot burning liquid can cause
splattering .
Self -contained breathing apparatus, special protective clothing

Person - related safety precautions:
Ensure adequate ventilation. Use appropriate protective equipment. Do not breathe
dust/fume/gas/mist/vapors/spray. Remove sources of ignition. Take precautionary measures against static
discharges All equipment used when handling the product must be grounded Avoid contact with skin,
eyes and clothing.

Prevent from entering sewers, waterways, or low areas.

Handling
Obtain special instructions before use. Do not handle until all safety precautions have been read and
understood. When using do not smoke. Explosion-proof general and local exhaust ventilation. Take
precautionary measures against static discharges. All equipment used when handling the product must be
grounded. Use non-sparking tools and explosion-proof equipment. Do not get in eyes, on skin, or on
clothing. Avoid prolonged exposure. Should be handled in closed systems, if possible. Wear appropriate
personal protective equipment. Wash hands thoroughly after handling. Avoid release to the environment.
Observe good industrial hygiene practices. Do not handle, store or open near an open flame, sources of
heat or sources of ignition. Avoid inhalation of vapors and spray mists.
Storage
Store in a cool, dry place. Store in original tightly closed container. Store in a well-ventilated place.

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Store locked up. Prevent electrostatic charge build-up by using common bonding and grounding
techniques.

Keep away from heat, sparks and open flame. Store away from incompatible materials
(Contd. On Page 3)
Eye/face protection:
Safety goggles
Hand protection:
Wear appropriate chemical resistant gloves.
If engineering controls do not maintain airborne concentrations below recommended exposure limits
(where applicable) or to an acceptable level (in countries where exposure limits have not been
established), an approved respirator must be worn.
Body Protection:
Wear appropriate chemical resistant clothing . Use of an impervious apron is recommended.

Appearance : dark Amber colour
Specific Gravity: 0.80 -0.93
pH(10 % in 3:1 IPA/DI Water ) : 9 .7 0 – 1 3.0


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Conditions to be avoided:
Avoid heat, sparks, open flames and other ignition sources. Avoid temperatures exceeding
the flash point. Contact with incompatible materials.
Strong oxidizing agents.
Dang erous products of decomposition.
No hazardous decomposition products are known

Effects of chronic exposure:
May be harmful if absorbed through skin. Prolonged inhalation may be harmful. Prolonged
exposure may cause chronic effects.
Irritancy of Product:
Skin irritation: Causes skin irritation.
Serious eye damage/eye irritation: Causes serious eye irritation
Skin sensitization:
May cause an allergic skin reaction.
(Contd. On Page 4)

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Respiratory sensitization:
No data is available on the product itself.
Carcinogenicity:
Suspected of causing cancer.
Carcinogenicity – ACGIH:
No data is available
IARC Monographs. Overall Evaluation of Carcinogenicity
Data not available
NTP Report on Carcinogens:
Data not available
OSHA Specifically Regulated Substances (29 CFR 1910.1001 - 1050):
Not listed
Reproductive toxicity:
This product is not expected to cause
Reproductive or developmental effects
Teratogenicity:
Embrotoxicity:
Not available
Mutagenicity:
Name of synergistic products/effects:
Not available

Aquatic Toxicity:
No data is available on the product itself
Ecotoxicity:
Toxic to aquatic life with long lasting effects.
Persistence and degradability
No data is available on the degradability of this product.
Bio accumulative potential
Partition coefficient n - octanol / water (log Kow):
No data available.
Mobil ity in soil:
No data available.
Other adverse effects:
None known.

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(Contd. On Page 5)

Product
Recommendation:
Collect and reclaim or dispose in sealed containers at licensed waste disposal site. Do not allow this
material to drain into sewers/water supplies. Do not contaminate ponds, waterways or ditches with
chemical or used container. Dispose of contents/container in accordance with
local/regional/national/international regulations. Un-cleaned packaging Recommendation:
Dispose in accordance with all applicable regulations.
14. Transport Information :

Not regulated
15. Regulations.
Risk phrases:
Not available
Safety phrases:
Not available

applicable.

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GENERIC CHEMICAL NAME – TRI-SODIUM PHOPSHATE

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USEFUL DEFINITIONS
 Alarm: An audible or visible means of indicating to the operator, equipment or process

malfunction or abnormal condition
 Alarm System: The collection of hardware and software that an alarm state, transmits the
message to be displayed to the operator, records the message, and generate alarm metrics
report.
 Auto-ignition temperature: Lowest temperature at which there is enough heat energy to

ignite vapours spontaneously.
 Flammable gas: A flammable gas is one that can burn when brought in contact with heat or
flame.
 Flammable Liquid: A flammable liquid is defined as one having flashpoint below 1000 F
(37.80 C) with vapour pressure not exceeding 40 psi (276 kPa).
 Combustible Liquid: Combustible liquids have a flashpoint at or above 1000 F (37.80 C).
When heated above their flashpoints; these liquids take on many of the characteristics of
flammable liquids.
 Explosive range: Range of gas or vapour mixture with air between the explosive limits
 Lower Explosive Limit: This is minimum concentration of flammable gas or vapour mixture
that will propagate flame when exposed to a source of ignition.
 Upper Explosive Limit: The maximum concentration of gas or vapour in air that will
propagate flame when exposed to a source of ignition.
 Flashpoint: This is the lowest temperature at which a liquid gives off sufficient vapour in air
at its surface to form a flammable mixture.
 PPM: Parts per Million, a unit of concentration.
 Threshold Limit Value (TLV): This refers to airborne concentrations of substances, and
represents conditions under which workers may be repeatedly exposed day after day
without adverse health effects. There are two categories of TLV.

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 TLV-Time Weighted Average (TLV-TWA): This refers to a time weighted average concentration for
a normal 8 hour day, in a 40 hour work week in which most workers can be exposed repeatedly
without adverse effect.
 TLV-Short Term Exposure Limit (STEL): This is concentration in which most workers can be
exposed continuously for a short period of time without suffering from irritation, chronic or
irreversible tissue damage, or narcosis to the degree which could impair self-rescue, work
efficiency or cause accidents, provided that the TWA has not been exceeded any time during a
normal work day even if the worker is within the 8 hour TWA. Exposures above the TWA and
up to the STEL should not be longer than 15 minutes and should not exceed 4 times a day.
Document Referred
1. Fire water P&ID/Layout

- PDRP270-8110-25-010-5001/5002/5003/5004/5005/5006/5007/5008/5009/5010/5011/ 5012/
5013/5014/5015/5016/5017/5018/5019
2. Fire & Equipment Layout PDRP270-8140-29-010-0007 Rev S1 Sheet 1 & 2
3. PDRP Fire Detection and Project Specification PDRP4280-8140-SP-0001_REV_F4
4. Fire & Gas Beacons, Gas Sounders, Deluge Valve, MCP, Flame Detector PDRP270- 8550-61-
010-0250 Rev S2/0251 Rev S2/0252 Rev S2/0253 Rev S2/0254 Rev S2/0255 Rev S2/0256 Rev
S2/0257 Rev S1/0258 Rev S1
5. Telephone Call Station, Speaker, Beacon PDRP4230-270-8540-80-010-0003 Rev S1 sheet1 &

2
6. CCTV camera PDRP4230-270-8540-80-010-0004 Rev S1
7. Escape route PDRP4210-8150-46-010-0002 REV A1

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12.8 GENERAL SAFETY RULES
 All persons must be fully conversant with the plant operation and safety guild-lines.
 Housekeeping and safety go hand to hand. It is as much important as the operation of the
unit.
o All stairways, platforms, approach paths must be kept clean, non-slippery and free
of obstructions all along.
o Oil soaked rags, rubbish, jute and waste paper are possible fire hazards.
o Hoses are to be racked neatly after use.
o Materials must not be placed where they may obstruct easy access to safety appliances, such
as safety showers, fire extinguishers, fire hydrant, hose boxes etc.
 Routine safety equipment inspection of the entire area should be conducted regularly.
 Safety valves visual inspection for proper seal, leakage or passing should be regularly
checked.
 Barricade all dug out area leaks that cannot be immediately corrected.
 Any smoky flange/valve gland etc. leaks should be immediately attended. If it is not
possible to attend, steam hose should be kept on it.
 All manholes should always be covered. All temporary lines/tubing/wiring as and when
required should be laid so that it does not become a safety hazard.
 Closed blow down tank should be kept empty as far as possible.
 Proper safety precautions should be taken while taking samples, hydrocarbon draining or
commissioning of any equipment.
 Drain condensate properly to a safer place before lighting up of gas burners.
 Before lighting furnace, purge the furnace box well with steam. Always light up furnace
first with pilot burner and then take gas burners & oil burners as required.
 All safety wears kept in control room and in furnace area should always be in good
condition.
 Oil soaked insulation must be removed before commissioning. Steam hose can be kept
wherever oil soaking is of minor type.
 Oil spillage in unit area must be immodestly identified and corrective action should be
initiated to prevent further spillage. Spill over oil must be cleaned immediately with the
help of water/hot water.
 Lighting of the plant to be checked periodically and sufficient lighting to be ensured. In
case lightings are not proper that shall immediately brought to the notice.
 Periodic checking of insulation in lines to be checked and in case insulation is worn-out
or damaged same must be replaced.

Page 301 of 592

Doc. No:
12.9 GENERAL SAFETY GUIDELINE
 Minimum PPE like helmet & Safety Shoes are needed inside the plant, PVC Hand Gloves
for Caustic & other chemical handling, Goggles & Face shield during furnace operation.
 Smoking should be permitted only in smoking booths.
 If an employee’s clothing becomes contaminated with caustic, alcohol, aromatic
hydrocarbons or any other chemical solution, he must remove clothes immediately and
shower.
 Defective tools should not be used.
 When using chisels, cold cuts, striking wrenches, hammers or punches, examine the
striking surfaces frequently for butts and other foreign matter. Non sparking tools
should be used.
 Use proper tools for the work involved, i.e. do not use a file for a bar, a hand wrench for a hammer
etc.
 Over stressing tools or equipment has frequently caused serious injuries, take precaution
to prevent injuries to yourself or others.
 In case of Working at Height using scaffolding, scaffold to be certified by proper
authority before use.
 Safety belts shall be used when working 2 meters or more above ground, where it is not
practical to make other provisions to prevent falling.
 Falls are the second largest cause of accidental deaths. Do not take the following chances.
o Failure to look where you are going.
o Running or jumping in work place.
o Standing on boxes, chairs and make shifts instead of ladders or platforms.
o Neglecting to use handrails and running on stairs.
o Failing to face ladder when carrying objects on the same.
 Tools and materials should not be dropped from heights. They must be carried down.
 Standing or walking under materials suspended by ropes, chains or cables should not
be permitted.
 All near miss incidents to be registered and corrective action to be taken to avoid
re- occurrences of the incidents.

Page 302 of 592

Doc. No:
CHAPTER-13
INTERLOCKS

Page 303 of 592

Doc. No:
13.1 CAUSE & EFFECT TABLE :

010- Set
Tag No Cause Effect
IZ Point
1. Desalter water circulation pumps (010-P-102
A/B) STOPS
LOW LOW
2. ESD valve on desalter water feed to Train-1
temperature to 1st
101 TZALL-1109 1150C (XZV-1013) CLOSES
stage desalter 010-V-
102A 3. Desalter Second stage water circulation
pumps (010-P-103A/B/C) STOPS.
1. Desalter water circulation pumps (010-P-
102 A/B) STOPS
LOW LOW crude 2. ESD valve on desalter water feed to Train-1
102 FZALL-1077 flow to the 1st stage 360T/hr (XZV-1013) CLOSES
desalter (010-V-102A)
3. Desalter Second stage water circulation
pumps (010-P-103A/B/C) STOPS.
LOW LOW voltage of
A/B) STOPS
129 EZT-1101A/B/C 1st stage crude desalter 30V
2. ESD valve on desalter water feed to train -1
(010-V-102A)
(XZV-1013) CLOSES
LOW LOW Interface
level in the 1st stage 1. Desalter water circulation pumps (010-P-102
103A LZALL-1032 20%
desalter (010-V-102 A/B) STOPS
A)
HIGH HIGH current
A/B) STOPS
132A IZAHH-1001 on 1st Crude Desalter 380A
2. ESD valve on desalter water feed to train -1
(010-V-102 A)
(XZV-1013) CLOSES
LOW LOW Interface
1. Desalter second stage water circulation
103B LZALL-1034 level in the 010-V-102 20%
pumps (010-P-103 A/B/C) STOPS
B
LOW LOW voltage of 1. Desalter second stage water circulation

2nd stage crude pumps (010-P-103 A/B/C) STOPS
130 EZALL-1003 30V
desalter (010-V-102
2. ESD valve on desalter water feed to train 1
B).
(XZV-1013) CLOSES
HIGH HIGH current
1. Desalter second stage water circulation
132B IZAHH-1002 on 2nd Crude Desalter 380A
pumps (010-P-103 A/B/C) STOPS
(010-V-102 B)

Page 304 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
2. ESD valve on desalter water feed to train 1
(XZV-1013) CLOSES
LOW LOW Level in
the desalter water 1. Desalter water make-up pumps (010-P-001
104 LZALL-1008 4.21%
surge drums (010-V- A/B) STOPS
001).
ESD valve (XZV-1061) on Train-1 Desalter
160 HZS-1061 Selector Switch (ESD)
Effluent line CLOSES
ESD valve (XZV-1561) on Train-2 Desalter
161 HZS-1561 Selector Switch (ESD)
Effluent line CLOSES
LOW LOW Level in
105 LZALL-1030 crude flash drum (010- 50% Flashed crude pumps (010-P-003 A/B/C) STOPS
V-003).
Local manual trip of

1. Flashed crude pumps (010-P-003 A/B/C)
HZS-1014B flashed crude pumps
STOPS
(010-P-003 A/B/C)
144
Manual trip from
control panel for fire
2. ESD valve on 010-P-003A/B/C (XZV-1014)
HZS-1014C & emergency of
suction CLOSES
flashed crude pumps
(010-P-003 A/B/C)
LOW LOW Level in

109 LZALL-1040 the kerosene draw off 54.55 Kerosene PA PUMPS 010-P-005A/B STOPS
tray.
LOW LOW Level in

110 LZALL-1044 the LAGO draw off 13.76% LAGO PA PUMPS 010-P-006A/B STOPS
tray
LOW LOW Level in
111 LZALL-1036 the CDU top pump 57.02% TPA PUMPS 010-P-004A/B/C STOPS
around draw off tray
LOW LOW Level in
112 LZALL-1048 the HAGO draw off 23.88% HAGO PA PUMPS 010-P-003A/B STOPS.
tray.

Page 305 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
LOW LOW Level in

Atmospheric Residue Pumps 010-P-007A/B/C
113 LZALL-1026 the crude distillation 2.94%
STOPS.
column bottom.
Local/Manual trip of
HZS1005B 1. LAGO PA PUMPS 010-P-006A/B STOPS.
LAGO pumps
146 Manual trip from

control room panel for 2. ESD valve on suction line of 010-P-006A/B
HZS1005C
fire & emergency of (XZV-1005) CLOSES
LAGO pumps
Local Manual trip of

HZS1017B 1. TPA PUMPS 010-P-004A/B/C STOPS.
TPA pumps

Control room panel for 2. ESD valve on suction line of 010-P-
HZS1017C
fire & emergency of 004A/B/C (XZV-1017) CLOSES
TPA pumps
HIGH HIGH Level in

ESD valve(XZV-1027) on stripping steam to
155 LZAHH-1026 the crude distillation 80%
crude column CLOSES
column bottom.

Atmospheric Residue 1. Atmospheric Residue PUMPS 010-P-
HZS1002B
PUMPS 010-P- 007A/B/C STOPS.
007A/B/C.
140
Manual trip from
Control room panel for 2. ESD valve on suction line of 010-P-
HZS1002C
fire & emergency of 007A/B/C (XZV-1002) CLOSES.
AR(RCO) pumps

1. Atmospheric HAGO PUMPS 010-P-030A/B
147 HZS1020B HAGO PUMPS 010-
STOPS.
P-030A/B.

Page 306 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
Manual trip from
control panel for fire 2. ESD valve on suction line of 010-P-030A/B
HZS1020C
& emergency of (XZV-1020) CLOSES
HAGO pumps
TPA pumps 010-P-

MS Inhibits starting of side cut Naphtha pumps 010-P-
143 004A/B/C running
1004AA/BA/CA 014 A/B/C
status.
LOW LOW Level in

117 LZALL-1052 11.24% Kerosene product pumps 010-P-008 A/B STOPS
the kerosene stripper
LOW LOW Level in

115 LZALL-1054 the LAGO stripper LAGO product pumps 010-P-009A/B STOPS
(010-C-003)

1. Atmospheric LAGO PUMPS 010-P-009A/B
HZS1007B LAGO PUMPS 010-P-
STOPS.
009A/B.
148
Manual trip from
HZS1007C
fire & emergency of (XZV-1007) CLOSES
LAGO product pumps
HIGH HIGH vibration
of AGO product cooler AGO product cooler 010-AC-005 Bay A fan 01
124A VZAHH-1003A
010-AC-005 for Bay motor STOPS
A fan 01
5mm/se
c
HIGH HIGH vibration
of AGO product cooler AGO product cooler 010-AC-005 Bay A fan 02
124B VZAHH-1003B
A fan 02

Page 307 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH vibration

124 of AGO product cooler AGO product cooler 010-AC-005 Bay B fan 01
VZAHH-1003C
C 010-AC-005 for Bay motor STOPS
B fan 01
HIGH HIGH vibration

of AGO product cooler AGO product cooler 010-AC-005 Bay B fan 02
124D VZAHH-1003D
B fan 02
HIGH HIGH vibration

124 of AGO product cooler AGO product cooler 010-AC-005 Bay C fan 01
VZAHH-1003E
E 010-AC-005 for Bay motor STOPS
C fan 01
HIGH HIGH vibration

124 of AGO product cooler AGO product cooler 010-AC-005 Bay C fan 02
VZAHH-1003F
F 010-AC-005 for Bay motor STOPS
C fan 02
HIGH HIGH vibration

of Kerosene product Kerosene product cooler 010-AC-004 fan 01
125A VZAHH-1002A
cooler 010-AC-004 motor STOPS
fan-01
5mm/se
c
HIGH HIGH vibration
125 of Kerosene product Kerosene product cooler 010-AC-004 fan 02
VZAHH-1002B
B cooler 010-AC-004 motor STOPS
fan-02
LOW LOW Level in

116 LZALL-1056 the HAGO stripper 11.24% HAGO product pumps 010-P-029A/B STOPS
(010-C-008)

Page 308 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
1. Atmospheric HAGO PUMPS 010-P-029A/B
HZS1009B HAGO PUMPS 010-
STOPS
P-029A/B.
149
Manual trip from
HZS1009C
fire & emergency of CLOSES(XZV-1009)
HAGO pumps
HIGH HIGH vibration

of Crude column 010-
Crude column 010-C-001 overhead condenser
126A VZAHH-1004A C-001 overhead
010-AC-007 Bay -A fan 01motor STOPS
condenser 010-AC-
007 of Bay -A fan 01
HIGH HIGH vibration

126 5mm/se Crude column 010-C-001 overhead condenser
VZAHH-1004 B C-001 overhead
B c 010-AC-007 Bay -A fan 02 motor STOPS
condenser 010-AC-
007 of Bay -A fan 02
HIGH HIGH vibration

126 Crude column 010-C-001 overhead condenser
VZAHH-1004 C C-001 overhead
C 010-AC-007 Bay -B fan 01 motor STOPS
condenser 010-AC-
007 of Bay -B fan 01

Page 309 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH vibration

of Crude column C-
126D VZAHH-1004D 001 overhead
010-AC-007 Bay -B fan 02 motor STOPS
condenser AC-007 of
Bay-B fan 02
HIGH HIGH vibration

VZAHH-1004 E C-001 overhead
E 010-AC-007 Bay C fan-01 motor STOPS
condenser 010-AC-
007 of Bay C fan-01
HIGH HIGH vibration

VZAHH-1004 F C-001 overhead
F 010-AC-007 Bay C fan-02 motor STOPS
condenser 010-AC-
007 of Bay C fan-02
HIGH HIGH vibration

126G VZAHH-1004G C-001 overhead
010-AC-007 Bay D fan-01 motor STOPS
condenser 010-AC-
007 of Bay D fan-01
HIGH HIGH vibration

126H VZAHH-1004H C-001 overhead
010-AC-007 Bay D fan-02 motor STOPS
condenser 010-AC-
007 of Bay D fan-02

Page 310 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH vibration
126 I VZAHH-1004 I C-001 overhead
010-AC-007 Bay E fan-01 motor STOPS
condenser 010-AC-
007 of Bay E fan-01
HIGH HIGH vibration
of Crude column C-
126 J VZAHH-1004 J 001 overhead
010-AC-007 Bay E fan-02 motor STOPS
condenser AC-007 of
Bay E fan-01
HIGH HIGH vibration
126K VZAHH-1004K C-001 overhead
010-AC-007 Bay F fan-01 motor STOPS
condenser 010-AC-
007 of Bay F fan-01
HIGH HIGH vibration
126 C-001 overhead Crude column 010-C-001 overhead condenser
VZAHH-1004 L
L condenser 010-AC- 010-AC-007 Bay F fan-02 motor STOPS
007 vibration Bay F
fan-02
HIGH HIGH vibration
of Crude column C-
VZAHH-1004M 001 overhead
M 010-AC-007 Bay G fan-01 motor STOPS
condenser AC-007 of
Bay G fan-01
HIGH HIGH vibration
126N VZAHH-1004N C-001 overhead
010-AC-007 Bay G fan-02 motor STOPS
condenser 010-AC-
007 of Bay G fan-02
HIGH HIGH vibration
126O VZAHH-1004O C-001 overhead
010-AC-007 Bay H fan-01 motor STOPS
condenser 010-AC-
007 of Bay H fan-01

Page 311 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH vibration
of Crude column C-
VZAHH-1004 P 001 overhead
P 010-AC-007 Bay H fan-02 motor STOPS
condenser AC-007 of
Bay H fan-02
LOW LOW Level in

CDU Overhead liquid pump 010-P-010 A/B
117 LZALL-1020 the CDU overhead 11.24%
STOPS
receiver 010-V-005.

1. CDU Overhead liquid pump 010-P-010 A/B
HZS1011B CDU Overhead liquid
STOPS.
pumps 010-P-029A/B.
150
Manual trip from
control room panel in
2. ESD valve (XZV-1011) on suction line of
HZS1011C fire & emergency of
010-P-010 A/B CLOSES
CDU Overhead liquid
pumps.
LOW LOW interface
level in Crude Column ESD valve (XZV-1006) on sour water to SWS
142 LZALL 1031 11.24%
Overhead receiver CLOSES.
boot 010-V-005
A/B) STOPS.
LOW LOW
2. ESD valve (XZV-1012) on desalter water
temperature to 1st 0
501 TZALL-1609 115 C from 010-P-001 A/B to train 2 CLOSES.
stage desalter 010-V-
202A
3. Desalter second stage water circulation pump
(010-P-203 A/B/C) STOPS
A/B) STOPS
LOW LOW Crude
flow to the 1st stage 2. ESD valve (XZV-1012) on desalter water
502 FZALL-1577 360T/hr
crude desalter( 010-V- from 010-P-001 A/B to train 2 CLOSES.
202A)
3. Desalter second stage water circulation pump
(P-203 A/B/C) STOPS
529 EZALL-1501 30V
A/B) STOPS

Page 312 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
LOW LOW voltage to
1st stage crude desalter
from 010-P-001 A/B to train 2 CLOSES.
( 010-V-202A)
LOW LOW Interface
level in the 1st stage Desalter water circulation pumps (010-P-202
503A LZALL-1532 20%
desalter ( 010-V- A/B) STOPS
202A)
HIGH HIGH current A/B) STOPS
532A IZAHH-1501 on 2nd crude desalter 380A
010-V-202A
LOW LOW Interface

level in the 2nd stage Desalter second stage water circulation pumps
503B LZALL-1534 20%
desalter ( 010-V- (010-P-203 A/B/C) STOPS
202B)
LOW LOW voltage of
A/B/C) STOPS
2nd stage crude
530 EZALL-1502 30V
desalter 2. ESD valve (XZV-1012) on desalter water
(010-V-202B). from 010-P-001 A/B to train 2 CLOSES.
HIGH HIGH current A/B/C) STOPS
532B IZAHH-1502 on 2nd crude desalter 380A
010-V-202B
HIGH HIGH level in

214 LZAHH-2044 Offgas Compressor 50% Off-gas Compressor 010-K-003 A/B STOPS.
Suct. drum V-006.
HIGH HIGH
201 TZAHH -2002 temperature 010-K- 1350C Offgas Compressor 010-K-003 A STOPS.
003 A outlet.

Page 313 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH
202 TZAHH -2004 temperature 010-K- 1350C Offgas Compressor 010-K-003 B STOPS.
003 B outlet.
HIGH HIGH vibration

of Recontact cooler Recontact cooler 010-AC-008 Bay A fan -
210A VZAHH-2008A
010-AC-008 Bay A 01motor STOPS
fan-01.
HIGH HIGH vibration

210 of Recontact cooler Recontact cooler 010-AC-008 Bay A fan-02
VZAHH-2008B
B 010-AC-008 Bay A motor STOPS.
fan-02
5mm/se
c
HIGH HIGH vibration
210 of Recontact cooler Recontact cooler 010-AC-008 Bay B fan-01motor
VZAHH-2008C
C 010-AC-008 Bay B STOPS
fan-01.
HIGH HIGH vibration

of Recontact cooler Recontact cooler 010-AC-008 Bay B fan-02
210D VZAHH-2008D
010-AC-008 Bay B motor STOPS
fan-02
HIGH HIGH level in

203 LZAHH-2030 Recontactor drum 010- 50% Off Gas compressor K-003 A/B STOPS
V-007
LOW LOW level in

Unstabilised Naphtha pumps 010-P-013A/B
229 LZALL-2048 Recontactor drum 010- 25.28%
STOPS.
V-007

Page 314 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
LOW LOW interface
level in Recontactor ESD valve (XZV-2016) in sour water from
215 LZALL-2045 11.24%
drum boot of 010-V- Recontactor drum 010-V-007 CLOSES.
007

1. Unstabilized Naphtha pumps 010-P-013A/B
HZS2001B Unstabilized Naphtha
STOPS.
pumps 010-P-013A/B.
216
Manual trip from
control room panel for 2. ESD valve on suction line of Unstabilized
HZS2001C fire & emergency of Naphtha pumps 010-P-013A/B (XZV-2001)
Unstabilized Naphtha CLOSES
pumps 010-P-013A/B.
LOW LOW return

temperature of ESD Valve (XZV-2011) on Naphtha stabilizer
204 TZALL-2012 1600C
Naphtha stabilizer bottom line CLOSES.
reboiler 010-E-038.
LOW LOW level in

ESD Valve XZV-2011 on Naphtha stabilizer
213 LZALL-2032 naphtha stabilizer 010- 11.24%
bottom line CLOSES.
C-004.
HIGH HIGH vibration

of Naphtha Stabilizer
5mm/se Naphtha Stabiliser Overhead condenser 010-AC-
211A VZAHH-2016A Overhead condenser
c 009 Bay A fan-01 motor STOPS
010-AC-009 Bay A
fan-01

Page 315 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH
vibration of Naphtha
211 Naphtha Stabilizer Overhead condenser 010-AC-
VZAHH-2016 B Stabilizer Overhead
B 009 Bay A fan-02 STOPS.
condenser 010-AC-
009 Bay A fan-02
HIGH HIGH vibration

VZAHH-2016C Overhead condenser
C 009 Bay B fan-01 STOPS.
010-AC-009 Bay B
Fan 01
HIGH HIGH vibration

Naphtha Stabiliser Overhead condenser 010-AC-
211D VZAHH-2016D Overhead condenser
009 Bay B Fan 02 STOPS.
010-AC-009 Bay B
Fan 02
HIGH HIGH vibration

VZAHH-2016E Overhead condenser
E 009 Bay C Fan 01 STOPS.
010-AC-009 Bay C
Fan 01
HIGH HIGH vibration

VZAHH-2016F Overhead condenser
F 009 Bay C Fan 02 STOPS.
010-AC-009 Bay C
Fan 02

Page 316 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH vibration

of Stabilized Naphtha
212A VZAHH-2019A Stabilized Naphtha cooler Bay A Fan 01 STOPS
cooler of Bay A Fan
01
HIGH vibration of
212 Stabilized Naphtha
VZAHH-2019 B Stabilized Naphtha cooler Bay A Fan 02 STOPS
B cooler of Bay A Fan
02
HIGH HIGH vibration

212 of Stabilized Naphtha
VZAHH-2019C Stabilized Naphtha cooler Bay B Fan 01 STOPS
C cooler of Bay B Fan
01
HIGH HIGH vibration

of Stabilized Naphtha
212D VZAHH-2019D Stabilized Naphtha cooler Bay B Fan 02 STOPS
cooler of Bay B Fan
02
HIGH HIGH
temperature of
ESD Valve XZV-2014 on Stabilized Naphtha line
217 TZAHH-2051 Stabilized Naphtha to 550C
to storage CLOSES.
storage from 010-E-
040 A/B
1. Naphtha Stabilizer reflux pumps 010-P-015
LOW LOW Level in A/B STOPS.
Naphtha stabilizer 2. Naphtha stabilizer overhead pumps 010-P-
205 LZALL-2034 25.28%
overhead receiver 016A/B/C STOPS.
(010-V-008) 3. ESD Valve XZV-2002 on suction line of
010-P-016 A&B CLOSES
Depressursing of 010- ESD Valve HV-2008 in depressusing line from
227 010-HZS-2008A
C-004 010-V-008 OPENS.

Page 317 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
LOW LOW Level in

Naphtha stabilizer 28.09% ESD Valve XZV-2015 in sour water from 010-V-
218 LZALL-2043
overhead receiver 010- 008 CLOSES.
V-008 BOOT
1. Local, Manual
trip of stabilized 1. Stabilized Naphtha reflux pumps 010-P-
HZS2007B
Naphtha reflux pumps 015A/B STOPS.
010-P-015A/B.
219 2. Manual trip from

control room panel for
fire & emergency of
HZS2007C stabilized Naphtha reflux pumps 010-P-015A/B
stabilized Naphtha
CLOSES
reflux pumps 010-P-
015A/B.
Local, Manual trip of

De-ethaniser bottom 1. De-ethaniser bottom pumps 010-P-002A/B/C
HZS2005B
pumps 010-P- STOPS.
002A/B/C.
220
Manual trip from
fire & emergency of 2. ESD valve (XZV-2005) on suction line of
HZS2005C
De-ethaniser bottom De-ethaniser pumps 010-P-002A/B/C CLOSES
pumps 010-P-
002A/B/C.
LOW LOW Level in

De-ethaniser bottom pumps 010-P-002A/B/C
206 LZALL-2036 de-ethaniser column 14.04%
STOPS.
010-C-005

Page 318 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point

Naphtha stabilizer 1. Naphtha stabilizer overhead pumps 010-P-
HZS2002B
overhead pumps 010- 016A/B/C STOPS.
P-016A/B/C.
225
Manual trip from
fire & emergency of
HZS2002C Naphtha stabilizer overhead pumps 010-P-
Naphtha stabilizer
016A/B/C CLOSES
overhead pumps 010-
P-016 A/B/C.
LOW LOW Level in

Deethaniser overhead pumps 010-P-018A/B
207 LZALL-2038 de-ethaniser overhead 42.13%
STOPS.
receiver 010-V-009
Depressurizing of 010- ESD Valve HV-2013 in depressusing line from

222 010-HIC-2013 A
C-005 010-V-009 OPENS.
LOW LOW Interface

Level in De-ethaniser ESD Valve XZV-2017 in sour water from 010-V-
221 LZALL-2046 22.47%
Overhead receiver 009 CLOSES.
010-V-009 BOOT
LOW LOW Level in

208 LZALL-2040 de-propaniser column 11.24% C4 LPG pumps 010-P-020A/B/C STOPS.
010-C-006

Page 319 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
LOW LOW Level in

De-propaniser
230 LZALL-2049 25.28% C3 LPG pumps 010-P-019A/B/C STOPS.
overhead receiver
010-V-010
HIGH HIGH Level in

De-propaniser
209 LZAHH-2024 77.81% ESD valve XZV-2009 in fuel gas line CLOSES
overhead receiver
010-V-010
Depressurizing of
Depropaniser ESD Valve XZV 2012 in depressusing line from
228 HZS-2012A
Overhead Reciever 010-V-010 OPENS.
010-V-010
LOW LOW Interface

Level in Depropanizer ESD Valve XZV-2018 in sour water from 010-V-
223 LZALL-2047 28.09%
Overhead receiver 010 CLOSES.
010-V-010 BOOT

HZS2003B C3 LPG pumps 010-P- 1. C3 LPG pumps 010-P-019A/B/C STOPS.
019A/B/C.

2. ESD valve (XZV-2003) on suction line of C3
LPG pumps 010-P-019A/B/C CLOSES
C3 LPG pumps 010-
P-019A/B/C.

226 HZS2004B C4 LPG pumps 010-P- 1. C4 LPG pumps 010-P-020A/B/C STOPS.
020A/B/C.

Page 320 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
Manual trip from

Control room panel for
2. ESD valve (XZV-2004) on suction line of C4
LPG pumps 010-P-020A/B/C CLOSES
C4 LPG pumps 010-
P-020A/B/C.
LOW LOW Level in 1. Vacuum residue pumps 010-P-025 B/C

bottom section of STOPS.
305 LZALL-3025 14%
vacuum column 010- 2. ESD valve (XZV-7001) on HP steam to
C-007 pumps 010-P-025A. CLOSES.

1. Vacuum residue pumps 010-P-025B/C
HZS3014B vacuum residue pumps
STOPS.
010-P-025A/B/C.
Manual trip from

332 Control room panel for
2. ESD valve (XZV-7001) on HP steam to
pump 010-P-025ACLOSES
vacuum residue pumps
010-P-025A/B/C.
3. ESD valve XZV-3014 on suction line to

pumps 010-P-025A/B/C CLOSES.
LOW LOW level on

306 LZALL-3034 recycle oil draw off 55.06% Recycle oil pumps 010-P-024A/B STOPS.
tray

333 HZS3004B recycle oil pumps 010- 1. Recycle oil pumps 010-P-024A/B STOPS
P-024A/B.

Page 321 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
Manual trip from

Control room panel for
2. ESD valve XZV-3004 suction line to pumps
010-P-024A/B CLOSES.
recycle oil pumps
010-P-024A/B.
LOW LOW level on

307 LZALL-3031 vacuum diesel draw 34.07% Vacuum diesel pumps 010-P-021A/B STOPS.
off tray

1. Vacuum diesel pumps 010-P-021A/B
HZS3009B vacuum diesel pumps
STOPS
010-P-021A/B

vacuum diesel pumps 010-P-021A/B CLOSES.
vacuum diesel pumps
010-P-021A/B
LOW LOW level on

308 LZALL-3032 56.18% VGO pumps 010-P-022A/B/C STOPS
VGO draw off tray
1. ESD valve XZV-3002 on LP steam from
convection section CLOSES.
HIGH HIGH level in
310 LZAHH-3023 69.73%
vacuum column 2. ESD valve on steam vent on LP steam from
convection section (XZV-3003) OPENS.

331 HZS3013B VGO pumps 010-P- 1. VGO pumps 010-P-022A/B/C STOPS
022A/B/C

Page 322 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
Manual trip from

VGO pumps 010-P-022A/B/C CLOSES.
VGO pumps 010-P-
022A/B/C
LOW LOW 1. ESD valve on LP steam from convection

temperature of section (XZV-3002) CLOSES.
280
316 TZALL-3081 Superheated LP steam
deg.C
from convection 2. ESD valve on steam vent on LP steam from
section convection section (XZV-3003) OPENS.
LOW LOW level on

309 LZALL-3033 34.55% HVGO pumps 010-P-023A/B/C STOPS
HVGO draw off tray

HZS3008B HVGO pumps 010-P- 1. HVGO pumps 010-P-023A/B/C STOPS
023A/B/C

HVGO pumps 010-P-023A/B/C CLOSES.
HVGO pumps 010-P-
023A/B/C
HIGH HIGH level in

ESD valve XZV-3031 on BFW supply to 010-E-
323 LZAHH-3052 HVGO/MP Steam 75.85%
149 CLOSES
generator 010-E-149
HIGH HIGH level in

ESD valve XZV-3040 on BFW to 010-E-150
324 LZAHH-3045 HVGO/LP Steam 78.65%
CLOSES
generator 010-E-150

Page 323 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
LOW LOW Interface

311 LZALL-3036 level in hot well drum 58.97% VDU sour water pumps 010-P-028A/B STOPS
010-V-013
HIGH HIGH
318 Vibration for vacuum 1. Vacuum diesel PA cooler 010-AC-016 Bay
VZAHH-3001A
A diesel PA cooler 010- A Fan 01 STOPS
AC-016 Bay A Fan 01
HIGH HIGH
VZAHH-3001B
B diesel PA cooler 010- A Fan 02 STOPS
AC-016 Bay A Fan 02
HIGH HIGH
VZAHH-3001C
C diesel PA cooler 010- B Fan 01 STOPS
AC-016 Bay B Fan 01
HIGH HIGH
VZAHH-3001D
D diesel PA cooler 010- B Fan 02 STOPS
AC-016 Bay B Fan 02
HIGH HIGH
VZAHH-3001E
E diesel PA cooler 010- C Fan 01 STOPS
AC-016 Bay C Fan 01
HIGH HIGH
VZAHH-3001F
F diesel PA cooler 010- C Fan 02 STOPS
AC-016 Bay C Fan 02

Page 324 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH
319 Vibration for VGO 1. VGO product cooler 010-AC-015 Bay A Fan
VZAHH-3022A
A Product cooler 010- 01 STOPS
AC-015 Bay A Fan 01
HIGH HIGH
319 Vibration for VGO 2. VGO product cooler 010-AC-015 Bay A Fan
VZAHH-3022 B
B Product cooler 010- 02 STOPS
AC-015 Bay A Fan 02
HIGH HIGH
319 Vibration for VGO 3. VGO product cooler 010-AC-015 Bay B Fan
VZAHH-3022 C
C Product cooler 010- 01 STOPS
AC-015 Bay B Fan 01
HIGH HIGH
319 Vibration for VGO 4. VGO product cooler 010-AC-015 Bay B Fan
VZAHH-3022D
D Product cooler 010- 02 STOPS
AC-015 Bay B Fan 02
HIGH HIGH
319 Vibration for VGO 5. VGO product cooler 010-AC-015 Bay C Fan
VZAHH-3022 E
E Product cooler 010- 01 STOPS
AC-015 Bay C Fan 01
HIGH HIGH
319 Vibration for VGO 6. VGO product cooler 010-AC-015 Bay C Fan
VZAHH-3022 F
F Product cooler 010- 02 STOPS
AC-015 Bay C Fan 02

Page 325 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH
319 Vibration for VGO 7. VGO product cooler 010-AC-015 Bay D Fan
VZAHH-3022G
G Product cooler 010- 01 STOPS
AC-015 Bay D Fan 01
HIGH HIGH
319 Vibration for VGO 8. VGO product cooler 010-AC-015 Bay D Fan
VZAHH-3022H
H Product cooler 010- 02 STOPS
AC-015 Bay D Fan 02
HIGH HIGH
Vibration for VGO 9. VGO product cooler 010-AC-015 Bay E Fan
319 I VZAHH-3022 I
Product cooler 010- 01 STOPS
AC-015 Bay E Fan 01
HIGH HIGH
Vibration for VGO 10. VGO product cooler 010-AC-015 Bay E Fan
319 J VZAHH-3022 J
AC-015 Bay E Fan 02
HIGH HIGH
Vibration for VGO 11. VGO product cooler 010-AC-015 Bay F Fan
319K VZAHH-3022K
AC-015 Bay F Fan 01
HIGH HIGH
319 Vibration for VGO 12. VGO product cooler 010-AC-015 Bay F Fan
VZAHH-3022 L
L Product cooler 010- 02 STOPS
AC-015 Bay F Fan 02

Page 326 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH Vibration for

319 VGO Product cooler 13. VGO product cooler 010-AC-015 Bay G Fan
VZAHH-3022M
M 010-AC-015 Bay G 01 STOPS
Fan 01
HIGH HIGH
Vibration for VGO 14. VGO product cooler 010-AC-015 Bay G Fan
319N VZAHH-3022N
AC-015 Bay G Fan 02
HIGH HIGH
Vibration for VGO 15. VGO product cooler 010-AC-015 Bay H Fan
319O VZAHH-3022O
AC-015 Bay H Fan 01
HIGH HIGH
319 Vibration for VGO 16. VGO product cooler 010-AC-015 Bay H Fan
VZAHH-3022 P
P Product cooler 010- 02 STOPS
AC-015 Bay H Fan 02
HIGH HIGH
Vibration for vacuum
Vacuum diesel product cooler 010-AC-014 Bay A
320A VZAHH-3003A diesel Product cooler
fan-01 STOPS
010-AC-014 Bay A
fan-01
HIGH HIGH
Vibration for vacuum
320 Vacuum diesel product cooler 010-AC-014 Bay A
VZAHH-3003 B diesel Product cooler
B fan-02 STOPS
010-AC-014 Bay A
fan-02
HIGH HIGH level in

325 LZAHH-3046 VR/LP Steam 78.65%
251A CLOSES
generator 010-E-251A

Page 327 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH level in

151A CLOSES
generator 010-E-151A
HIGH HIGH level in

ESD valve XZV-3036 on BFW to 010-E-251B
CLOSES
generator 010-E-251B
HIGH HIGH level in

ESD valve XZV-3037 on BFW to 010-E-251C
CLOSES
generator 010-E-251C
HIGH HIGH level in

ESD valve XZV-3038 on BFW to 010-E-151B
CLOSES
generator 010-E-151B
HIGH HIGH level in

ESD valve XZV-3039 on BFW to 010-E-151C
CLOSES
generator 010-E-151C
LOW LOW flow of

cooling water to 3200 ESD valve on MP steam supply to Ejector 010-
540 FZALL-3077
Booster Stage MT/hr EJ-001A/B/C CLOSES
condensors
LOW LOW liquid

401 LZALL-4010 level in Amine 11.24% Rich amine pumps 010-P-033A/B STOPS
absorber 010-C-010
LOW LOW liquid

level in Amine
403 LZALL-4013 14.29% ABD pumps 010-P-034 STOPS
Blowdown Drum 010-
V-018

Page 328 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH level in

ESD valve XZV-4001 on Lean Amine to 010-C-
402 LZAHH-4012 low pressure scrubber 80.34%
009 CLOSES
010-C-009
LOW LOW level in

404 LZALL-4014 low pressure scrubber 11.24% Rich amine pumps 010-P-031A/B STOPS
010-C-009
LOW LOW level in

901 LZALL-9005 AVU LP FLARE 56.8% LP Flare KOD pumps 010-P-301A/B STOPS
KOD 010-V-301
HIGH HIGH
temperature in AVU
907 TZAHH-9001 650C LP Flare KOD pumps 010-P-301A/B STOPS
LP FLARE KOD
010-V-301
LOW LOW level in

Crude pre-heat Train-1 Crude pre-heat train 1 CBD Drum pumps 010-P-
902 LZALL-9007 3.23%
CBD Drum 010-V- 610 STOPS
610
HIGH HIGH
temperature in crude Crude pre-heat train 1 CBD Drum pumps 010-P-
908 TZAHH-9032 650C
pre-heat train 1 CBD 610 STOPS
Drum 010-V-610
LOW LOW level in

Crude pre-heat Train-2 Crude pre-heat train-2 CBD Drum pumps 010-P-
903 LZALL-9010 3.23%
CBD Drum 010-V- 611 STOPS
611

Page 329 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
HIGH HIGH
temperature in Crude Crude pre-heat train-2 CBD Drum pumps 010-P-
909 TZAHH-9033 650C
pre-heat Train-2 CBD 611 STOPS
Drum 010-V-611
LOW LOW level in

904 LZALL-9013 CDU area CBD Drum 3.82% CDU area CBD Drum pumps 010-P-612 STOPS
010-V-612
HIGH HIGH
temperature in CDU
910 TZAHH-9034 650C CDU area CBD Drum pumps 010-P-612 STOPS
area CBD Drum
010-V-612
LOW LOW level in

905 LZALL-9016 VDU area CBD Drum 2.3% VDU area CBD Drum pumps 010-P-613 STOPS
010-V-613
HIGH HIGH
temperature in VDU
911 TZAHH-9035 650C VDU area CBD Drum pumps 010-P-613 STOPS
area CBD Drum
010-V-613
LOW LOW level in

Naphtha stabilizer Naphtha stabilizer CBD Drum pumps 010-P-614
906 LZALL-9019 15%
CBD Drum 010-V- STOPS
614
HIGH HIGH
temperature in
Naphtha stabilizer CBD Drum pumps 010-P-614
912 TZAHH-9036 Naphtha stabilizer 650C
STOPS
CBD Drum 010-V-
614

Page 330 of 592

Doc. No:
010- Set
Tag No Cause Effect
IZ Point
LOW LOW level in

Atmospheric Suspect condensate pumps 010-P-615A/B
913 LZALL-9023 61.5%
condensate flash Drum STOPS
010-V-615
HIGH HIGH
Vibration for
914 Condensate flash drum cooler 010-AC-615 Fan A
VZAHH-9001A condensate flash drum
A STOPS
cooler 010-AC-615
Fan A
HIGH HIGH
Vibration for
914 Condensate flash drum cooler 010-AC-615 Fan B
VZAHH-9001 B condensate flash drum
B STOPS
cooler 010-AC-615
Fan B
HIGH HIGH
Vibration for blow 1. Blow down cooler 010-AC-616 Fan A
915A VZAHH-9002A
down cooler 010-AC- STOPS
616 Fan A
HIGH HIGH
915 Vibration for blow 2. Blow down cooler 010-AC-616 Fan B
VZAHH-9002 B
B down cooler 010-AC- STOPS
616 Fan B

Page 331 of 592

Doc. No:
13.2 List of DCS interlocks
010-I Tag No Cause Set Point Effect
1. Flow control valve (FV-1124) on Atm.

Residur for start-up & VDU bypass OPENS.
Permissive to VDU
1025 HS-1025
bypass
2. Flow control valve (FV-1624) on Atm.
Residur for start-up & VDU bypass OPENS.
Low pressure in TOP

6260 PAL-1092 PA pumps discharge 9 Kg/Cm2g Stand by pump (010-P-004 A/B/C) STARTS
header
High Level in Hot Well

6250 LAH-3020 40%/20% Stand by pump (010-P-027 A/B) STARTS
Oil Drum (010-V-013)
High Level in Hot Well

On-Off valve XV-3022 on sour water to Hot well
6240 LAH-3022 Oil Coalescer (010-V- 85%
drum 010-V-013 OPENS
015)
Low Level in Hot Well

On-Off valve XV-3022 on sour water to Hot well
6240 LAL-3022 Oil Coalescer (010-V- 15%
drum 010-V-013 CLOSES
015)
Low Liquid Level in

6210 LAL-4005 Amine Blowdown drum 15% Amine Blowdown pump 010-P-034 STOPS
(010-V-018)
Low Pressure in AGO

Standby AGO seal fluid pump 010-P-035 A/B
1110 PAL-6001 seal fluid pump 17 Kg/Cm2g
STARTS
discharge header
Low Pressure in VGO

Standby VGO seal fluid pump 010-P-036 A/B
1120 PAL-6002 seal fluid pump 20 Kg/Cm2g
STARTS
discharge header

Page 332 of 592

Doc. No:
010-I Tag No Cause Set Point Effect
Low Level in ESD valve XV-9026 on Acid Flare to Amine

6310 LAL-9026 15%
Condensate Pot CBD CLOSES
Low Level in AVU LP

6270 LAL-9002 16% LP Flare KOD pumps 010-P-301A/B STOPS
Flare KOD (010-V-301)
High (H1) Level in

Primary AVU LP Flare KOD pump 010-P-
6270 LAH-9002 AVU LP Flare KOD 57%
301A/B STARTS
(010-V-301)
High (H2) Level in

LAHH- Stand by AVU LP Flare KOD pump 010-P-
6270 AVU LP Flare KOD 70%
9002 301A/B STARTS
(010-V-301)
LOW level in Crude

LAL-9008 Crude pre-heat train-1 CBD Drum pumps 010-P-
6280 pre-heat Train-1 CBD 15%
A 610 STOPS
Drum 010-V-610
LOW level in Crude

LAL-9011 Crude pre-heat train-2 CBD Drum pumps 010-P-
6290 pre-heat Train-2 CBD 15%
A 611STOPS
Drum 010-V-611
LOW level in CDU

LAL-9014
5450 Area CBD Drum 010- 15% CDU Area CBD Drum pumps 010-P-612 STOPS
A
V-612
LOW level in VDU

LAL-9017
5460 Area CBD Drum 010- 15% VDU Area CBD Drum pumps 010-P-613 STOPS
A
V-613

Page 333 of 592

Doc. No:
13.3 List of Furnace Interlocks

CDU FURNACE (F-101/201) & VDU FURNACE (F-002)
010
Tag No Cause Set point Effect
-IZ
1. Stack damper PV-1098 OPEN
2. Flue Gas damper PV-1035 OPEN.
If stack damper & Flue Gas damper fails to
open or arch pressure does not reduce within
30 seconds following effects will occur.
1. ESD valve on fuel gas supply to heater
CLOSES (XZV-1022)
1. PZAHH- Furnace arch
CLOSES (XZV-1049)
1124A/B/C pressure HIGH
106 +5 mm wc 3. Main Fuel Gas bleed valve XZV-1050
2. ML-1018 C /1019 HIGH
C Both ID fans trips. OPEN
4. ESD valve on fuel oil supply to heater
CLOSES (XZV-1024)
5. ESD valve on fuel oil return CLOSES
(XZV-1026)
6. ESD valve in FO line to Burner ( XZV-
1046 A-P) CLOSES
7. Oil gun steam purge shut-off valves
ZXV-1057 A-P OPENS
8. Crude charge heater F-201 trips
1. LOW LOW Feed 1. Crude charge heater F-201 trips
flow to the crude 2. ESD valve on fuel gas supply to heater
1. FZALL-1016 CLOSES (XZV-1022)
charge heater 010-
A/B/C
F-0101 350 t/hr 3. ESD valve on fuel gas supply to heater
2. TZAHH-1123
2. HIGH HIGH CLOSES (XZV-1049)
A/B/C
crude temperature 376oC 4. Main Fuel Gas bleed valve XZV-1050
3. ML-1020 AC &
at outlet of furnace OPEN
1020 BC
107 (010-F-101) 22.5 t/hr 5. ESD valve on fuel oil supply to heater
4. FZALL-1084
3. Both FD fans CLOSES (XZV-1024)
A/B/C
tripped 50 mm wc 6. ESD valve on fuel oil return CLOSES
5. PZALL-9319
4. LOW LOW flow (XZV-1026)
A/B/C
of Combustion air 43.75 t/hr 7. ESD valve in FO line to Burner ( XZV-
6. FZALL-9307A to
5. LOW LOW 1046 A-P) CLOSES
H A/B/C
Combustion air 8. Oil gun steam purge shut-off valves
pressure ZXV-1057 A-P OPENS

Page 334 of 592

Doc. No:
010
-IZ
6. LOW LOW
process feed flow
APH bypass damper opens (XZV-1030) &
APH inlet damper CLOSES (XZV-1031)
CLOSES.
If above said dampers fails to open/Close
within 30 seconds the following effects will
occur.
1. Both ID fans (010-K-002 A/B) TRIPS
CLOSES (XZV-1022)
HIGH HIGH or
205oC 3. ESD valve on fuel gas supply to heater
TZAHH-1212 A/B/C LOW LOW flue CLOSES (XZV-1049)
633
TZALL-1212 A/B/C gas temperature at
128oC 4. Main Fuel Gas bleed valve XZV-1050
APH outlet. OPEN
CLOSES (XZV-1024)
(XZV-1026)
1046 A-P) CLOSES
ZXV-1057 A-P OPENS
1. LOW LOW 1. ESD valve on fuel gas supply to heater
1. PZALL- pressure of Fuel CLOSES (XZV-1022)
0.2 kg/cm2g
1165A/B/C Gas to Burner 2. ESD valve on fuel gas supply to heater
118
2. PZAHH 2. HIGH HIGH CLOSES (XZV-1049)
2.45 kg/cm2g
1165A/B/C pressure of Fuel 3. Main Fuel Gas bleed valve XZV-1050
Gas to Burner. OPEN
1. LOW LOW 1. Fuel Oil to heater (010-F-101) ESD valve
pressure of Fuel Oil XZV-1024 CLOSES.
1. PZALL -
to Burner. 2.4 kg/cm2g 2. Fuel Oil to heater (010-F-101) ESD valve
1172A/B/C
2. HIGH HIGH XZV-1026 CLOSES.
2. PZAHH -
119 pressure of Fuel Oil 7 kg/cm2g 3. Fuel Oil to heater (010-F-101) ESD valve
1172A/B/C
to Burner. XZV-1046 A-P CLOSES.
3. PZALL-1083
3. LOW LOW 1.5 kg/cm2g
A/B/C 4. XZV-1057 A-P (Atomizing steam)
Differential
pressure across CLOSES

Page 335 of 592

Doc. No:
010
-IZ
Atomizing steam
and Fuel oil
1. Stack damper damper PV-1098 OPENS.
Consequence of IZ- Consequence of IZ- 2. Flue Gas damper PV-1035 OPENS.
634 106,0107,(118&119) 106,0107,(118&11 After 30 Sec of the above effects
,633,640&644 9),633,640&644
1. ID fan trip
2. FD fan trips
1. FD fan B attains 100% load. FD fan A
ML-1020 AC FD fan A tripped
(XZV-1037) discharge CLOSES.
635
2. FD fan A attains 100% load. FD fan B
ML-1020 BC FD fan B tripped
1. Flue gas inlet damper (XZV-1028) to
WHB CLOSES.
2. WHB bypass damper XZV-1029 OPENS.
If Flue gas inlet damper CLOSE and bypass

damper OPEN action does not take place
within 30 seconds following effects will occur.
CLOSES (XZV-1022)
LOW LOW level CLOSES (XZV-1049)
640 LZALL-1055 of Steam drum 010- 15% 3. Main Fuel Gas bleed valve XZV-1050
WHB-001. OPEN
CLOSES (XZV-1024)
(XZV-1026)
1046 A-P) CLOSES
ZXV-1057 A-P OPENS

Page 336 of 592

Doc. No:
010
-IZ
LOW LOW MP
1. ESD valve XZV-1025 on BFW to
121 TZALL-1136 steam temperature 280oC
desuperheater CLOSES
from desuperheater
1. Stack damper PV-1098 OPENS.

2. Flue Gas damper PV-1035 OPENS.
Interlock activation 3. APH bypass damper XZV-1030 CLOSES
642 IZ-0640 & IZ-0633
simultaneously
4. Both ID fans trips.
5. WHB bypass damper XZV-1029
CLOSES.
Failure of one of 3. Running ID fan STOPS
ML-1018 C & ML- the ID fan during 4. APH flue gas inlet damper XZV-1031
643 CLOSES
1019 C WHB/APH bypass
condition 5. APH flue gas bypass damper XZV-1030
CLOSES
6. WHB flue gas inlet damper XZV-1028
CLOSES
CLOSES (XZV-1022)
CLOSES (XZV-1049)
4. Main Fuel Gas bleed valve XZV-1050
OPEN
Tripping of heater 5. ESD valve on fuel oil supply to heater
645 - CLOSES (XZV-1024)
010-F-201
(XZV-1026)
1046 A-P) CLOSEs
ZXV-1057 A-P
9. Flue gas outlet duct damper PV-1035
OPEN

Page 337 of 592

Doc. No:
010
-IZ
1. Steam vent valve XZV-9301 on LP steam
LOW LOW
from convection section OPENS.
temperature of LP
122 TZALL-1137 190oC
steam from
2. ESD valve XZV-9302 on superheated
convection section.
steam to strippers CLOSES.
CLOSES (XZV-1022)
CLOSES (XZV-1049)
OPEN
CLOSES (XZV-1024)
(XZV-1026)
1046 A-P) CLOSEs
HZS-3000 A ZXV-1057 A-P
(Control Room Emergency Push 9. Flue gas outlet duct damper PV-1035
631 HWC) button for heater OPEN
HZS-3000 BA 010-F-101 10. Stack/Flue Gas damper PV-1098 OPENS.
(Field)
11. Pilot Fuel gas shut off valves XZV-1023
CLOSES
CLOSES
13. Pilot Fuel Gas bleed valve XZV-1054
OPEN
14. Pilot Fuel Gas valves to burners XZV-
1045 A-P CLOSES
15. ID Fan trip
16. FD fan trip
17. Flash crude pump 010-P-003 A-C STOPS
18. Coil purge steam valves XZV-1001 A-H
OPEN

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Doc. No:
010
-IZ
Following effects will take place if LOW
LOW or HIGH HIGH pressure of pilot gas
continuous for 5 sec
CLOSES (XZV-1022)
CLOSES (XZV-1049)
OPEN
1. Pilot Gas
1. PZALL- CLOSES (XZV-1024)
pressure LOW 0.5 kg/cm2g
1167A/B/C 6. ESD valve on fuel oil return CLOSES
644 LOW (5 seconds)
2. PZAHH- (XZV-1026)
2. HIGH HIGH(5 1.5 kg/cm2g
1167A/B/C 7. ESD valve in FO line to Burner ( XZV-
seconds)
1046 A-P) CLOSEs
ZXV-1057 A-P
CLOSES
CLOSES
OPEN
1045 A-P CLOSES
TT-1125 (LOW 1. Soot blower drain shutdown valve XZV-
I- Soot Blower
LOW) 1043 OPEN
063 Operation in
PT-1006 (LOW 2. Soot blower inlet shutdown valve XZV-
2 progress
LOW) 1042 CLOSES
Based on individual flame scanner input
respective fuel oil shutdown valves CLOSE &
Oil gun steam purge valves shall OPEN
646 BZE-1002 A-P Loss of Main flame
1046 A-P) CLOSES
ZXV-1057 A-P OPENS

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Doc. No:
010
-IZ
Pilot gas block and bleed valves to operate
only when all pilot gas burner shut-off valves
1. Pilot gas burner 1. BMS leak test are closed and pilot leak test cleared
shut-off valves XZV- permissive
638 1045 A-P
OPEN
2. Pilot gas header
2. XL-1006 leak test cleared
OPEN
CLOSES
Main fuel gas block and bleed valves to
operate only when all burner leak test cleared
1. Main Fuel gas and one of the pilot is ON.
header leak test
1. XL-1027 1. ESD valve on fuel gas supply to heater
cleared
639 2. XL-1009 to XL- OPEN (XZV-1022)
2. Pilot Flame
1024 2. ESD valve on fuel gas supply to heater
scanner ON (atleast
OPEN (XZV-1049)
one)
CLOSES
FURNACE(010-F-201)
2. Flue Gas damper PV-1535 OPEN.
If stack damper & Flue Gas damper fails to
open or arch pressure does not reduce within
30 seconds following effects will occur.
1. Furnace arch CLOSES (XZV-1522)
1. PZAHH- 2. ESD valve on fuel gas supply to heater
pressure HIGH
1624A/B/C CLOSES (XZV-1549)
506 HIGH 5 mm wc
2. ML-1018 C /1019 3. Main Fuel Gas bleed valve XZV-1550
2. Both ID fans
C OPEN
trips.
CLOSES (XZV-1524)
(XZV-1526)
1546 A-P) CLOSES
ZXV-1557 A-P OPENS

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Doc. No:
010
-IZ
1. LOW LOW Feed 1. Crude charge heater F-101 trips
flow to the crude 2. ESD valve on fuel gas supply to heater
charge heater 010- CLOSES (XZV-1522)
F-201 3. ESD valve on fuel gas supply to heater
1. FZALL-1516
2. HIGH HIGH CLOSES (XZV-1549)
A/B/C 350 t/hr
crude temperature 4. Main Fuel Gas bleed valve XZV-1550
2. TZAHH-1623
at outlet of furnace OPEN
A/B/C 376oC
(010-F-201) 5. ESD valve on fuel oil supply to heater
3. ML-1020 AC &
3. Both FD fans CLOSES (XZV-1524)
507 1020 BC 22.5 t/hr
tripped
4. FZALL-1584 6. ESD valve on fuel oil return CLOSES
4. LOW LOW flow
A/B/C 20 mm wc (XZV-1526)
of Combustion air
5. PZALL-9319 7. ESD valve in FO line to Burner ( XZV-
5. LOW LOW
A/B/C 43.75 t/hr 1546 A-P) CLOSES
Combustion air
6. FZALL-9308 A-H
pressure
6. LOW LOW 8. Oil gun steam purge shut-off valves
process feed flow ZXV-1557 A-P OPENS
in any pass
APH bypass damper OPEN (XZV-1030) &
APH inlet damper CLOSES (XZV-1031).
occur.
HIGH HIGH or CLOSES (XZV-1522)
190 deg.C
TZAHH-1212 A/B/C LOW LOW flue 3. ESD valve on fuel gas supply to heater
633
TZALL-1212 A/B/C gas temperature at CLOSES (XZV-1549)
128 deg.C
APH outlet. 4. Main Fuel Gas bleed valve XZV-1550
OPEN
CLOSES (XZV-1524)
(XZV-1526)
1546 A-P) CLOSES
ZXV-1557 A-P OPENS

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Doc. No:
010
-IZ
1. LOW LOW 1. ESD valve on fuel gas supply to heater
1. PZALL- pressure of Fuel CLOSES (XZV-1522)
0.2 kg/cm2g
1665A/B/C Gas to Burner 2. ESD valve on fuel gas supply to heater
518
2. PZAHH 2. HIGH HIGH CLOSES (XZV-1549)
2.45 kg/cm2g
1665A/B/C pressure of Fuel 3. Main Fuel Gas bleed valve XZV-1550
Gas to Burner. OPEN
1. LOW LOW 1. Fuel Oil to heater (010-F-201) ESD valve
pressure of Fuel Oil XZV-1524 CLOSES.
to Burner. 2. Fuel Oil to heater (010-F-201) ESD valve
1. PZALL -
2. HIGH HIGH 2.4 kg/cm2g XZV-1526 CLOSES.
1672A/B/C
pressure of Fuel Oil 3. Fuel Oil to heater (010-F-201) ESD valve
2. PZAHH -
519 to Burner. 7 kg/cm2g XZV-1546 A-P CLOSES.
1672A/B/C
3. LOW LOW
3. PZALL-1583
Differential 1.5 kg/cm2g
A/B/C 4. XZV-1557 A-P (Atomizing steam)
pressure across
Atomizing steam CLOSES.
and Fuel oil
1. Stack damper damper PV-1098 OPENS.
Consequence of IZ- Consequence of IZ- 2. Flue Gas damper PV-1535 OPENS.
664 506,0507,(518&519) 506,0507,(518&51 After 30 Sec of the above effects
,633,640&644 9),633,640&644
1. ID fan trip
2. FD fan trips
ML-1020 AC FD fan A tripped
635
ML-1020 BC FD fan B tripped
WHB CLOSES.
LOW LOW level If Flue gas inlet damper CLOSE and bypass
640 LZALL-1055 of Steam drum 010- 15 % damper OPEN action does not take place
WHB-001. within 30 seconds following effects will occur.
CLOSES (XZV-1522)
CLOSES (XZV-1549)

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Doc. No:
010
-IZ
OPEN
CLOSES (XZV-1524)
(XZV-1526)
1546 A-P) CLOSES
ZXV-1557 A-P OPENS
Interlock activation 3. APH bypass damper XZV-1030 CLOSES
642 IZ-0640 & IZ-0633
simultaneously
5. WHB bypass damper XZV-1029
CLOSES.
Failure of one of 3. Running ID fan STOPS
ML-1018 C the ID fan during 4. APH flue gas inlet damper XZV-1031
643 CLOSES
ML-1019 C WHB/APH bypass
condition 5. APH flue gas bypass damper XZV-1030
CLOSES
CLOSES
CLOSES (XZV-1522)
Tripping of heater 3. ESD valve on fuel gas supply to heater
668 - CLOSES (XZV-1549)
010-F-201
OPEN
CLOSES (XZV-1524)

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Doc. No:
010
-IZ
(XZV-1526)
1546 A-P) CLOSEs
ZXV-1557 A-P
OPEN
LOW LOW
temperature of LP
522 TZALL-1637 190 deg.C
steam from
2. ESD valve XZV-1529 on superheated
convection section.
steam to strippers CLOSES.
CLOSES (XZV-1522)
CLOSES (XZV-1549)
OPEN
CLOSES (XZV-1524)
(XZV-1526)
1. HZS-3000 A
(Control Room Emergency Push
1546 A-P) CLOSEs
631 HWC) button for heater
2. HZS-3000 BB 010-F-201
ZXV-1557 A-P
(Field)
OPEN
CLOSES
CLOSES
OPEN
1545 A-P CLOSES

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Doc. No:
010
-IZ
15. ID Fan trip
16. FD fan trip
17. Flash crude pump 010-P-003 A-C STOPS
18. Coil purge steam valves XZV-1501 A-H
OPEN
CLOSES (XZV-1522)
CLOSES (XZV-1549)
OPEN
Pilot Gas pressure
CLOSES (XZV-1524)
LOW LOW(5 0.5 kg/cm2g
PZALL-1667A/B/C 6. ESD valve on fuel oil return CLOSES
644 seconds)
PZAHH-1667A/B/C (XZV-1526)
HIGH HIGH(5 1.5 kg/cm2g
seconds) 7. ESD valve in FO line to Burner ( XZV-
1546 A-P) CLOSEs
ZXV-1557 A-P
CLOSES
CLOSES
OPEN
1545 A-P CLOSES
I- Soot Blower
LOW) 1543 OPEN
066 Operation in
2 progress
LOW) 1542 CLOSES
I- Soot Blower
LOW) 1559OPEN
066 Operation in
3 progress
LOW) 1558 CLOSES

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Doc. No:
010
-IZ
669 BZE-1502 A-P Loss of Main flame
1546 A-P) CLOSES
ZXV-1557 A-P OPENS
are closed and pilot leak test cleared
1. Pilot gas burner 1. BMS leak test
shut-off valves XZV- permissive 1. Pilot Fuel gas shut off valves XZV-1523
665
1545 A-P 2. Pilot gas header OPEN
2. XL-1506 leak test cleared 2. Pilot Fuel gas shut off valves XZV-1553
OPEN
CLOSES
header leak test
cleared
666 2.XL-1509 to XL- OPEN (XZV-1522)
2. Pilot Flame
scanner ON (atleast
OPEN (XZV-1549)
one)
CLOSES
Vacuum Heater (010-F-002)
If stack damper fails to open or arch pressure
does not reduce within 30 seconds following
effects will occur.
1. Furnace arch
1. PZAHH-3053 1. ESD valve on fuel gas supply to heater
pressure HIGH
A/B/C CLOSES (XZV-3026)
302 HIGH 5 mm wc
2. ML-3028 C /3029 2. ESD valve on fuel gas supply to heater
2. Both ID fans
C CLOSES (XZV-3048)
trips.
OPEN
CLOSES (XZV-3023)

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010
-IZ
(XZV-3024)
3044 A-T) CLOSES
ZXV-3059 A-T OPENS
8. Treated Vent Gas shut-off valve to burner
XZV-3058 CLOSES
1. LOW LOW Feed 1. ESD valve on fuel gas supply to heater
flow to the crude CLOSES (XZV-3026)
charge heater 010- 2. ESD valve on fuel gas supply to heater
1. FZALL-9305
F-002 CLOSES (XZV-3048)
A/B/C
2. HIGH HIGH 3. Main Fuel Gas bleed valve XZV-3049
2. TZAHH-3047 468.2 t/hr
crude temperature OPEN
A/B/C
at outlet of furnace 4. ESD valve on fuel oil supply to heater
3. ML-3001 AC & 415 deg.C
(010-F-101) CLOSES (XZV-3023)
3001 BC
3. Both FD fans 5. ESD valve on fuel oil return CLOSES
317 4. FZALL-3072 25 t/hr
tripped (XZV-3024)
A/B/C & 3073
4. LOW LOW flow 6. ESD valve in FO line to Burner ( XZV-
A/B/C 20 mm wc
of Combustion air 3044 A-T) CLOSES
5. PZALL-9318
5. LOW LOW 7. Oil gun steam purge shut-off valves
A/B/C 39.0 t/hr
Combustion air ZXV-3059 A-T OPENS
6. FZALL-9306 A-L
pressure
A/B/C
6. LOW LOW 8. Treated Vent Gas shut-off valve to burner
process feed flow XZV-3058 CLOSES
in any pass
APH bypass damper OPEN (XZV-3022) &
APH inlet damper CLOSES (XZV-3011).
HIGH HIGH or occur.
190 deg.C
TZAHH-3107A/B/C LOW LOW flue 1. ESD valve on fuel gas supply to heater
603
TZALL-3107A/B/C gas temperature at CLOSES (XZV-3026)
128 deg.C
APH outlet. 2. ESD valve on fuel gas supply to heater
CLOSES (XZV-3048)
OPEN
CLOSES (XZV-3023)

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Doc. No:
010
-IZ
(XZV-3024)
3044 A-T) CLOSES
ZXV-3059 A-T OPENS
XZV-3058 CLOSES
LOW LOW 1. ESD valve on fuel gas supply to heater
pressure of Fuel CLOSES (XZV-3026)
0.2 kg/cm2g
PZALL-3080A/B/C Gas to Burner 2. ESD valve on fuel gas supply to heater
313
PZAHH 3080 A/B/C HIGH HIGH CLOSES (XZV-3048)
2.45 kg/cm2g
pressure of Fuel 3. Main Fuel Gas bleed valve XZV-3049
Gas to Burner OPEN
1. LOW LOW 1. ESD valve on fuel oil supply to heater
pressure of Fuel Oil CLOSES (XZV-3023)
to Burner. 2. ESD valve on fuel oil return CLOSES
1. PZALL -3084
2. HIGH HIGH 2.4 kg/cm2g (XZV-3024)
A/B/C
pressure of Fuel Oil 3. ESD valve in FO line to Burner ( XZV-
2. PZAHH -3084
314 to Burner. 7 kg/cm2g 3044 A-T) CLOSES
A/B/C
3. LOW LOW
3. PZALL-3095
Differential 1.5 kg/cm2g
A/B/C 4. Oil gun steam purge shut-off valves
pressure across
Atomizing steam ZXV-3059 A-T OPENS
and Fuel oil
WHB CLOSES.
If Flue gas inlet damper CLOSE and bypass

LOW LOW level damper OPEN action does not take place
610 LZALL-3054 of Steam drum 010- 15 % within 30 seconds following effects will occur.
WHB-001.
CLOSES (XZV-3026)
CLOSES (XZV-3048)
OPEN

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Doc. No:
010
-IZ
CLOSES (XZV-3023)
(XZV-3024)
3044 A-T) CLOSES
ZXV-3059 A-T OPENS
XZV-3058 CLOSES
Interlock activation 2. APH Flue Gas bypass damper XZV-3022
612 IZ-0603 & IZ-0610
simultaneously CLOSES
2. Running ID fan STOPS
Failure of one of 3. APH flue gas inlet damper XZV-3011
ML-3028 C the ID fan during CLOSES
613
ML-3029 C WHB/APH bypass 4. APH flue gas bypass damper XZV-3022
condition CLOSES
CLOSES
LOW LOW
temperature of LP
315 TZALL-3081 190 deg.C
steam from
2. ESD valve XZV-3002 on superheated steam
convection section.
to strippers CLOSES.
1. HZS-3001 A CLOSES
(Control Room Emergency Push 3. Pilot Fuel gas shut off valves XZV-3052
601 HWC) button for heater CLOSES
2. HZS-3001 B 010-F-002 4. Pilot Fuel Gas bleed valve XZV-3054
(Field) OPEN
5. Pilot gas to burner shut-off valves XZV-
3045 A-T CLOSES

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Doc. No:
010
-IZ
CLOSES (XZV-3026)
CLOSES (XZV-3048)
OPEN
CLOSES (XZV-3023)
(XZV-3024)
3044 A-T) CLOSES
11. Oil gun steam purge shut-off valves ZXV-
3059 A-T OPENS
XZV-3058 CLOSES
13. Both ID fans (010-K-005 A/B) TRIP
14. Both FD fans (010-K-004 A/B) TRIP

15. AR Pump 010-P-007 A/B/C TRIPS
16. Coil purge steam shutdown valve XZV-
3041 A-L OPENS
17. Recycle Oil pump 010-P-024 A/B TRIPS
CLOSES
Pilot Gas pressure
LOW LOW(5
0.5 kg/cm2g CLOSES
PZALL-3078 A/B/C seconds)
312 3. Pilot Fuel Gas bleed valve XZV-3054
PZAHH-3078 A/B/C HIGH HIGH Pilot
1.5 kg/cm2g OPEN
Gas pressure (5
4. Pilot gas to burner shut-off valves XZV-
seconds)
3045 A-T CLOSES
CLOSES (XZV-3026)
CLOSES (XZV-3048)

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Doc. No:
010
-IZ
OPEN
CLOSES (XZV-3023)
(XZV-3024)
3044 A-T) CLOSES
11. Oil gun steam purge shut-off valves ZXV-
3059 A-T OPENS
XZV-3058 CLOSES
TT-3095(LOW 1. Soot blower drain shutdown valve XZV-
I- Soot Blower
LOW) 3043 OPEN
060 Operation in
2 progress
LOW 3042 CLOSES
I- Soot Blower
LOW) 3064 OPEN
061 Operation in
4 progress
LOW) 3063 CLOSES
615 BZE-3002 A-T Loss of Main flame
3044 A-T) CLOSES
XZV-3059 A-T OPENS
are closed and pilot leak test cleared
1. Pilot gas burner 1. BMS leak test
shut-off valves XZV- permissive 1. Pilot Fuel gas shut off valves XZV-3027
608
3045 A-T 2. Pilot gas header OPEN
2. XL-3006 leak test cleared 2. Pilot Fuel gas shut off valves XZV-3052
OPEN
CLOSES

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Doc. No:
010
-IZ
header leak test
cleared
609 2. XL-3009 to XL- OPEN (XZV-3026)
2. Pilot Flame
scanner ON (atleast
OPEN (XZV-3048)
one)
CLOSES
LOW LOW MP
ESD valve XZV-3035 on BFW to
316 TZALL-3073 steam temperature 280 deg. C
desuperheater CLOSES.
from desuperheater
Stack damper damper PV-3118 OPENS.

Consequence of Consequence of IZ- After 30 Sec of the above effects
604 IZ302,0312,317,(313 302,0312,317,(313
& 314),603,610 & 314),603,610 1. ID fan trip
2. FD fan trips
1. FD fan A tripped
1. ML-3001 AC 2. LOW LOW
(XZV-3001A) discharge CLOSES.
2. FZALL-3072 Combustion Air
A/B/C flow
605
3. ML-3001 BC 3. FD fan B tripped
4. FZALL- 4. LOW LOW
(XZV-3001 B) discharge CLOSES.
3073A/B/C Combustion Air
flow
Consequence of IZ- 1. ESD valve XZV-0008 on discharge line
302,0312,317,(313 from 011-K-0001 A/B CLOSES
& 2. ESD valve XZV-0009 on vent gas to 010-
Consequence of
314),603,610,601 C-009 CLOSES
250 IZ302,0312,317,(313
& 314),603,610,601
Tripping of
Vacuum Charge 3. ESD valve XZV-0010 to CCBD OPEN
heater

Page 352 of 592

Doc. No:
13.4 INSTRUMENT ALARM VALUE

A) FLOW TRANSMITTER
Sr. Operating
Tag No. Service Description UOM Alarm Value
No. Condition
Low-
Normal Low High
Low
010-E-102/202 CRUDE OIL
1 010-FT-1001 Kg/h 1802596 1982856
INLET FLOW
010-E-102 CRUDE OIL INLET
2 010-FT-1002 Kg/h 901298 405584
FLOW
010-E-202 CRUDE OIL INLET
3 010-FT-1003 Kg/h 901298 405584
FLOW
010-P-021A/B VACCUM DIESEL
4 010-FT-1045 Kg/h 299525 134786
OUTLET TO 010-E-202 FLOW
010-P-021A/B VACCUM DIESEL
5 010-FT-1046 Kg/h 299525 134786
010-E-107 WET CRUDE/AGO
6 010-FT-1004 Kg/h 450600 202770
PROD INLET FLOW
010-E-106 WET CRUDE INLET
7 010-FT-1048 Kg/h 540900 243405
FLOW
010-P-102 A/B DESALTER
8 010-FT-1127 kg/h 53528.2 21411
WATER DISCHARGE
010-P-103 A/B/C DESALTER
9 010-FT-1129 kg/h 53528.2 21411
WATER DISCHARGE
010-V-102A HEATED CRUDE
10 010-FZT-1077 Kg/h 987264 394906
INLET FLOW
010-P-102 A/B DESALTER
11 010-FT-1007 Kg/h 85990 34396
WATER DISCHARGE
010-P-001A/B DESALTER
12 010-FT-1008 Kg/h 85900 34360
WATER OUTLET FLOW
13 010-FT-1010 Kg/h 172049 68820
WATER OUTLET FLOW
010-E-131 DESALTED CRUDE
14 010-FT-1011 Kg/h 135700 61065
INLET FLOW
15 010-FT-1051 Kg/h 768904 346007
INLET FLOW
010-E-129 LAGO/HAGO
16 010-FT-1053 Kg/h 185100 74040
PRODUCT INLET FLOW
TRAIN-2 LAGO/HAGO
17 010-FT-1054 Kg/h 185100 74040
PRODUCT INLET FLOW
010-C-001 LOW PRESSURE
18 010-FT-1034B Kg/h 24247 12261
INLET STEAM FLOW

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Doc. No:
Sr. Operating
No. Condition
010-C-001 TPA INLET FROM
19 010-FT-1036 Kg/h 2200000 990000
010-E-104 FLOW
010-P-004A/B/C TPA REFLUX
20 010-FT-1056 Kg/h 462773 208247
OUTLET TO 010-C-001 FLOW
010-P-004A/B/C TPA OUTLET
21 010-FT-1057 Kg/h 1100000 495000
TO TRAIN-2 FLOW
010-P-004A/B/C TPA OUTLET
22 010-FT-1058 Kg/h 1100000 495000
TO 010-E-104 FLOW
010-P-005A/B KEROSENE PA
23 010-FT-1038A Kg/h 315000 141750
OUTLET FLOW
24 010-FT-1038B Kg/h 315000 141750
OUTLET FLOW
010-P-005A/B KEROSENE
25 010-FT-1039A Kg/h 459362 206713
REFLUX OUTLET FLOW
26 010-FT-1039B Kg/h 459362 206713
REFLUX OUTLET FLOW
27 010-FT-1059 Kg/h 157500 70875
OUTLET FLOW
28 010-FT-1060 KERO PA TO TRAIN-2 Kg/h 157500 73575
010-P-006A/B LAGO REFLUX
29 010-FT-1040A Kg/h 187789 84505
010-P-006A/B LAGO REFLUX
30 010-FT-1040B Kg/h 187789 84505
010-C-001 LAGO PA INLET
31 010-FT-1041A Kg/h 792176 356479
FROM 010-E-119/219 FLOW
010-C-001 LAGO PA INLET
32 010-FT-1041B Kg/h 792176 356479
FROM 010-E-119/219 FLOW
010-P-030A/B HAGO REFLUX
33 010-FT-1042A Kg/h 315256 141865
010-P-030A/B HAGO REFLUX
34 010-FT-1042B Kg/h 315256 141865
010-P-030A/B HAGO PA
35 010-FT-1066 OUTLET TO 010-E-123A/B Kg/h 325000 146250
FLOW
010-P-030A/B HAGO PA
36 010-FT-1067 Kg/h 325000 146250
OUTLET TO TRAIN-2 FLOW
010-E-132 HAGO PA TO 010-C-
37 010-FT-1115A Kg/h 650000 292500
001 FLOW
010-E-132 HAGO PA TO 010-C-
38 010-FT-1115B Kg/h 650000 292500
001 FLOW

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Doc. No:
Sr. Operating
No. Condition
010-C-002 LP STEAM INLET
39 010-FT-1020 Kg/h 5100 2295
FLOW
40 010-FT-1021 Kg/h 130000 52000
DISCHARGE FLOW
41 010-FT-1023 Kg/h 4500 2025
FLOW
010-P-009A/B OUTLET LAGO
42 010-FT-1024 Kg/h 320200 144090
PRODUCT TO 010-E-129 FLOW
43 010-FT-1028 Kg/h 670 302
FLOW
010-P-029A/B HAGO PRODUCT
44 010-FT-1029 Kg/h 50020 20000
45 010-FT-1097 010-E-127 OUTLET FLOW Kg/h 338787 135515
010-E-037A SIDECUT NAPTHA
46 010-FT-1091 Kg/h 100000 45000
INLET FLOW
47 010-FT-1504 Kg/h 446094 200742
FLOW
48 010-FT-1548 Kg/h 535491 240971
FLOW
HEATED CRUDE FROM 010-E-
49 010-FZT-1577 Kg/h 987264 394906
208 TO 010-A-201
010-P-202A/B DISCHARGE
50 010-FT-1627 Kg/h 53528.2 21411
FLOW TO VESSEL
010-P-203A/B/C DESALTER
51 010-FT-1507 WATER DISCHARGE FLOW Kg/h 85990 34396
CONTROL
52 010-FT-1508 WATER OUTLET TO 010-E-213 Kg/h 85990 34396
FLOW
010-A-201 DESALTER WATER
53 010-FT-1629 Kg/h 53528.2 21411
TO VESSEL
54 010-FT-1511 Kg/h 135700 61065
INLET FLOW
55 010-FT-1551 Kg/h 768904 346007
INLET FLOW
56 010-FT-1597 010-E-227 OUTLET FLOW Kg/h 338787 135515
010-P-013A/B UNSTABILISED
57 010-FT-2001B Kg/h 250988 112945 329422
NAPTHA DISCHARGE FLOW

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Doc. No:
Sr. Operating
No. Condition
010-C-004 REFLUX INLET
58 010-FT-2002 Kg/h 98346 39338 118015
FLOW
010-E-038 LAGO PA TO 010-E-
59 010-FT-2020 Kg/h 362421 163089
219 FLOW
010-E-038 LAGO PA TO 010-E-
60 010-FT-2021 Kg/h 362421 163089
119 FLOW
010-E-040A/B STABILISED
61 010-FT-2004 NAPHTHA OUTLET TO STOR Kg/h 327437 360181
FLOW
010-E-037A/B/C STABILISED
62 010-FT-2005 Kg/h 327437 360181
NAPHTHA TO NAPHTHA HDT
010-P-015A/B REFLUX OUTLET
63 010-FT-2006 Kg/h 98346 47206
TO 010-C-004 FLOW
64 010-FT-2009 Kg/h 2036 814
FLOW
010-E-043 LAGO PA INLET
65 010-FT-2022 Kg/h 73000 32850
FLOW
010-P-002A SPILLBACK
66 010-FT-2023 Kg/h 9612 3845
010-E-044 SOUR LPG PRODUCT
67 010-FT-2029 Kg/h 19225 8651
TRIM CLR INLET FLOW
010-P-002B DE-ETHANISER
68 010-FT-2030 BOTTOMS PUMP DISCHARGE Kg/h 9612 3845
FLOW
010-P-002C DE-ETHANISER
69 010-FT-2031 BOTTOMS PUMP DISCHARGE Kg/h 9612 3845
FLOW
010-P-018A/B REFLUX OUTLET
70 010-FT-2011 Kg/h 7443 2977
TO 010-V-009
71 010-FT-2012 Kg/h 21934 8774
FLOW
010-E-048 C4 LPG PRODUCT
72 010-FT-2034 Kg/h 16826 6730
COOLER SHELL INLET FLOW
010-P-019A C3 LPG PUMP
73 010-FT-2015 Kg/h 13500 5406
REFLUX FLOW
010-P-019A/B/C C3 LPG
74 010-FT-2016 Kg/h 5103 2041 6379
OUTLET TO STORAGE FLOW
75 010-FT-2037 C3 LPG PUMPS REFLUX FLOW Kg/h 26999 10800
010-P-019B C3 LPG PUMP SPILL
76 010-FT-2038 Kg/h 13500 5406
BACK FLOW

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Doc. No:
Sr. Operating
No. Condition
010-P-019C C3 LPG PUMP SPILL
77 010-FT-2039 Kg/h 13500 5406
BACK FLOW
010-P-016A/B/C NAPTHA
78 010-FT-2007 Kg/h 10024 4008
DISCHARGE FLOW
010-P-016A/B/C NAPTHA
79 010-FT-2008 Kg/h 20048 8015
DISCHARGE FLOW
010-P-016A NAPHTHA
80 010-FT-2032 STABILISER OVHD PUMP Kg/h 10024 4008
DISCH FLOW
010-P-016B NAPHTHA
81 010-FT-2033 STABILISER OVHD PUMP Kg/h 10024 4008
DISCH FLOW
010-P-020A C4 LPG PUMP
82 010-FT-2018 Kg/h 8413 3365
SPILL BACK FLOW
010-P-020B C4 LPG PUMP
83 010-FT-2035 Kg/h 8413 3365
SPILL BACK FLOW
010-P-020C C4 LPG PUMP
84 010-FT-2036 Kg/h 8413 3365
SPILL BACK FLOW
010-C-007 STRIPPING STEAM
85 010-FT-3007B Kg/h 20340 8136
INLET FLOW
010-C-007 VACUUM RESIDUE
86 010-FT-3008A Kg/h 148596 59436
QUENCH INLET FLOW
010-C-007 VACUUM RESIDUE
87 010-FT-3008B Kg/h 148596 59436
QUENCH INLET FLOW
010-P-024A/B RECYCLE OIL
88 010-FT-3012 Kg/h 102223 40889
DISCHARGE FLOW
010-P-024A/B RECYCLE OIL
89 010-FT-3013 Kg/h 102223 40889
DISCHARGE FLOW
010-P-024 A/B RECYCLE OIL
90 010-FT-3064 Kg/h 102223 40889
DICHARGE FLOW
010-STR-004A/B HVGO INLET
91 010-FT-3014A Kg/h 7000000 280000
FLOW
92 010-FT-3014B Kg/h 7000000 280000
FLOW
93 010-FT-3016B Kg/h 235373 94149
FLOW
010-P-023A/B/C HVGO
94 010-FT-3047 Kg/h 987770 395108
DISCHARGE FLOW
010-E-149 BOILER FEED
95 010-FT-3018 Kg/h 3893 1752
WATER INLET FLOW

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Doc. No:
Sr. Operating
No. Condition
010-E-150 BOILER FEED
96 010-FT-3020 Kg/h 2926 1317
WATER INLET FLOW
010-V-014 SOUR WATER INLET
97 010-FT-3024 Kg/h 272 109
FLOW
010-P-028A/B SOUR WATER
98 010-FT-3026 Kg/h 159000 63600
OUTLET TO HOT WELL FLOW
010-STR-001A/B INLET
99 010-FT-3027B Kg/h 540000 216000
VACCUM DIESEL FLOW
010-STR-002A/B VACUUM
100 010-FT-3029B Kg/h 118203 47281
DIESEL INLET FLOW
010-STR-003A/B VGO PA INLET
101 010-FT-3030B Kg/h 1015733 406293
FLOW
010-AC-014 VACUUM DIESEL
102 010-FT-3058 Kg/h 59050 23620
INLET FLOW
010-E-151 VACCUM RESIDUE
103 010-FT-3049 Kg/h 528978 211591
TO DCU FLOW
104 010-FT-3038 010-E-251A WB INLET FLOW Kg/h 5426 2442
105 010-FT-3009 010-E-151A WB INLET FLOW Kg/h 5426 2442
106 010-FT-3039 010-E-251B WB INLET FLOW Kg/h 5426 2442
107 010-FT-3060 010-E-251C WB INLET FLOW Kg/h 5426 2442
010-E-151B BOILER FEED
108 010-FT-3042 Kg/h 5426 2442
WATER INLET FLOW
010-E-151C BOILER FEED
109 010-FT-3061 Kg/h 5426 2442
WATER INLET FLOW
010-EJ-001A/B/C AVU
110 010-FT-3075 Kg/h 70524 56419
BOOSTER STAGE EJECTORS
COOLING WATER SUPPLY TO
111 010-FT-3076 Kg/h 7955200 3977600
010-E-053
COOLING WATER SUPPLY TO
112 010-FZT-3077 Kg/h 7955200 3182080
010-E-053
010-C-010 LEAN AMINE INLET
113 010-FT-4001B Kg/h 15322 9193
FLOW
010-V-016 OFFGAS KNOCKOUT
114 010-FT-4005 Kg/h 2262 2488
DRUM OFFGAS FLOW
010-C-009 LEAN AMINE INLET
115 010-FT-4002B Kg/h 5717 2287
FLOW
010-P-035 A/B DISCHARGE
116 010-FT-6001 Kg/h 7771 6803
FLOW

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Doc. No:
Sr. Operating
No. Condition
010-P-036 A/B DISCHARGE
117 010-FT-6002 Kg/h 8271 6642
FLOW
B) PRESSURE TRANSMITTERS
Sr. Operating
No. Condition
Normal Low-Low Low High
CRUDE OIL FROM
1 010-PT-1118 kg/cm2(g) 30 27 33
STORAGE
010-V-003 DESALTED
2 010-PT-1019 CRUDE INLET kg/cm2(g) 14.5 13
PRESSURE
010-V-003 CRUDE
3 010-PT-1021 OUTLET TO CRUDE kg/cm2(g) 3.8 3 5
COLUMN PRESSURE
010-V-003 DESALTED
4 010-PT-1022 CRUDE INLET kg/cm2(g) 14.5 13
PRESSURE
010-C-001 OVHD
5 010-PT-1041 VAPOUR OUTLET TO kg/cm2(g) 1.2 1 1.4
010-AC-007 PRESSURE
010-C-001 HC
6 010-PT-1087 VAPOURS AT TRAY kg/cm2(g) 1.65 1.9
D5 PRESSURE
010-P-004A/B/C TOP
7 010-PT-1092 PA OUTLET TO 010-E- kg/cm2(g) 9
104 PRESSURE
010-V-005 FUEL GAS
8 010-PT-1072 OUTLET TO FLP/FG kg/cm2(g) 0.47 0.2 1.5
HEADER PRESSURE
010-P-007A
ATMOSPHERIC
9 010-PT-1183 kg/cm2(g) 2.292 2
RESIDUE INLET
PRESSURE
010-P-007B
ATMOSPHERIC
10 010-PT-1184 kg/cm2(g) 2.292 2
RESIDUE INLET
PRESSURE

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Doc. No:
010-P-007C
ATMOSPHERIC
11 010-PT-1185 kg/cm2(g) 2.292 2
RESIDUE INLET
PRESSURE
010-V-006 OUTLET
12 010-PT-2001 kg/cm2(g) 0.5 0.2 1
OFFGAS PRESSURE
010-K-003A OFFGAS
13 010-PT-2004 OUTLET TO 010-AC- kg/cm2(g) 8.1 7.1 9.5
008 PRESSURE
010-K-003B OFF GAS
14 010-PT-2003 kg/cm2(g) 8.1 7.1 9.5
OUTLET PRESSURE
010-V-007 OFFGAS
15 010-PT-2011 kg/cm2(g) 6.4 8
OUTLET PRESSURE
010-C-004 NAPHTHA
16 010-PT-2014 TO 010-AC-009 kg/cm2(g) 10.5 9.4 11.5
PRESSURE
010-V-008 OVHD
17 010-PT-2018 VAPOUR OUTLET TO kg/cm2(g) 9.797 8 11
010-AC-008 PRESSURE
010-C-005 DE-
18 010-PT-2026 ETHANISER OVHD. kg/cm2(g) 15.5 14.5 16.5
OUTLET PRESSURE
010-V-009 OFF
19 010-PT-2065 GAS/FUEL GAS kg/cm2(g) 15.1 16
OUTLET PRESSURE
010-C-006
20 010-PT-2033 DEPROPANISER TO kg/cm2(g) 14.9 14 16
010-E-046 PRESSURE
010-V-010
DEPROPANISER
21 010-PT-2038 kg/cm2(g) 14.3 13 15.5
OVERHEAD
RECEIVER PRESSURE
22 010-PDT-3006 010-C-007 - BED 1 - DP mmHg 2.9 3.5
010-C-007 VACCUM
23 010-PT-3019A OUTLET TO 010-A-001 kg/cm2(g) 15.97 25
PRESSURE
010-C-007 VACCUM
24 010-PT-3019B OUTLET TO 010-A-001 kg/cm2(g) 15.97 25
PRESSURE
010-C-007 VACCUM
25 010-PT-3019C OUTLET TO 010-A-001 kg/cm2(g) 15.97 25
PRESSURE

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26 010-PDT-3038 010-C-007 - BED 3 - DP mmHg 5.7 6

010-C-007 VACUUM
27 010-PDT-3040 mmHg 5.7 6
COLUMN - BED 5 - DP
010-C-007 VACUUM
28 010-PT-3041 COLUMN BOTTOM kg/cm2(g) 40 70
PRESSURE
29 010-PDT-3042 010-C-007 BED 2 - DP mmHg 2.9 3.5
30 010-PDT-3099 010-C-007 - BED 4 - DP mmHg 5.8 6
010-C-007 VACUUM
31 010-PT-3100 COLUMN BOTTOM kg/cm2(g) 40 35 70
PRESSURE
010-C-007 VACUUM
32 010-PT-3102 COLUMN LOWER kg/cm2(g) 40 35 70
PRESSURE
010-STR-004A/B
33 010-PDT-3012 DIFFERENTIAL kg/cm2 0.3 0.7
PRESSURE
010-STR-005A/B
PRESSURE
010-STR-001A/B
PRESSURE
010-STR-002A/B
PRESSURE
010-STR-003A/B
PRESSURE
010-EJ-001B AVU
38 010-PT-3119 BOOSTER STAGE kg/cm2(a) 0.023 0.025
EJECTORS
010-EJ-001C AVU
EJECTORS
010-EJ-001A AVU
40 010-PT-3121 BOOSTER STAGE kg/cm2(g) 0.023 0.025
EJECTORS
010-EJ-001A/B/C AVU
41 010-PT-3129 BOOSTER STAGE kg/cm2(g) 10.967 9.87 12.06
EJECTORS

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010-EJ-001B SM
42 010-PT-3132 kg/cm2(g) 14 12.6
STEAM INLET
010-EJ-001C SM
43 010-PT-3133 kg/cm2(g) 14 12.6
STEAM INLET
010-EJ-001A SM
44 010-PT-3134 kg/cm2(g) 14 12.6
STEAM INLET
010-EJ-002A AVU 1ST
45 010-PT-3122 kg/cm2(a) 0.105 0.116
STAGE EJECTORS
010-EJ-002B AVU 1ST
46 010-PT-3123 kg/cm2(a) 0.105 0.116
STAGE EJECTORS
010-EJ-002C AVU 1ST
47 010-PT-3124 kg/cm2(a) 0.105 0.116
STAGE EJECTORS
010-EJ-003A/B/C AVU
EJECTORS
010-EJ-002A SM
49 010-PT-3138 kg/cm2(g) 14 12.6
STEAM INLET
010-EJ-002B SM
50 010-PT-3139 kg/cm2(g) 14 12.6
STEAM INLET
010-EJ-002C SM
51 010-PT-3140 kg/cm2(g) 14 12.6
STEAM INLET
010-EJ-003A AVU 2ND
52 010-PT-3125 kg/cm2(a) 0.33 0.363
STAGE EJECTORS
010-EJ-003B AVU 2ND
53 010-PT-3126 kg/cm2(a) 0.33 0.363
STAGE EJECTORS
1.1.1 010-EJ-003C
54 010-PT-3127 AVU 2ND STAGE kg/cm2(a) 0.33 0.363
EJECTORS
1.1.2 010-E-055
55 010-PT-3131 SOUR GAS OUTLET kg/cm2(a) 1.24 1.36
FORM EXCHANGER
010-EJ-003A SM
56 010-PT-3135 kg/cm2(g) 14 12.6
STEAM INLET
010-EJ-003B SM
57 010-PT-3136 kg/cm2(g) 14 12.6
STEAM INLET
010-EJ-003C SM
58 010-PT-3137 kg/cm2(g) 14 12.6
STEAM INLET
010-V-016 OFF GAS
59 010-PT-4020 kg/cm2(g) 6 7
PRESSURE
010-V-017 FG OUTLET
60 010-PT-4005 kg/cm2(g) 5.5 6.5
PRESSURE

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010-V-018 AMINE
61 010-PT-4019 BLOW DOWN DRUM kg/cm2(g) 0.5 1
PRESSURE
010-C-009 LOW
62 010-PT-4007 PRESSURE SCRUBBER kg/cm2(g) 0.2 0.1
PRESSURE
010-C-009 LOW
63 010-PDT-4008 PRESSURE SCRUBBER mmHg 7 12
DIFF. PRESSURE
010-C-009 LOW
64 010-PDT-4009 PRESSURE SCRUBBER mmHg 7 12
DIFF. PRESSURE
010-P-035 A/B
65 010-PT-6001 kg/cm2(g) 19.2 17
DISCHARGE
DP ACROSS
66 010-PDT-6001A kg/cm2(g) 0.05 0.07
STRAINER - AGO
DP ACROSS
67 010-PDT-6001B kg/cm2(g) 0.05 0.07
STRAINER - AGO
010-P-036 A/B
68 010-PT-6002 kg/cm2(g) 22.4 20
DISCHARGE PR
DP ACROSS
69 010-PDT-6002A kg/cm2(g) 0.05 0.07
STRAINER - VGO
DP ACROSS
70 010-PDT-6002B kg/cm2(g) 0.05 0.07
STRAINER - VGO
MP STEAM
71 010-PT-9008 DISTRIBUTION kg/cm2(g) 14 12.5 15
PRESSURE
HP STEAM
72 010-PT-9010 DISTRIBUTION kg/cm2(g) 40 39 42
PRESSURE
LP STEAM
73 010-PT-9027 DISTRIBUTION kg/cm2(g) 4 3.5 5
PRESSURE
LP CONDENSATE
74 010-PT-9029 DISTRIBUTION kg/cm2(g) 3.3 2.5 4
PRESSURE
BOILER FEED WATER
75 010-PT-9013 kg/cm2(g) 28 24
HEADER PRESSURE
COOLING WATER
SUPPLY
76 010-PT-9015 kg/cm2(g) 5.5 5
DISTRIBUTION
PRESSURE

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COOLING WATER
SUPPLY
77 010-PT-9058 kg/cm2(g) 5.5 5
DISTRIBUTION
PRESSURE
INSTRUMENT AIR
78 010-PT-9019 DISTRIBUTION kg/cm2(g) 7 5
PRESSURE
PLANT AIR
PRESSURE
NITROGEN
PRESSURE
FUEL GAS
81 010-PT-9023 DISTRIBUTION kg/cm2(g) 3.76 3.5 4.3
PRESSURE
FUEL GAS RETURN
82 010-PT-9059 kg/cm2(g) 5 4.5
HEADER PRESSURE
FUEL OIL SUPPLY
PRESSURE
FUEL OIL RETURN
84 010-PT-9033 DISTRIBUTION kg/cm2(g) 2.5 2
PRESSURE
FLUSHING OIL
SUPPLY
85 010-PT-9035 kg/cm2(g) 5.99 4
DISTRIBUTION
PRESSURE
010-V-610 CRUDE
PREHEAT (TRAIN1)
86 010-PT-9041 kg/cm2(g) 0.5 0.55
CBD DRUM
PRESSURE
010-V-611 CRUDE
PREHEAT (TRAIN2)
87 010-PT-9044 kg/cm2(g) 0.5 0.55
CBD DRUM
PRESSURE
010-V-612 CDU AREA
88 010-PT-9047 CLOSED BLOWDOWN kg/cm2(g) 0.5 0.55
DRUM PRESSURE
010-V-613 VDU AREA
89 010-PT-9050 CLOSED BLOWDOWN kg/cm2(g) 0.5 0.55
DRUM PRESSURE

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010-V-614 NAPHTHA
90 010-PT-9053 STABILISER CBD kg/cm2(g) 0.5 0.55
DRUM PRESSURE
C) LEVEL TRANSMITTERS
Sr. Operating
No. Condition
Low- High-
Normal Low High
Low High
010-V-001 DESALTER
1 010-LZT-1008 WATER SURGE DRUM MM 200
LEVEL
010-V-001 DESALTER
2 010-LT-1007 WATER SURGE DRUM MM - 1310 6840
LEVEL
010-V-003 CRUDE
3 010-LZT-1030 MM - 500
FLASH DRUM LEVEL
010-V-003 CRUDE
4 010-LT-1010A MM 3650 1500 5800
FLASH DRUM LEVEL
010-V-003 CRUDE
5 010-LT-1010B MM 3650 1500 5800
FLASH DRUM LEVEL
010-V-004 FUEL GAS
6 010-LT-1012 MM - 200 1700
KO DRUM LEVEL
010-C-001 CRUDE
7 010-LZT-1036 DISTILLATION MM 900
COLUMN LEVEL
010-C-001 CRUDE
8 010-LT-1038A DISTILLATION MM 950 1910
COLUMN LEVEL
010-C-001 CRUDE
9 010-LT-1038B DISTILLATION MM 950 1910
COLUMN LEVEL
010-C-001 CRUDE
COLUMN LEVEL
010-C-001 CRUDE
COLUMN LEVEL
010-C-001 CRUDE
COLUMN LEVEL

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010-C-001 CRUDE
COLUMN LEVEL
010-C-001 CRUDE
DISTILLATION
14 010-LT-1046A MM 950 1930
COLUMN STAGE D3
LEVEL
010-C-001 CRUDE
DISTILLATION
15 010-LT-1046B MM 950 1930
COLUMN STAGE D3
LEVEL
010-C-001 CRUDE
16 010-LT-1028A DISTILLATION MM 1100 300 1900
COLUMN LEVEL
010-C-001 CRUDE
17 010-LT-1028B DISTILLATION MM 1100 300 1900
COLUMN LEVEL
010-C-001 CRUDE
18 010-LZT-1026 DISTILLATION MM 1100 300 1900
COLUMN LEVEL
010-C-001 CRUDE
COLUMN LEVEL
010-C-001 CRUDE
COLUMN LEVEL
010-C-001 CRUDE
COLUMN LEVEL
010-C-002 KEROSENE
22 010-LZT-1052 MM 300
STRIPPER LEVEL
010-C-002 KEROSENE
23 010-LT-1014A MM 1200 400 2100
STRIPPER LEVEL
010-C-002 KEROSENE
24 010-LT-1014B MM 1200 400 2100
STRIPPER LEVEL
010-C-003 LAGO
25 010-LZT-1054 MM 300
STRIPPER LEVEL
010-C-003 LAGO
26 010-LT-1016A MM 1300 400 2300
STRIPPER LEVEL
010-C-003 LAGO
27 010-LT-1016B MM 1300 400 2300
STRIPPER LEVEL

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010-C-008 HAGO
28 010-LT-1018A MM 1950 400 3600
STRIPPER LEVEL
010-C-008 HAGO
29 010-LZT-1056 MM 300
STRIPPER LEVEL
010-C-008 HAGO
30 010-LT-1018B MM 1950 400 3600
STRIPPER LEVEL
010-V-005 CRUDE
31 010-LT-1022A COLUMN OVERHEAD MM 2150 1300 3000
RECEIVER LEVEL
010-V-005 CRUDE
32 010-LT-1022B COLUMN OVERHEAD MM 2150 1300 3000
RECEIVER LEVEL
010-V-005 CRUDE
33 010-LZT-1020 COLUMN OVERHEAD MM 350
RECEIVER LEVEL
010-V-005 CRUDE
34 010-LZT-1031 COLUMN OVERHEAD MM 300
RECEIVER LEVEL
010-V-005 CRUDE
35 010-LT-1024 COLUMN OVHD MM 1800 600 2700
RECEIVER LEVEL
010-V-006 OFFGAS
COMPRESSOR
36 010-LT-2002A MM 350 1000
SECTION DRUM
LEVEL
010-V-006 OFFGAS
COMPRESSOR
37 010-LT-2002B MM 350 1000
SECTION DRUM
LEVEL
010-V-006 OFFGAS
COMPRESSOR
38 010-LZT-2044 MM 1150
SECTION DRUM
LEVEL
010-V-007
39 010-LZT-2045 RECONTACTOR MM 300
DRUM LEVEL
010-V-007
DRUM LEVEL
010-V-007
41 010-LT-2004A RECONTACTOR MM 1800 600 2700
DRUM LEVEL

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010-V-007
42 010-LT-2004B RECONTACTOR MM 1800 600 2700
DRUM LEVEL
010-V-007
43 010-LT-2006A RECONTACTOR MM 1850 1100 2600
DRUM LEVEL
010-V-007
44 010-LT-2006B RECONTACTOR MM 1850 1100 2600
DRUM LEVEL
010-V-007
DRUM LEVEL
010-C-004 NAPHTHA
46 010-LZT-2032A MM 300
STABILISER LEVEL
010-C-004 NAPHTHA
47 010-LZT-2032B MM 300
STABILISER LEVEL
010-C-004 NAPHTHA
48 010-LZT-2032C MM 300
STABILISER LEVEL
010-C-004 NAPHTHA
49 010-LT-2007A MM 1050 500 1800
STABILISER LEVEL
010-C-004 NAPHTHA
50 010-LT-2007B MM 1050 500 1800
STABILISER LEVEL
010-V-008 NAPTHA
51 010-LT-2011A STABILISER OVHD MM 1900 1100 2700
RECEIVER LEVEL
010-V-008 NAPTHA
52 010-LT-2011B STABILISER OVHD MM 1900 1100 2700
RECEIVER LEVEL
010-V-008 NAPTHA
53 010-LZT-2034A STABILISER OVHD MM 1900 350
RECEIVER LEVEL
010-V-008 NAPTHA
54 010-LZT-2034B STABILISER OVHD MM 1900 350
RECEIVER LEVEL
010-V-008 NAPTHA
55 010-LZT-2034C STABILISER OVHD MM 1900 350
RECEIVER LEVEL
010-V-008 NAPTHA
56 010-LZT-2043 STABILISER OVHD MM 300
RECEIVER LEVEL
010-V-008 SOUR
57 010-LT-2012A MM 775 500 1050
WATER OUTLET TO

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SOUR WTR SEWER

LEVEL
010-V-008 SOUR
WATER OUTLET TO
58 010-LT-2012B MM 775 500 1050
SOUR WTR SEWER
LEVEL
010-C-005 DE-
59 010-LZT-2036A MM 200
ETHANISER LEVEL
010-C-005 DE-
60 010-LZT-2036B MM 200
ETHANISER LEVEL
010-C-005 DE-
61 010-LZT-2036C MM 200
ETHANISER LEVEL
010-C-005 DE-
62 010-LT-2014A MM 1600 400 3000
ETHANISER LEVEL
010-C-005 DE-
63 010-LT-2014B MM 1600 400 3000
ETHANISER LEVEL
010-V-009 DE-
ETHANISER
64 010-LZT-2046 MM 300
OVERHEAD
RECEIVER LEVEL
010-V-009 DE-
ETHANISER
65 010-LT-2016A MM 400 600
OVERHEAD
RECEIVER LEVEL
010-V-009 DE-
ETHANISER
66 010-LT-2016B MM 400 600
OVERHEAD
RECEIVER LEVEL
010-V-009 PROCESS
67 010-LZT-2038 WATER OUTLET MM 300
LEVEL
010-V-009 PROCESS
68 010-LT-2042A WATER OUTLET MM 500 400 600
LEVEL
010-V-009 PROCESS
69 010-LT-2042B WATER OUTLET MM 500 400 600
LEVEL
010-C-006
70 010-LZT-2040A DEPROPANISER MM 300
LEVEL

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010-C-006
71 010-LZT-2040B DEPROPANISER MM 300
LEVEL
010-C-006
72 010-LZT-2040C DEPROPANISER MM 300
LEVEL
010-C-006
73 010-LT-2018A DEPROPANISER MM 750 400 1200
LEVEL
010-C-006
74 010-LT-2018B DEPROPANISER MM 750 400 1200
LEVEL
010-V-010
DEPROPANISER
75 010-LZT-2049A MM 350
OVHD RECEIVER
LEVEL
010-V-010
DEPROPANISER
76 010-LZT-2049B MM 350
OVHD RECEIVER
LEVEL
010-V-010
DEPROPANISER
77 010-LZT-2049C MM 350
OVHD RECEIVER
LEVEL
010-V-010
DEPROPANISER
78 010-LZT-2047 MM 300
OVHD RECEIVER
LEVEL
010-V-010
DEPROPANISER
79 010-LZT-2024A MM 1400
OVHD RECEIVER
LEVEL
010-V-010
DEPROPANISER
80 010-LZT-2024B MM 1400
OVHD RECEIVER
LEVEL
010-V-010
DEPROPANISER
81 010-LZT-2024B MM 1400
OVHD RECEIVER
LEVEL
010-V-010
82 010-LT-2020A MM 800 600 1200
DEPROPANISER

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OVHD RECEIVER
LEVEL
010-V-010
DEPROPANISER
83 010-LT-2020B MM 800 600 1200
OVHD RECEIVER
LEVEL
010-V-010
DEPROPANISER
84 010-LT-2022A MM 750 450 1050
OVERHEAD
RECEIVER LEVEL
010-V-010
DEPROPANISER
85 010-LT-2022B MM 750 450 1050
OVERHEAD
RECEIVER LEVEL
010-V-011 VENT GAS
86 010-LT-3002 KNOCKOUT DRUM MM 400 1000
LEVEL
010-C-007 VACCUM
87 010-LT-3004A MM 730 855
COLUMN TOP LEVEL
010-C-007 VACCUM
88 010-LT-3004B MM 730 855
COLUMN TOP LEVEL
010-C-007 VACUUM
89 010-LT-3006A COLUMN MIDDLE MM 950 1100
LEVEL
010-C-007 VACUUM
90 010-LT-3006B COLUMN MIDDLE MM 950 1100
LEVEL
010-C-007 VACUUM
LEVEL
010-C-007 VACUUM
LEVEL
010-C-007 VACUUM
LEVEL
010-C-007 VACUUM
LEVEL
010-C-007 VACUUM
95 010-LZT-3023 COLUMN LOWER MM 7000 7550
LEVEL

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010-C-007 VACUUM
96 010-LT-3011A COLUMN LOWER MM 750 500 1650
LEVEL
010-C-007 VACUUM
97 010-LT-3011B COLUMN LOWER MM 750 500 1650
LEVEL
010-C-007 VACUUM
98 010-LZT-3025 COLUMN LOWER MM 750 450
LEVEL
010-C-007 VACUUM
99 010-LZT-3031 COLUMN LOWER MM 680
LEVEL
010-C-007 VACUUM
LEVEL
010-C-007 VACUUM
LEVEL
010-C-007 VACUUM
LEVEL
010-C-007 VACUUM
103 010-LT-3039 MM 7000 6750 7300
COLUMN LOW LEVEL
010-E-149 HVGO / MP
104 010-LZT-3052 STEAM GENERATOR MM 850
LEVEL
010-E-149 HVGO / MP
105 010-LT-3015A STEAM GENERATOR MM 650 800
LEVEL
010-E-149 HVGO / MP
106 010-LT-3015B STEAM GENERATOR MM 650 800
LEVEL
010-E-150 HVGO / LP
107 010-LZT-3045 STEAM GENERATOR MM 980
LEVEL
010-E-150 HVGO / LP
108 010-LT-3017A STEAM GENERATOR MM 780 900
LEVEL
010-E-150 HVGO / LP
109 010-LT-3017B STEAM GENERATOR MM 780 900
LEVEL

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010-V-013 HOT WELL

110 010-LT-3020 MM 1100 1700
DRUM LEVEL
010-V-013 HOT WELL
111 010-LT-3018 MM 1500 1350 1700
DRUM LEVEL
010-V-015 HOTWELL
112 010-LT-3022 MM 200 450
OIL COALESCER
010-V-013 HOT WELL
113 010-LZT-3036 MM 1300
DRUM LEVEL
010-V-013 HOT WELL
114 010-LT-3037 MM 1100 350 500 1700 1850
DRUM LEVEL
010-V-015 HOT WELL
115 010-LT-3038 OIL COALESCER MM 200 450
LEVEL
010-V-014 SOUR GAS
116 010-LT-3044 MM 850 400 1700
SEAL DRUM LEVEL
010-E-251A VACUUM
117 010-LZT-3046 RESIDUE / LP STEAM MM 1620 1770
GENERATOR LEVEL
010-E-251A VACUUM
118 010-LT-3027A RESIDUE / LP STEAM MM 1620 1570 1700
GENERATOR LEVEL
010-E-251A VACUUM
119 010-LT-3027B RESIDUE / LP STEAM MM 1620 1570 1700
GENERATOR LEVEL
010-E-151A VACUUM
120 010-LZT-3047 RESIDUE / MP STEAM MM 1620 1770
GENERATOR LEVEL
010-E-151A VACUUM
121 010-LT-3013A RESIDUE / MP STEAM MM 1620 1570 1700
GENERATOR LEVEL
010-E-151A VACUUM
122 010-LT-3013B RESIDUE / MP STEAM MM 1620 1570 1700
GENERATOR LEVEL
010-E-251B VACUUM
GENERATOR LEVEL
010-E-251B VACUUM
GENERATOR LEVEL
010-E-251B VACUUM
GENERATOR LEVEL

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010-E-251C VACUUM
GENERATOR LEVEL
010-E-251C VACUUM
GENERATOR LEVEL
010-E-251C VACUUM
GENERATOR LEVEL
010-E-151B VACUUM
GENERATOR LEVEL
010-E-151B VACUUM
GENERATOR LEVEL
010-E-151B VACUUM
GENERATOR LEVEL
010-E-151C VACUUM
GENERATOR LEVEL
010-E-151C VACUUM
GENERATOR LEVEL
010-E-151C VACUUM
GENERATOR LEVEL
010-V-016 OFFGAS
135 010-LT-4002 KNOCKOUT DRUM MM 350 700
LEVEL
010-C-010 AMINE
136 010-LZT-4010 MM 300
ABSORBER LEVEL
010-C-010 AMINE
137 010-LT-4004A MM 400 1000
ABSORBER LEVEL
010-C-010 AMINE
138 010-LT-4004B MM 400 1000
ABSORBER LEVEL
010-V-018 AMINE
139 010-LT-4005 BLOW DOWN DRUM MM 350 1070
LEVEL
010-V-017 TREATED
140 010-LT-4007 GAS KNOCKOUT MM 350 700
DRUM LEVEL

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010-V-018 AMINE
141 010-LZT-4013 BLOW DOWN DRUM MM 200
LEVEL
010-V-018 AMINE
142 010-LT-4011 BLOW DOWN DRUM MM 350 1070
LEVEL
010-C-009 LOW
143 010-LZT-4012 PRESSURE SCRUBBER MM 750 1130
LEVEL
010-C-009 LOW
144 010-LZT-4014 PRESSURE SCRUBBER MM 300
LEVEL
010-C-009 LOW
145 010-LT-4009A PRESSURE SCRUBBER MM 750 500 1000
LEVEL
010-C-009 LOW
146 010-LT-4009B PRESSURE SCRUBBER MM 750 500 1000
LEVEL
010V-019 AGO SEAL
147 010-LT-6001A FLUID SURGE DRUM MM 300 910 2750
LEVEL
010V-019 AGO SEAL
148 010-LT-6001B MM 300 910 2750
FLUID SURGE DRUM
149 010-LT-6010A 010-V-020 LEVEL MM 840 2450
150 010-LT-6010B 010-V-020 LEVEL MM 840 2450
151 010-LT-9026 CONDENSATE POT MM 450 1050 1300
010-V-301 AVU LP
152 010-LT-9002 FLARE KO DRUM MM 400 1750 3100
LEVEL
010-V-301AVU LP
153 010-LT-9003 FLARE KO DRUM MM 3100
LEVEL
010-V-301 AVU LP
154 010-LZT-9005 FLARE KO DRUM MM 400
LEVEL
010-V-610 CRUDE
155 010-LT-9006 PREHEAT (TRAIN1) MM 1350
CBD DRUM LEVEL
010-V-610 CRUDE
156 010-LZT-9007 PREHEAT (TRAIN1) MM 200
CBD DRUM LEVEL

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010-V-610 CRUDE
157 010-LT-9008 PREHEAT (TRAIN1) MM 350 1350
CBD DRUM LEVEL
010-V-611 CRUDE
158 010-LT-9009 PREHEAT (TRAIN2) MM 1350
CBD DRUM LEVEL
010-V-611 CRUDE
159 010-LZT-9010 PREHEAT (TRAIN2) MM 200
CBD DRUM LEVEL
010-V-611 CRUDE
160 010-LT-9011 HEAT (TRAIN1) CBD MM 350 1350
DRUM LEVEL
010-V-612 CDU AREA
161 010-LT-9012 CLOSED BLOWDOWN MM 450 1350
DRUM LEVEL
010-V-612 CDU AREA
162 010-LZT-9013 CLOSED BLOWDOWN MM 200
DRUM LEVEL
010-V-612 CDU AREA
DRUM LEVEL
010-V-613 VDU AREA
164 010-LT-9015 CLOSED BLOWDOWN MM 1350
DRUM LEVEL
010-V-613 VDU AREA
165 010-LZT-9016 CLOSED BLOWDOWN MM 200
DRUM LEVEL
010-V-613 VDU AREA
DRUM LEVEL
010-V-614 NAPHTHA
167 010-LT-9018 STABILISER CBD MM 1350
DRUM LEVEL
010-V-614 NAPHTHA
168 010-LZT-9019 STABILISER CBD MM 200
DRUM LEVEL
010-V-614 NAPHTHA
169 010-LT-9020 STABILISER CBD MM 350 1350
DRUM LEVEL
010-V-615 ATM
170 010-LT-9022 CONDENSATE FLASH MM 750 1600
DRUM LEVEL

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010-V-615 ATM
171 010-LZT-9023 CONDENSATE FLASH MM 200
DRUM LEVEL
010-V-616
172 010-LT-9025 BLOWDOWN DRUM MM 460 300 620
LEVEL

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CHAPTER – 14
INSPECTION REQUIREMENT & SCHEDULE

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14. CRITICAL EQUIPMENTS
Atmospheric and vacuum unit is a mother unit of the refinery and crude is the feed of this unit.
Crude carries different type of salts long with hydrocarbons. These salts are having very
corrosive in nature in one or another form at different section of this as well as other unit. To
overcome this corrosion problem and remove salts before processing two stages desalting and
Corrosion inhibitors chemicals are dosed.
Ammonia and corrosion inhibitor i.e. Ahuralan is used in the distillation column overhead
circuit before condensation and caustic is dosed before desalting system. Hundred percent salt
removal and manual pH control is very difficult to maintain in the existing system. To
overcome the corrosion /erosion problem, different higher grade metallurgy is used in the
problematic equipments. Size and geometry of the pipeline circuits were also changed in the
11C-01 overhead circuit after air coolers to overcome erosion problem.
Following is the list of critical equipments and pipeline circuits based on the corrosion erosion
problems: -
• 010-F-101 / 102 (Crude Heaters)

• 010-F-002 (Vacuum Heater)
• 010-C-001 (Crude Distillation Column)
• 010-C-007 (Vacuum Distillation Column)
• 010-C-001 CDU Column Overhead Circuit
• 010-C-007 VDU Column Overhead Circuit
• 010-A-001 Vacuum Overhead Cooler
• AS circuit - Crude circuit from 010E-124A/B & 010E-127A/B/C/D/E/F/G/H to 010-F-101.
• AS circuit - RCO circuit 010-C-001 to 010P-007A/B/C TO 010-F-002
• AS circuit - HAGO circuit FROM 010-C-001
• SS circuit - Demulsifier injection line to Desalted crude line ex. 010V102A
• CS circuit - Desalter water injection line to Desalted crude line ex. 010V102A
• SS circuit - Anti-foulant injection line to Desalted crude line ex. 010V102B
• SS circuit - FLO to inlet of 010-E-117(S/S)
• AS circuit -HVGO PA circuit (010C-007 to 010-P-023A/B/C to 010-E-124A (S/S) to 010-
E-149(T/S).
• FLO to inlet line of 010-E-122(S/S)
• FLO to inlet of 010-E-124A(S/S)
• AS Circuit - CBD line outlet of 010-E-124B(S/S)
• FLO to inlet of 010-E-117(S/S)
• AS Circuit - Heated crude circuit (010F-101/201 to 010-C-001)
• SS Circuit - Corrosion inhibitor dosing line to 010-C-001 O/H line
• SS Circuit - Neutralizing amine dosing line to 010-C-001 O/H line
• AS Circuit - HAGO Stripper overhead line (010C-008 to 010-C-001)

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• AS Circuit - HAGO PA line (010C-001 to 010-P-030A/B to 010-E-123A/B(S/S)

• AS Circuit - HAGO Product line (010C-001 to 010-C-008 to 010-P-029A/B to 010-E-
129(S/S)
• SS Circuit - FLO to inlet line of 010-P-007A/B/C.
• SS Circuit - FLO to LAGO Reflux line of 010-C-003.
• SS/AS Circuit - FLO to HAGO Reflux line of 010-C-008.
• AS Circuit - HAGO Reflux line of 010-C-008.
• AS Circuit – Superheated LP Steam line to 010-C-008.
• SS Circuit - FLO to inlet of 010-E-118A/C/E(S/S)
• SS Circuit - FLO to outlet of 010-E-118A/E(S/S)
• AS Circuit – Flashed crude by-pass line from 010-E-127A (T/S) to 010-E-127H (T/S).
• AS Circuit – Flashed crude line Ex. 010-E-127D/H (T/S) to 010-F-101.
• SS Circuit - FLO to inlet of 010-E-208(S/S)
• SS Circuit - Demulsifier injection line to Desalted crude line ex.010-V-202A
• CS Circuit - Desalter water injection line to Desalted crude line ex.010-V-202A.
• SS Circuit - Anti-foulant injection line to Desalted crude line ex.010-V-202B
• AS Circuit – HVGO PA circuit (010C-007 to 010-P-023A/B/C to 010-E-224A (S/S) to
010-E-229(T/S).
• AS Circuit – Flashed crude line Ex. 010-E-224B (T/S) to 010-F-201.
• AS Circuit – Flashed crude line Ex. 010-P-003A/B/C to 010-E-229.
• AS Circuit – Hot HAGO PA line from 010-P-030A/B to 010-E-223A/B(S/S)
• AS Circuit – Preheated Preflashed Crude circuit from 010E-224A/B & 010E-
227A/B/C/D/E/F/G/H to 010-F-201.
• SS Circuit - FLO to inlet of 010-E-218A/C/E(S/S)
• SS Circuit - FLO to VR outlet of 010-E-227A/E(S/S)
• AS Circuit – Flashed crude line Ex. 010-E-227D/H(T/S) to 010-F-201
• SS Circuit - Corrosion inhibitor dosing line to 010-C-004 O/H line
• SS Circuit – Heated Atm. Residue from 010-F-002 to 010-C-002.
• SS Circuit – Recycle Oil Ex. 010-P-024A/B to inlet line of Heated Atm. Residue to 010-F-
002.
14.2 INSPECTION FREQUENCY

Regular Inspection of equipment is the key for keeping its health in good condition. Frequency for
inspection is generally related with the shutdown frequency of the unit. However, the complete Front
End Engineering Design was done based on run length of 05 years for all the Units. Therefore, for
AVU, the run length shall be 05 years. However, as per OISD STD.128, all the new vessels shall be
inspected within 02 years of operation. Thereafter, the periods of future inspection shall be scheduled
on the basis of established corrosion rates, the type of service, remaining corrosion allowance and the

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life expectancy.
The revisioning & testing of safety valves is carried out at site before putting in position. Thereafter,
the same is planned in shutdown only.
14.3 FURNACES
Sl. No. Tag No. Description Frequency of Inspection

1. 010-F-101 Crude Charge Furnace 2 years
2. 010-F-201 Crude Charge Furnace 2 years
3. 010-F-002 Vacuum Furnace 2 years
14.3 COLUMNS
Sl. No. Tag No. Description Frequency of Inspection
1 010-C-001 Crude Distillation Column 2 years
2 010-C-002 Kerosene Stripper 2 years
3 010-C-003 LAGO Stripper 2 years
4 010-C-004 Naphtha Stabiliser 2 years
5 010-C-005 De-ethaniser 2 years
6 010-C-006 Depropaniser 2 years
7 010-C-007 Vacuum Distillation Column 2 years

2 years
8 010-C-008 HAGO Stripper 2 years
9 010-C-009 Low Pressure Scrubber 2 years
10 010-C-010 Amine Absorber 2 years

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14.4 VESSELS
Sl. No. Tag No. Description Frequency of Insp
1 010-V-001 Desalter Water Surge Drum 2 years
2 010-V-003 Crude Flash Drum 2 years

3 010-V-004 Fuel Gas KO Drum 2 years
4 010-V-005 Crude Column OVHD Receiver 2 years
5 010-V-006 Off Gas Comp. Suction Drum 2 years
6 010-V-007 Recontactor Drum 2 years

7 010-V-008 Naphtha Stabiliser OVHD Receiver 2 years
8 010-V-009 De-ethaniser OVHD Receiver 2 years
9 010-V-010 Depropaniser OVHD Receiver 2 years

10 010-V-011 Vent Gas KOD 2 years
11 010-V-013 Hot Well 2 years
12 010-V-014 Sour Gas Seal Drum 2 years
13 010-V-015 Hot Well Oil Coalescer 2 years
14 010-V-016 Off Gas KOD 2 years
15 010-V-017 Treated Gas KOD 2 years
16 010-V-018 Amine Blowdown Drum 2 years
17 010-V-019 AGO Seal Fluid Surge drum 2 years
18 010-V-020 VGO Seal Fluid Surge drum 2 years
19 010-V-301 LP Flare KOD 2 years
20 010-V-610 Crude Preheat Train 1 Closed Drain 2 years

Drum

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Sl. No. Tag No. Description Frequency of Insp
21 010-V-611 Crude Preheat Train 2 Closed Drain 2 years

Drum
22 010-V-612 CDU Area Closed Drain Drum 2 years

23 010-V-613 VDU Area Closed Drain Drum 2 years
24 010-V-614 NSU Area Closed Drain Drum 2 years

25 010-V-615 Atm Condensate Flash Drum 2 years
26 010-V-616 Blowdown Drum 2 years

27 010-V-102 Crude Desalter 2 years
A/B
28 010-V-202 Crude Desalter 2 years
A/B
14.5 EXCHANGERS
Sl. No. Tag No. Service Inspection

Frequency
1 010-E-017 Kerosene Product Trim Cooler 2 years
2 010-E-035 Recontactor Trim Cooler 2 years
3 010-E-036 Naphtha Stabilizer Trim Cooler 2 years
4 010-E-037 Naphtha Stabiliser Feed/Bottoms 2 years

Exchanger
5 010-E-038 Naphtha Stabiliser Reboiler 2 years
6 010-E-040 Stabilised Naphtha Trim Cooler 2 years
7 010-E-042 De-ethaniser OVHD Condenser 2 years

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Frequency
8 010-E-043 De-Ethaniser Reboiler 2 years
9 010-E-044 Sour LPG Trim Cooler 2 years
10 010-E-046 Depropaniser Overhead Condenser 2 years
11 010-E-047 De-Propaniser Reboiler 2 years
12 010-E-048 C4 LPG Product Cooler 2 years
13 010-E-102/E-202 Wet Crude /Vac Diesel Exchanger 2 years
14 010-E-103/E-203 Wet Crude/AGO Product Exchanger 2 years
15 010-E-104/E-204 Wet Crude/TPA Exchanger 2 years
16 010-E-106/E-206 Wet Crude/Kero PA Exchanger 2 years
17 010-E-107/E-207 Wet Crude/AGO Product Exchanger 2 years
18 010-E-108/E-208 Wet Crude/Hot VGO Product 2 years

Exchanger
19 010-E-110 Vacuum Diesel PA Cooler 2 years
20 010-E-113/E-213 Desalter Water Feed/Effluent 2 years

Exchanger
21 010-E-116/E-216 Desalting Water Feed/AGO Product 2 years

Exchanger
22 010-E-117/E-217 Desalted Crude/Vacuum Residue 2 years

Product Exchanger
23 010-E-118/E-218 Desalted Crude/VGO Exchanger 2 years
24 010-E-119/E-219 Desalted Crude/LAGO PA Exchanger 2 years
25 010-E-122/E-222 Flashed crude/VGO Exchanger 2 years
26 010-E-123/E-223 Flashed Crude/HAGO PA Exchanger 2 years
27 010-E-124/E-224 Flashed Crude/HVGO Exchanger 2 years

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Frequency
28 010-E-126/E-226 Flashed Crude/Vacuum Residue 2 years

Product Exchanger
29 010-E-127/E-227 Flashed Crude/Vacuum Residue 2 years

Exchanger
30 010-E-128/E-228 Desalted Crude/AGO Product 2 years

Exchanger
31 010-E-129/E-229 Flashed Crude/AGO Product 2 years

Exchanger
32 010-E-131/E-231 Desalted Crude/Kero PA Exchanger 2 years
33 010-E-132/E-232 Flashed Crude/HAGO PA Exchanger 2 years
34 010-E-149 HVGO/MP Steam Generator 2 years
35 010-E-150 HVGO Product/LP Steam Generator 2 years
36 010-E-151/E-251 Vacuum Residue/LP Steam Generator 2 years

A-C
37 010-E-152/E-252 Desalter Effluent Water Cooler 2 years

A-B
38 010-E-616 Blowdown Cooler 2 years
14.6 AIR FIN COOLERS
Sl. Tag No. Service Frequency of

No. Inspection
1 010-AC-004 Kerosene Product Cooler 2 years
2 010-AC-005 AGO Product Cooler 2 years

3 010-AC-007 Crude Column Overhead Condenser 2 years

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4 010-AC-008 Recontactor Cooler 2 years
5 010-AC-009 Naptha Stabiliser Overhead Condenser 2 years
6 010-AC-010 Stabilised Naptha Cooler 2 years
7 010-AC-014 Vacuum Diesel Product Cooler 2 years
8 010-AC-015 VGO Product Cooler 2 years
9 010-AC-016 Vacuum Diesel PA Air Cooler 2 years
10 010-AC-615 Condensate atm. Flash drum air cooler 2 years
11 010-AC-616 Intermittent Blowdown drum air cooler 2 years
14.8 EJECTORS
Sl. Tag No Description Frequency of

No. Inspection
1. 010-EJ-001A/B/C Booster Ejector 5 years
2. 010-EJ-002A/B/C 1ststage ejector 5 years
3. 010-EJ-003A/B/C 2ndstage ejector 5 years
14.9 WASTE HEAT BOILERS
Sl. Tag. No Description Frequency of

No Inspection
1 WHB-001 Crude Charge Heater Waste Heat Boiler 2 years
2 WHB-002 Vacuum Charge Heater Waste Heat Boiler 2 years

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14.10 MISCELLANEOUS EQUIPMENTS
Sl. Item Number Service

No.
1 APH-001 Flue Gas Air Preheater
2 APH-002 Flue Gas Air Preheater
3 DS-001 MP Steam Desuperheater (CDU)
4 DS-002 MP Steam Desuperheater (VDU)
8 SL-001A/B Crude Charge heater inlet Air filter / Silencer
9 SL-002A/B Vacuum Charge heater inlet Air filter / Silencer
10 SK-001 Crude Charge heater stack
11 SK-002 Vacuum Charge heater stack
12 STR-001A/B Vacuum Diesel PA Strainer
13 STR-002A/B Vacuum Diesel Reflux
14 STR-003A/B VGO PA Strainer
15 STR-004A/B HVGO PA Strainer
16 STR-005A/B Wash Oil Strainer
14.11 SAFETY VALVES
Sl. Frequency of
PSV no.
No Inspection
1 010-PSV-1015 2 years
2 010-PSV-1001 A/B 2 years

3 010-PSV-1002 A/B 2 years
4 010-PSV-1003 2 years
5 010-PSV-1004 A/B/C 2 years

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Sl. Frequency of
PSV no.
No Inspection
6 010-PSV-1005 A/B 2 years
7 010-PSV-1006 A 2 years
8 010-PSV-1006B-H 2 years
9 010-PSV-1007 2 years
10 010-PSV-1017 2 years
11 010-PSV-1018 2 years
12 010-PSV-1019 2 years
13 010-PSV-1016 2 years
14 010-PSV-1008 A/B 2 years
15 010-PSV-1011 A/B 2 years
16 010-PSV-1012 A/B 2 years

17 010-PSV-1512 A/B 2 years
18 010-PSV-1501 A/B 2 years
19 010-PSV-1502 A/B 2 years

20 010-PSV-1503 2 years
21 010-PSV-1511 A/B 2 years
22 010-PSV-2001 A/B 2 years
23 010-PSV-2002 A/B 2 years
24 010-PSV-2003 A/B 2 years
25 010-PSV-2005 A/B 2 years
26 010-PSV-2006 A/B 2 years
27 010-PSV-2007 2 years
28 010-PSV-2008 2 years

Page 388 of 592

Doc. No:
Sl. Frequency of
PSV no.
No Inspection
29 010-PSV-2020 2 years
30 010-PSV-2019 2 years
31 010-PSV-2018 2 years
32 010-PSV-2009 A/B 2 years
33 010-PSV-2010 A/B 2 years

34 010-PSV-2011 2 years
35 010-PSV-2012 2 years
36 010-PSV-2013 A/B 2 years
37 010-PSV-2014 A/B 2 years
38 010-PSV-2015 2 years
39 010-PSV-2024 2 years
40 010-PSV-2023 2 years
41 010-PSV-2022 2 years
42 010-PSV-2016 2 years
43 010-PSV-2017 A/B 2 years
44 010-PSV-2025 2 years
45 010-PSV-3001 2 years
46 010-PSV-3002 A/B 2 years
47 010-PSV-3003 A/B 2 years
48 010-PSV-3011 A/B 2 years
49 010-PSV-3009 A/B 2 years
50 010-PSV-3009 A/B 2 years
51 010-PSV-3010 2 years

Page 389 of 592

Doc. No:
Sl. Frequency of
PSV no.
No Inspection
52 010-PSV-3031 2 years
53 010-PSV-3028 2 years
54 010-PSV-3029 2 years
55 010-PSV-3030 2 years
56 010-PSV-3032 2 years
57 010-PSV-3012/13 2 years
58 010-PSV-3014/15 2 years
59 010-PSV-3020 A/B 2 years
60 010-PSV-3021 A/B 2 years
61 010-PSV-3016/17 2 years
62 010-PSV-3018/19 2 years
63 010-PSV-3024/25 2 years
64 010-PSV-3022/23 2 years
65 010-PSV-4003 2 years
66 010-PSV-4004 2 years
67 010-PSV-4002 2 years
68 010-PSV-4001 2 years
69 010-PSV-4005 2 years
70 010-PSV-4006 2 years
71 010-PSV-4007 2 years
72 010-PSV-4008 2 years
73 010-PSV-4010 2 years
74 010-PSV-9001 A/B 2 years

Page 390 of 592

Doc. No:
Sl. Frequency of
PSV no.
No Inspection
75 010-PSV-9002 A/B 2 years
76 010-PSV-9003 2 years
14.12 PROCESS LINES
Sl. Description Frequency of Insp.

No.
1 Crude Oil Circuit 5 years
2 Transfer Line 5 years
3 010-C-01 Bottom Circuit 5 years

4 HGO Circuit 5 years
5 LGO Circuit 5 years
6 LGO Circulating Reflux Circuit 5 years

7 Kero/ATF 5 years
8 Kero CR Circuit 5 years

9 Heavy Naphtha Circuit 5 years
10 Over Head Naphtha Circuit 5 years
11 Over Head Naphtha Circulating Reflux Circuit 5 years
12 Over Head Heavy Naphtha Reflux 5 years
13 Stabilised Naphtha Circuit 5 years
14 Stabilised Naphtha Circuit 5 years

15 Over Head Naphtha to Stab 5 years
16 LPG Circuit 5 years
17 Fuel Gas Circuit 5 years

Page 391 of 592

Doc. No:
Sl. Description Frequency of Insp.

No.
18 Natural Gas Circuit 5 years
19 Condensate Water Line Circuit 5 years
20 Brine Water Line Circuit 5 years
21 Ammonia Circuit 5 years

Caustic Circuit
Corrosion Inhibitor Circuit
VDU
22 Transfer Line Circuit 5 years
23 RCO Circuit 5 years

24 HVGO Line Circuit 5 years
25 Vacuum Residue Circuit 5 years
26 LVGO Circuit 5 years
27 Vacuum Slop Circuit 5 years
28 LDO Circuit 5 years

29 11C01 O/H Circuit 5 years

Page 392 of 592

Doc. No:
14.13 SPECIAL METALLURGY USED
Atmospheric and Vacuum unit is very prone to corrosion and erosion problem. To avoid these problem
special higher grades metallurgy is used in the following equipments and pipeline circuits.
Sl.No Metallurgy Equipments and pipelines circuits

01 Monel lining 010C-001 & 010C-007 column top portion of shell
Super Duplex
02 Stainless Crude column overhead condenser
steel
5Cr-1/2 Mo Preheated pre-flashed crude circuit, HAGO circuit, etc.
Crude Heater convection and radiation tubes, transfer line,
03 9Cr-1Mo
RCO circuit etc.
Vacuum Heater convection and radiation tubes, pipe lines of

04 9Cr-1Mo Atm. Residue circuit, HVGO circuit, transfer line, VR circuit
etc.
05 SS321 Tube bundles of ejector condenser 12J-1 & 2 A/B/C/D.
Neutralizing Amine dosing, corrosion Inhibitor dosing,

06 SS304L
vacuum diesel PA Return, vacuum diesel reflux, wash oil,
Demulsifier dosing, Anti-foulant dosing, FLO lines, Recycle

07 SS316L
Oil circuit.
12Cr(SS410)
08 010-V-001, 010-V-003, 010-V-004,
internals
010-V-005, 010-V-006, 010-V-007, 010-V-008, 010-V-013,
09 SS316L internals 010-V-014, 010-V-015, 010-V-017, 010-V-018, 010-V-610,
010-V-611, 010-V-612, 010-V-613, 010-V-614, 010-V-301
10 SS316L Lining 010-V-005, 010-V-007, 010-V-008, 010-V-010, 010-V-015
SS316Lvortex
11 010-V-009, 010-V-010
breaker
12 12 Cr (SS410) 010-V-011
13 SS304L Demister 010-V-011

Page 393 of 592

Doc. No:
Sl.No Metallurgy Equipments and pipelines circuits

14 Gunnite Lining 010-V-013
15 SS304L internals 010-V-016
010-STR-001A/B, 010-STR-002A/B, 010-STR-003A/B, 010-

16 SS filter element
STR-004A/B, 010-STR-005A/B,
Super Duplex
17 010-AC-007 (Tube bundle)
Stainless Steel
010-AC-008 (Tube bundle), 010-AC-009 (Tube bundle), 010-

Duplex Stainless
18 E-113 A/B/C (Tube bundle), 010-E-152 (Tube bundle), 010-
Steel
E-213 A/B/C (Tube bundle), 010-E-252 (Tube bundle)
19 12 Cr (SS410) 010-E-123 A/B (Tube bundle), 010-E-149 (Tube bundle)
010-E-123 A/B (Shell), 010-E-124 A/B (Shell), 010-E-127 A-
20 12 Cr (SS410) lining H (Shell), 010-E-223 A/B (Shell), 010-E-224 A/B (Shell),
010-E-227 A-H (Shell),
010-E-124 A/B (Tube bundle), 010-E-127 A-H (Tube bundle),
21 SS304
010-E-227 A-H (Tube bundle), 010-E-224 A/B (Tube bundle)
22 SS316L 010-E-035 (Tube bundle)

Page 394 of 592

Doc. No:
CHAPTER-15
EQUIPMENT HANDING OVER AND TAKING OVER
PROCEDURES

Page 395 of 592

Doc. No:
15.1 PUMPS
a. HANDOVER TO ELECTRICAL
Sl. NOT
ACTIVITY YES REMARK
No REQD.
Inform the DCS panel in charge before carrying out the
1
operation.
2 Stop the motor as per procedure.

De-energize the motor from the substation and De-energized
3
tag to be tied near the ON/OFF switchboard.
De-energization to be checked by respective area JEA and

4 de-energization confirmation to be uploaded in Elockout
system in INTRANET
‘DO NOT OPERATE’ work board is to be displayed near
5
the equipment area.
6 Give clearance to E/M for the job.
b. HANDOVER TO MECHANICAL COLD PUMP

Sl.
ACTIVITY YES NOT REQD. REMARK
No
Inform the DCS panel in charge before carry out the

1
operation.
2 Stop the pump as per standard procedure. Isolate the pumps.
Depressurize and drain the pump and ensure the

3
suction/discharge B/Vs are holding.
4 In case of LPG pump depressurize to flare.
De-energize the motor from the substation and hang de-

5
energize tag on the switch.
De-energization to be checked by respective area JEA and

6 de-energization confirmation to be uploaded in Elockout
system in INTRANET

Page 396 of 592

Doc. No:
Sl.
No
Ensure MEN AT WORK/ DO NOT OPERATE display near

7
the equipment area.
8 Give clearance for blinding and M/M job.
c. HANDOVER TO MECHANICAL HOT PUMP
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
1 Inform the DCS panel in charge before carry out the operation.
2 Stop the pump as per procedure.
3 Isolate the pumps , ensure the warm up line B/V properly closed
4 Isolate the C/W supply, return B/Vs, seal flushing steam etc.
Allow the pump to cool and then only drain the material to CBD,
5
depressurize the pump.
High viscous material service pumps are to be flushed with FLO
6
before draining.
De-energize the motor from the substation and hang de-energize

7
tag on the switch
De-energization to be checked by respective area JEA and de-

8 energization confirmation to be uploaded in Elockout system in
INTRANET
9 Keep a charged cold/hot water hose near the area.
10 Give clearance for blinding and M/M job.

Page 397 of 592

Doc. No:
d. TAKE OVER FROM ELECTRICAL

Sl. NOT
ACTIVITY YES REMARK
NO REQD.
2 Ensure the area cleaning/ housekeeping has been done properly.
If the motor is decoupled, get it coupled by M/M and check the

3
coupling guard in place.
4 Check the free rotation of the shaft.
5 Check physically all the foundation bolts are tightened properly.
6 Check the earthing strip is placed back properly.

Ensure that all LOTO keys are returned back by respective
7
departments
Ensure that all permits issued against the equipment are closed
8
by respective departments
7 Energize the motor from the substation.
8 Remove all the display tags/boards.
9 Start the motor as per normal procedure in presence of E/M

incharge.
10 Check the abnormal sound, vibration etc. If any abnormality

observed inform the S/I immediately.

Page 398 of 592

Doc. No:
e. TAKE OVER FROM MECHANICAL MAINTENANCE COLD PUMPS
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
2 Ensure the house keeping of the area is done properly

In case of seal replacement job, check seal test after de-blinding
3 suction/discharge (open the suction B/V completely) and before
coupling alignment job.
4 Check cooling water flow, flushing steam, seal oil etc.
6 Ensure the coupling guard is placed properly.

The disturbed flanges (de-blinded flanges) to be checked for
7
loose /short/long bolting.
Check the lube oil cup for oil quality and oil level up to the
8
marking.
9 Check the pressure gauges are in position.
Open the casing vent bleeder for air displacement and close it
10
after air removal.

11
departments
12
Energize the motor and start the pump in presence of M/M

13
incharge.
Check physically for any leak, abnormal sound, vibration etc and
14
if any abnormality observed, inform to S/I.

Page 399 of 592

Doc. No:
f. TAKE OVER FROM MECHANICAL MAINTENANCE HOT PUMPS
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
2 Ensure the house keeping of the area done properly
3 De -blind suction/discharge flanges.
Open the casing vent bleeder and open the suction B/V. After
4
displacing the air completely
Close the vent bleeder B/V and put the pump in warm
5
condition by opening the warm up line B/V slowly.
7 Ensure the coupling guard is placed properly.
The disturbed flanges (de-blinded flanges) to be checked for

8 loose /short/long bolting and if any leak observed, attain it
immediately ( Hot bolting)
Check the lube oil cup for oil quality and oil level up to the
9
marking.
10 Check the pressure gauges are in position.

Open the casing vent bleeder for air displacement and close it
11
after air removal.

12
departments
13
Energize the motor and start the pump in presence of M/M

14
incharge.
Check physically for any leak, abnormal sound, vibration etc

15
and if any abnormality observed inform to S/I.

Page 400 of 592

Doc. No:
15.2 EXCHANGERS
a. HANDOVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
1 Inform the panel in charge before carrying out the operation.
2 Gradually open the hot side B/P B/V.
3 Gradually open the cold side B/P B/V.
4 Close the I/L B/V of hot side.
5 Close the I/L B/V of cold side.
6 Isolate O/L B/V of both hot and cold side.
7 Allow the exchanger to cool.
8 De-blind shell & tube sides CBD drain line and HPV bleeders.
After sufficient cooling start the drain of both side slowly to
9
CBD.
High viscous material to be flushed with flushing oil till clear
10
FLO observed in OWS drain line.
11 Open the HPV bleeder to ensure completely draining.
Give clearance for blinding job of S/S, T/S I/L & O/L and also
12
CBD drain line.
13 After blinding job completed, H/O the exchanger to M/M.

Page 401 of 592

Doc. No:
b. TAKE OVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
1 Inform the panel in charge before carrying out the operation.
2 De-blind S/S, T/S I/L & O/L and also CBD drain line.
3 Check for any loose bolting, improper bolting.
4 Check bull plugs, thermo wells, pressure gauge etc.
5 Ensure insulation and earthing connection jobs are completed.
Connect one end of a steam hose at HPV bleeder and the open
6
end to be placed in the nearest OWS channel.
HPV bleeder B/V to be kept open. Charge flushing oil in T/S &
7
S/S of the exchanger slowly to remove air.
Drain the T/S & S/S material to CBD for a few minutes and
8
then after close the CBD drain line B/V.
Once total air found replaced isolate the B/V of vent bleeder
9
and flushing oil B/Vs.
10 Slowly open the O/L B/V of colder side material.
11 Slowly open (a few threads) of I/L B/V of colder side material.
Gradually increase the opening of O/L & I/L B/V of cold side
12 slowly and observe any smoke/ flange leaks (If any arrest it
through hot bolting).
13 Slowly open the O/L B/V of hot side material.
14 Slowly open I/L B/V of hot side (few threads).
Gradually increase the opening of O/L & I/L B/V of hot side
15 slowly and observe any smoke/ flange leaks (if any arrest it
through hot bolting).
16 Slowly close the B/P B/V of cold side.
17 Slowly close the B/P B/V of hot side.

Page 402 of 592

Doc. No:
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
If any smoke/leak noticed, give clearance for hot bolting (avoid
18
hammering during hot bolting).
15.3 AIR COOLERS
a) HANDOVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
1 Inform panel in charge before carrying out the operation.
2 Open the hydrocarbon side B/P B/V slowly.
3 Close the I/L B/V of hydro carbon side.
4 Close the O/L B/V of hydro carbon side.
5 Close the cooling water side I/L & O/L B/V.
6 Drain cooling water from the L.P drain bleeders.
De blind hydro carbon side CBD drains line & slowly drain the
7
material to CBD.
De-blind HPV of both hydro carbon side & cooling water side
8
and open the respective B/V.
Ensure the draining is completed and flush the hydro carbon

9
side with water/steam.
Give the clearance for I/L & O/L nozzles blinding, hand over
10
the equipment to M/M.

Page 403 of 592

Doc. No:
b) TAKE OVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
1 Inform panel in charge before carrying out the operation.
2 Check the area to be cleaned properly.
3 Check for any improper bolting in disturbed flanges.
4 Check the bull plugs, thermo wells, PG are placed properly.
Connect a steam hose at the HPV bleeders and the open end of
5
the steam hose to be placed at the nearest OWS funnel.
6 Ensure both HPV of S/S & T/S are fully open.
7 De blind S/S & T/S inlet and outlet flanges.
Open cooling water I/L B/V slowly and bleed out air
8
completely from its HPV bleeders.
Once the air is totally removed, open the cooling water O/L
9
B/V slowly.
Open the H/C I/L B/V very slowly keeping the HPV B/V full
10
open to bleed out the air.
Once the air is removed completely close the HPV bleeder and
11
open the O/L B/V very slowly.
12 Observe for any leak/smoke.
13 Close the B/P B/V slowly.
14 Inform the panel in charge.
Give clearance for blinding HPV bleeders, S/S, T/S &

15
CBD drain.

Page 404 of 592

Doc. No:
15.4 VESSEL
a) HANDOVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
Empty out vessel material by pumping out entire contents to

1 SLOP tanks/Rundown circuit. Residual H/C & boot water to
be drained to CBD.
2 Isolate all vessel inlet and outlet valves
Depressurize the vessel to flare. Depressurize by opening the

3
PSV bypass valve
4 De-blind vessel steam out line and local vent valve

Cordon off area during steaming and intimate nearby unit
5 personnel that local vent steam will contain traces of HC, H2S
etc
6 Start steaming of vessel initially by opening PSV bypass.

After 3 hours of steaming towards flare, open local vent valve
7 and isolate the PSV bypass valve. Ensure that design
temperature and pressure limits are maintained while steaming.
Periodical removal of condensate from drains to be done to

8
minimize hammering inside the vessels.
9 Continue steaming in local vent for at least 8 hours
Vessel blinding / wedge opening to be done as per master blind

10
list
Once all process/HC/caustic/nitrogen blinds are blinded, start
11
final steaming done for @ 16 Hrs
Hot / cold Water washing to be done (Use DM water if the
12
vessel of SS make or SS clad) if required
13 Drain all residual water

Page 405 of 592

Doc. No:
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
Final blinding to be done as per blind list and cross checked

14
with blind list
Open manhole and check internals for residual sludge. Sludge

15
may contain pyrophoric materials.
Exhaust fan and air hose provided and air circulation is to be
16
established for 16 hours.
Gas test done (H2S, HC and Oxygen) reading noted along with
17
time in presence of F&S.
Man entry clearance given. Man entry register along with
18 manhole watcher to be available during man entry inside
vessel.
b) TAKE OVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
All jobs related to all departments completed and all permits
1
are closed
Vessel internal is clear from debris/scaffoldings/temporary

2
lightings etc.
All nozzles / instrument tappings are clear and thoroughness

3
has been checked
4 Demister pad and vortex breaker are clear and intact
5 Vessel internals are intact
6 Man holes are boxed up
7 De-blind the vessel as per master blind list

Page 406 of 592

Doc. No:
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
8 All instruments are in boxed up condition
9 Confirm no short & long bolting exists in all flanges
Carry out leak check in vessel flanges by pressuring

10 NITROGEN wherever available. In case NITROGEN is
unavailable, connect air hose for pressurization
11 Check all flanges for leak by soap solution
If no leak is observed, start steaming of vessel by opening

12
local vent.
Once full bore steam is observed at vessel top, open PSV

13 bypass and close local vent. Steam the vessel towards flare for
30 minutes.
Backup gas inside vessel by keeping PSV bypass in open

14 condition. Additionally gas back up can be done by opening
FG line if available.
15 All instruments are taken in line.
16 All drain / vent points closed and capped / blinded
15.5 COLUMN
a) HANDOVER
Sl.
NO
Empty out column material by pumping out entire contents to

1 SLOP tanks/Rundown circuit. Residual H/C to be drained to
CBD.
2 Drain column material nearest to first isolation valves
Observe column tray levels. Periodically check in local OWS for

3
complete draining of tray hold up volume.
4 Drain out the column reboiler in case it exists.

Page 407 of 592

Doc. No:
Sl.
NO
5 Column inlet and outlet valves Isolated.
6 De-pressurise the column towards flare by opening PSV bypass.
7 De-blind vent and steam out connection of the Column.
Start steaming and initially steam out the column towards flare
8
by opening PSV bypass.
Stop AFC coolers if any in overhead circuit to prevent

9 condensation of steam. Bypass overhead coolers if any to prevent
steam condensation.
Once steaming towards flare is done for 12 hours, open local
10
steam vent.
11 Drain condensate from all points, trays, pump suction etc.
12 Continue steaming towards local vent for 24 hours.
Column blinding / wedge opening to be done as per master blind

13
list
14 Post blinding, steaming to be done for 24 hours in local vent.

Hot / cold Water washing done (Use DM water if the vessel of
15
SS make or SS clad)
16 Drain all residual water from local drain points
17 Final blinding to be done as per blind list

Open manholes in columns. Observe if any sludge is present
18
inside columns. Sludge may be pyrophoric in nature.
19 Install exhaust fans/ de-humidifiers at manholes
After air circulation for 24 hours, take gas test readings in

20
presence of F&S.
Man entry clearance given id gas test readings are acceptable.

21 Man entry register along with manhole watcher to be available
during man entry inside vessel.

Page 408 of 592

Doc. No:
b) TAKE OVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
Ensure all jobs related to various departments are completed and
1
permits closed
2 Column internals are clear from debris
3 All trays have been fixed properly
4 All tray valves are present and free for movement
5 Downcomer & over flow Weir are in position and as per drawing
All nozzles / instrument tapings are clear and all tapings

6
thoroughness checked
7 Demister pad ,vortex breaker / coke trap are clear and intact
8 Column internals are intact (reflux nozzles, sparger etc)
No debris, scaffolding etc are seen inside the column and all man
9
holes are boxed up
10 De-blind the vessel as per master blind list
11 All instruments are boxed up
12 Confirm no short & long bolting in all flanges/manholes
Carry out leak check in vessel flanges by pressuring NITROGEN

13 wherever available. In case NITROGEN is unavailable, connect
air hose for pressurization
Conduct leak test with soap solution and tighten all flanges
14 wherein leak is observed. Repeat leak test once flange tightening
is completed.
Start steaming of column in local vent. Once steam is observed at

15 local vent, start steaming of column towards flare by opening
PSV bypass.

Page 409 of 592

Doc. No:
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
Stop steaming towards flare after 1 hours of steaming towards
16 flare. Keep flare isolation valve in open position for gas backup.
Alternatively, if FG provision is present open FG for gas backup.
15 Lineup all instruments
16 Blind all column drain and cap all LPD
15.6 FO BURNER
a) HANDOVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
1 Inform panel in charge before isolating the burners.
2 Wear PPE and safety glasses.
3 Close the FO B/V of the respective burner.
4 Close the atomizing steam B/V of the burner

Open the flushing steam B/V and flush the burner thoroughly till
5 all the oil contents in the burner is flushed out (can be observed
through peep hole).
6 Close the flushing steam B/V and H/O the burners to M/M.
b) TAKE OVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
1 Check the area is cleaned properly
Before connection of Fuel oil/atomizing steam line check the

2 thoroughness of both the lines by opening flushing steam and
atomizing steam B/V.
Ensure FO & atomizing steam line are boxed up at appropriate

3
points of the oil gun

Page 410 of 592

Doc. No:
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
(Steam to steam and FO to FO markings).
Open atomizing steam B/V and flushing steam B/V to check any
4
leak from flanges/joints and attain it immediately if any.
5 Close atomizing and flushing steam B/V after leak checking.

Ensure the pilot burner is ‘ON’ before taking the concern burner
6
in line and inform the panel in charge about the operation.
First open the atomizing steam B/V and then charge fuel oil (B/V
7
50% open).
8 Adjust the atomizing steam B/V till the burner gets lighted.
9 Adjust the air register to get a proper flame.

Open the atm. Steam and FO B/V of the burner completely and
10
inform the panel in charge

Page 411 of 592

Doc. No:
15.7 START UP OF COMPRESSOR

a) DCS START PERMISSIVE PAGE (010-K-003A)
TYPE OF TRIP INTERLOCK NO. TAG NO. DESCRIPTION SET POINT PERMISSIVE
PZT 6101 LOW LOW PRESSURE AT 1ST STAGE SUCTION
TZT 6103 HIGH HIGH TEMPERATURE AT 1ST STAGE GAS END-1
IZ 600
PROCESS TZT 6112 HIGH HIGH TEMPERATURE AT 1ST STAGE GAS END-3
TRIP PZT 6108 HIGH HIGH PRESSURE AT 2ND STAGE DISCHARGE
I 2430 PT 6181 CW TO CYLYNDER JACKET PRESSURE LOW
IZ 601 PZT 6138 LOW LOW FRAME OIL HEADER PRESSURE
I 2440 PT 6137 FRAME OIL HEADER PRESSURE LOW
IZ 604 PZT 6142 LUBRICATOR PRESSURE LOW LOW
MHS-6104 EMERGENCY STOP
IZ 607
UA-6160 MOTOR STOP DUE TO PURGE FAILURE
COMMON ML 6109 COMMON TRIP
TRIP ML 6108 MOTOR TRIP ON ELECTRICAL FAULT
I 2460
ML 6110 COMMON ALARM
ML 6106 MOTOR RUNNING
TZAHH 6144 A COMPRESSOR MAIN BEARING TEMP.
MECHNICAL IZ 602 TZAHH 6147 A COMPRESSOR MAIN BEARING TEMP.
TRIP TZAHH 6148 A COMPRESSOR MAIN BEARING TEMP.
IZ 603 VZAHH 6105 COMPRESSOR FRAME VIBRATION
TZAHH 6160 MOTOR WINDING TEMP HIGH HIGH
ELECTRICAL TZAHH 6162 MOTOR WINDING TEMP HIGH HIGH
IZ 606
TRIP TZAHH 6163 MOTOR BEARING TEMP HIGH HIGH
TZAHH 6164 MOTOR BEARING TEMP HIGH HIGH
VZTHH 6107 MAIN MOTOR VIBRATION HIGH HIGH

Page 412 of 592

Doc. No:
b) DCS START PERMISSIVE PAGE (010-K-003A)

TYPE OF TRIP INTERLOCK NO. TAG NO. DESCRIPTION SET POINT PERMISSIVE
PZT 6201 LOW LOW PRESSURE AT 1ST STAGE SUCTION
IZ 610
PROCESS TZT 6212 HIGH HIGH TEMPERATURE AT 1ST STAGE GAS END-3
TRIP PZT 6208 HIGH HIGH PRESSURE AT 2ND STAGE DISCHARGE
I 2430 PT 6181 CW TO CYLYNDER JACKET PRESSURE LOW
IZ 611 PZT 6238 LOW LOW FRAME OIL HEADER PRESSURE
I 2540 PT 6237 FRAME OIL HEADER PRESSURE LOW
IZ 614 PZT 6242 LUBRICATOR PRESSURE LOW LOW
MHS-6204 EMERGENCY STOP
IZ 617
UA-6260 MOTOR STOP DUE TO PURGE FAILURE
COMMON ML 6209 COMMON TRIP
TRIP ML 6208 MOTOR TRIP ON ELECTRICAL FAULT
I 2560
ML 6210 COMMON ALARM
ML 6206 MOTOR RUNNING
MECHNICAL IZ 612 TZAHH 6247 A COMPRESSOR MAIN BEARING TEMP.
TRIP TZAHH 6248 A COMPRESSOR MAIN BEARING TEMP.
IZ 613 VZAHH 6205 COMPRESSOR FRAME VIBRATION
ELECTRICAL TZAHH 6262 MOTOR WINDING TEMP HIGH HIGH
IZ 616
TRIP TZAHH 6263 MOTOR BEARING TEMP HIGH HIGH
TZAHH 6264 MOTOR BEARING TEMP HIGH HIGH
VZTHH 6207 MAIN MOTOR VIBRATION HIGH HIGH

Page 413 of 592

Doc. No:
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
1 Before starting the compressor make sure the system is purged

with nitrogen and leak test done.
2 Displace nitrogen by fuel gas/process gas to LP flare.
3 Ensure nitrogen line is isolated and blinded.
4 Make sure that compressor suction/discharge isolation B/Vs are
opened, discharge circuit lined up to 010-V-007.
5 Make sure that compressor suction/discharge isolation B/Vs are
opened, discharge circuit lined up to 010-V-007.
6 Ensure discharge safety valves are lined up properly.
7 Inform DCS panel in charge before carrying out the operation.
8 An audible alarm will be heard; Acknowledge the alarm, reset
SHUT DOWN/ANNUNCIATOR push button.
9 If all shut down switches are normal (contacts closed), the
COMPRESSOR READY- TO START status is illuminated.
10 Do manual barring of compressor is compressor is started after a
period of long gap/duration.
11 Press COMPRESSOR START push button, The COMPRESSOR
RUNNING status light is illuminated.
12 Select the desired operating capacity with the capacity control
selector switch.
Make sure that compressor is running without any abnormal
13 sound/vibration and achieve design process parameters with
respect to selector switch load capacity.
15.8 STRAINERS
a) TAKEOVER
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
1 Considering the standby strainer is filled with flushing oil during

air removal.
2 De-blind the CBD drain line blind at the second isolation B/V
U/S flange.
3 Crack open the strainer I/L B/V and CBD Drain B/V.

Page 414 of 592

Doc. No:
Sl. NOT
ACTIVITY YES REMARK
NO REQD.
Gradually increase the opening of strainer I/L B/V and CBD

4 drain B/V in view of replacing the cold FLO by the hot reflux/PA
liquid.
5 Once the CBD drain line becomes hot, stop draining to CBD.
6 Keeping the strainer O/L B/V in closed position, make sure there
is no leak from any flanges.
7 Gradually open O/L B/V of the strainer and take the strainer fully
on line.
8 Now close I /L and O/L B/Vs of the strainer to be isolated. Note
differential pressure reading of the strainer taken in line.
9 If required hot bolting can be done for the strainer which is taken
on line. (Smoky flange/drop wise leak)
10 Isolated strainer can be handed over to M/M as per Strainer
handing over procedure.

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Doc. No:
15.10 STEAM EJECTORS

a. TAKEOVER
Sl.NO ACTIVITY YES NOT REMARK
REQD
1. Ensure shell & tube side line up of all ejector condensers.
(Booster stage 010-E-53A-M, First stage 010-E-54 and second
stage 010-E-55.)
2.Make sure of water level in the Barometric vessel, 010-V-013 and
OFF GAS seal drum 010-V-014.
3. Ensure treated OFF gas from knock out drum 010-V-11 to 010-
F-002 is isolated, its 6 inch vent to atmosphere B/V is kept
opened.
4. Keep crack open the low point drain bleeder at the U/S of HIC-
3013(C/V&S/D kept closed).
5. Charge MP Steam by opening main isolation B/V and drain out
header condensate through low point drain.
6. Keep crack open all low point drain bleeders at the D/S of HIC
3013and at the U/S of HVs 3014,HV-3015,HV-3016 of booster
stage ejectors,HV-3020,HV-3021,HV-3022 of first stage ejectors
and HV-3017,HV-3018,HV-3019.
7. Line up any one of the strainer.(keep other one as standby)
8. Initially line up steam entrainment separator drain at the D/S of
the steam trap to open area., After ensuring the function of the
steam trap, route condensate to 010-V-615.(atmospheric
condensate flash drum)
9. Charge steam by gradually opening HIC-3013 and drain out
header condensate completely through all low point drain
bleeders. Once condensate is drained from the header, close all
low point drain bleeders.
10. COMMISSIONING OF SECOND STAGE EJECTORS
11. First open ejector steam by opening HV-3017 of second stage
ejector, 010-EJ-003A and then its vapour I/L B/V. Check
vacuum at the vapour I/L line pressure gauge.
12. Similarly commission the other two second stage ejectors. 010-
EJ-003B/010-EJ-003C by opening the respective steam HVs.
13. COMMISSION FIRST STAGE EJECTORS.
14. Commission first stage all three ejectors on line one by one by
adopting the above procedure.
15. COMMISSIONING OF BOOSTER STAGE EJECTORS

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Doc. No:

REQD
16. Before commissioning booster stage Ejectors take steam C/V on
AUTO mode.
17. First commission steam for lower capacity ejector 010-EJ-001A.
18. Open vacuum column over head gasses vapour I/L butterfly
valve very slowly.
19. Take column top pressure C/V, PIC-3019 on AUTO to maintain
required vacuum.
20. If require, close 010-V-11 vent valve.
21. Start 010-V-013 bottom water/oil pumps.
22. Depends on the vapour load, commission the next higher
capacity booster stage ejector 010-EJ-001B and then 010-EJ-
001C.
23. Verify local instrument readings with DCS.(pressure,
temperature)
15.10 STEAM GENERATORS

a. TAKE OVER
REQD
1. 1 Ensure with I/M all instruments have been fixed, level gauge is
cleaned and all interlocks are checked.
2. 2 Make sure that hydro carbon I/L and O/L B/Vs of the steam
generators are kept closed.
3. 3 De-blind I/L & O/L CBD& OWS drain lines of hydro carbon
coil.(open)
4. 4 De-blind water side drain to OWS.(open)
5. 5 De-blind FLO line first isolation B/V D/S flange. (Open).
6. 6 Open I/L &O/L lines HPV and LPD bleeder caps.
7. 7 Open vent line B/V of steam generator.
8. 8 Open drain line B/V to OWS.
9. 9 Keep open HPV bleeder and charge FLO slowly.

Page 417 of 592

Doc. No:

REQD
10. 1 Drain out condensate, if any, through O/L line LPD bleeder to
0 OWS.
11. 1 Once FLO found coming out, close drain bleeder and continue
1 FLO filling.
12. 1 Check for any hydrocarbon tube leak by opening steam
2 generator’s drain to OWS.
13. 1 Bleed out air through HPV bleeder. When full bore FLO found
3 coming out, isolate FLO B/V and HPV bleeder.
14. 1 Take @ 60% level in the steam generator; Drain out if any dirty
4 water, to OWS.
15. 1 Ensure Steam generator’s main O/L B/V and warm line’s B/V to
5 furnaces are kept closed.
16. 1 During cold circulation FLO can be replaced along with crude.
6
17. 1 If taking steam generator after maintenance( during normal
7 operation), by opening AR/VR I/L B/V to the steam generator
displace FLO slowly to CBD till CBD drain line is warm.
18. 1 Open O/L B/V and slowly close bypass B/V of the steam
8 generator. (AR/VR).
19. 1 Take BFW C/V on Auto.
9
20. 2 When dry steam comes out of the vent line, throttle vent line
0 B/V and pressurise the steam generators.
21. 2 Crack open the O/L B/Vs of the steam generators, drain out line
1 condensate near 010-F-101 main headers of LP/MP steam.
22. 2 Gradually increase steam generators steam O/L B/Vs opening
2 and charge steam to the respective headers MP/LP near 010-
2 F0101.Close steam generators vent line B/V.
23. 2 Start phosphate dosing and adjust dosing rate according to blow
3 down sample laboratory results.

Page 418 of 592

Doc. No:
15.1 WHB & APH

a) TAKEOVER
Sl. ACTIVITY YES NOT REMARK
REQD
NO
1 Ensure all inter locks related to APH is kept bypassed.
2 Ensure power to FD and ID fans.
3 Open low point drain bleeders provided at the bottom of FD and
ID fans and drain out condensate,
4 Make sure that Individual furnaces flue gas dampers are fully
opened, main stack damper is fully opened, WHB &APH is totally
bypassed, FD fans discharge dampers are fully opened, air
dampers to the furnaces are kept opened and FD fans suction
damper is fully closed.
5 Start FD fans 010-K-001A/B one after another, gradually increase
load by opening suction damper as per the requirement of air.
6 Commission steam to steam air pre heater 010-E-030, initially
drain out condensate to OWS, then take steam trap on line and
route condensate to low pressure condensate recovery header.
7 Physically check for vibration, any abnormal sound and amps.
Verify local indications are matching with DCS.
COMMISSIONING OF BFW TO STEAM DRUM AND WASTE
HEAT BOILER
8 Before charging BFW into steam drum and waste heat boiler,
make sure that alkali boil out material is drained completely.
9 Ensure PSV line up.
10 Make sure, MP steam from WHB to furnaces super heating coils is
kept isolated.
11 Ensure steam drum vent line B/V is open, drain line B/Vs of steam
drum and BFW line to WHB kept isolated.
12 Charge BFW into steam drum and build up level @ 50%-60%.
COMMISSIONING OF FLUE GAS TO WHB
13 Open flue gas I/L damper of waste heat boiler and O/L damper
on flue gas APH bypass duct to ID fan suction.(WHB bypass
damper to stack must be kept closed)
14 Open I/L and O/L SOB of the waste heat boiler.
15 Open SOBs on the flue gas duct of the ID fan’s discharge to main
stack.

Page 419 of 592

Doc. No:
16 Drain condensate from ID fans casing drain.

17 When furnace flue gas temperature reaches @ 3800C, Start any
one of the ID fans.
18 Gradually open ID fan’s suction damper and increase load.
19 Similarly take the second ID fan on line.
20 Gradually close main stack damper in steps leaving 25% opening,
observe furnace arch pressure, ID suction pressure, WHB flue gas
I/L and O/L temperature, main Stack flue gas temperature.
21 Open furnace super heating coil O/L vent to atmosphere through
silencer.
22 When dry steam comes out of steam drum vent line, gradually stop
venting, build up pressure and divert steam to furnace super
heating coils after draining line condensate.
23 Take BFW to steam drum on cascade mode to control steam drum
level.
24 Vent out steam till steam temperature at furnace O/L increases @
2500C.
25 Take BFW TIC on line and route MP steam from furnace O/L to
main MP steam header.
26 Start phosphate dosing, adjust dosing rate according to laboratory
blow down sample report.
COMMISSIONING OF APH
27 Open low point drain of air pre heater and drain out condensate, if
any.
28 Open flue gas I/L damper, I/L&O/L SOBs of APH.
29 Watch flue gas temperature and pressure at APH O/L.
30 When flue gas temperature at APH O/L is >1200C, admit air to
APH by opening the SOBs.
31 Reduce the opening of TIC on APH air bypass duct. Close flue gas
APH bypass damper and take TIC in the air bypass line on AUTO
to maintain flue gas EX APH temperature.
32 After ensuring healthy status of indications on PLC take all
interlocks related to APH on line one by one.
33 Verify local pressure, temperature indications are matching with
DCS.
34 Close main stack damper fully and operate furnace on balance
draft mode.

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Doc. No:
15.12 FURNACE START-UP

a) F-101 & F-201
The heater startup sequence is controlled by BMS logic and monitored from the BMS display in the field.
After taking all departmental clearances heater should be visually inspected prior to proceeding with start-
up.
The heater start up sequence is comprised of the following states.
1. Ensure of Shut down condition.
2. Permissive for Idle condition.
3. PG and FG header leak test and Pre-purge
4. Pilot ignition
5. Main burner ignition.
Shut down condition: The heater is considered to be in shut down state when both pilot and main fuel gas
and fuel oil burner headers are shut down. The heaters enter the shutdown state when any of the following
are active.
1. Loss of idle state permissive
2. Heater emergency switches
3. Time out shut down (pilot ignition time exceeded)
Idle Condition: To leave the shutdown state, BMS advances the heater logic to idle state if:
1. The heater shutdowns are clear
2. All the idle state permissive are met
3. MCR operator conforms that all the relevant interlocks are reset to the field operator.
Permissive list for idle condition
 Heater emergency switches are not activated
 Pilot shutdown flag is cleared
 Main shut down flag is cleared
 No pilot/main flames are detected.
 All pilot flame rods and main flame scanners are healthy
 All pilot header B/V closed(limit switches activated for CLOSE position)
 The pilot header bleed valves OPEN.
 The Main fuel gas header B/Vs CLOSED
 The main fuel gas header bleed valves OPEN
 The main fuel oil supply header B/V closed
 The main fuel oil return B/V closed
 The main stack damper 010-PV-1098 OPEN

Page 421 of 592

Doc. No:
When the above permissive are maintained (idle state),the BMS can advance the heater logic to the PRE
PURGE state by pressing 010-HZS-9310 from the MCR for PRMISSION TO START LEAK TEST which
will be indicated by a lamp in the local panel (010-XZL-1003)
LEAK TEST PERMISSIVE CONDITIONS (F-101)
PERMISSIVE
TAG NO. DESCRIPTION
CONDITION
HZS-3000A HEATER EMERGENCY S/D SWI SWITCHE NOT ACTIVATED
XZV-1023 PILOT U/S S/D VALVE OF BLOCK BLEED CLOSE
XZV-1053 PILOT D/S S/D VALVE OF BLOCK BLEED CLOSE
XZV-1054 PILOT S/D VENT VALVE OF BLOCK BLEED OPEN

XZV-1045 A PILOT INDIVIDUAL S/D VALVE OF BURNER -1 CLOSE
XZV-1045 B PILOT INDIVIDUAL S/D VALVE OF BURNER -2 CLOSE
XZV-1045 C PILOT INDIVIDUAL S/D VALVE OF BURNER -3 CLOSE

XZV-1045 D PILOT INDIVIDUAL S/D VALVE OF BURNER -4 CLOSE
XZV-1045 E PILOT INDIVIDUAL S/D VALVE OF BURNER -5 CLOSE
XZV-1045 F PILOT INDIVIDUAL S/D VALVE OF BURNER -6 CLOSE

XZV-1045 G PILOT INDIVIDUAL S/D VALVE OF BURNER -7 CLOSE
XZV-1045 H PILOT INDIVIDUAL S/D VALVE OF BURNER -8 CLOSE
XZV-1045 I PILOT INDIVIDUAL S/D VALVE OF BURNER -9 CLOSE
XZV-1045 J PILOT INDIVIDUAL S/D VALVE OF BURNER -10 CLOSE
XZV-1045 K PILOT INDIVIDUAL S/D VALVE OF BURNER -11 CLOSE
XZV-1045 L PILOT INDIVIDUAL S/D VALVE OF BURNER -12 CLOSE
XZV-1045
PILOT INDIVIDUAL S/D VALVE OF BURNER -13 CLOSE
M
XZV-1045 N PILOT INDIVIDUAL S/D VALVE OF BURNER -14 CLOSE

Page 422 of 592

Doc. No:
XZV-1045 O PILOT INDIVIDUAL S/D VALVE OF BURNER -15 CLOSE
XZV-1045 P PILOT INDIVIDUAL S/D VALVE OF BURNER -16 CLOSE
XZV-1022 MAIN FUEL GAS U/S S/D VALVE OF BLOCK BLEED CLOSE
MAIN FUEL GAS D/S S/D VALVE OF BLOCK

XZV-1049 CLOSE
BLEED
MAIN FUEL GAS S/D VENT VALVE OF BLOCK

XZV-1050 OPEN
BLEED
ALL MANUAL ISOLATION VALVE OF INDIVIDUAL

MANUAL CLOSE
BURNNER
XZV-1024 FUEL OIL SUPPLY S/D VALVE CLOSE
XZV-1026 FUEL OIL RETURN S/D VALVE CLOSE
ALL PILOT FLAME DETECTION NOT DETECTED
ALL MAIN FLAME DETECTION NOT DETECTED
PV-1098 MAIN STACK DAMPER OPEN
PV-1035 STACK DAMPER OF F-101 OPEN

MINIMUM PASS FLOW FOR ALL THE PASS ARE
DETECTED
ESTABLISHED
IF THE ABOVE CONDITIONS SATISFIED THEN PRESS HZS 9310 PERMISSION FOR LEAK
TEST
PERMISSIVE
TAG NO. DESCRIPTION
CONDITION
HZS-3000B HEATER EMERGENCY S/D SWI SWITCHE NOT ACTIVATED


Page 423 of 592

Doc. No:

XZV-1545
PILOT INDIVIDUAL S/D VALVE OF BURNER -13 CLOSE
M
MAIN FUEL GAS D/S S/D VALVE OF BLOCK

XZV-1549 CLOSE
BLEED

XZV-1550 OPEN
BLEED

MANUAL CLOSE
BURNNER

Page 424 of 592

Doc. No:
PV-1535 STACK DAMPER OF F-201 OPEN

DETECTED
ESTABLISHED
IF THE ABOVE CONDITIONS SATISFIED THEN PRESS HZS 9324 PERMISSION FOR LEAK
TEST
LEAK TEST FOR PILOT AND MAIN FUEL GAS
 Leak test shall be carried out with Nitrogen gas.

 Press 010-HZS-1801and 010-HZS-1901 on the local panel to start PILOT LEAK test
 S/D valves on the nitrogen line 010-XZV-1055 will open.
 A lamp on the local panel indicates PILOT LEAK TEST IN PROGRESS.
 If the downstream pressure fails to reach the upper set point 0.95Kg/Cm2 within the pressurization
period(2 mins &adjustable)the BMS switches the leak test S/D valves to the closed position, PILOT
LEAK TEST FAILED indication lamp illuminates on the local panel and the TEST IN PROGRESS
lamp on the local panel goes OFF.
 If the upper test pressure is reached within the pressurization period the BMS switches the leak test
nitrogen S/D valves (XZV-1055/1555) to the closed position, the test in progress lamp remains ON
and depressurization timer starts.
 If the downstream pressure falls below the lower set point 0.55Kg/cm2 during the depressurization
period BURNER LEAK TEST FAILED lamp illuminates on the local panel and the TEST IN
PROGRESS lamp goes off.
 IF the pressure holds above the lower set point during depressurization period the test has been
successful then the TEST IN PROGRESS lamp goes off and PILOT LEAK TEST CLEAR lamp
illuminates on the local panel.
MAIN FUEL GAS HEADER LEAK TEST
 Press 010-HZS-1083 and (010-HZS-1093 forCCH2) on the local panel to start main FG leak test.

Page 425 of 592

Doc. No:
 The BMS switches nitrogen S/D valves XZV-1047 (XZV-1547 for CCH2) to the open position for
a limited period.
 A lamp on the local panel indicates BURNER LEAK TEST IN PROGRESS.
 If the downstream pressure fails to reach the upper set point 1.85Kg/cm2 within the pressurization
period(5minutes and adjustable) the BMS switches the nitrogen S/D valves to closed
position.(XZV-1047/1547).
 BURNER LEAK TEST FAILED lamp on the local panel illuminates and the TEST IN PROGRESS
indication lamp goes off.
 If the upper test pressure is reached within the pressurization period the BMS switches the nitrogen
S/D valves to closed position, the TEST IN PROGRESS lamp remains ON and the depressurization
timer starts.
 If the downstream pressure falls below the lower set point 0.35 Kg/cm2 during the depressurization
period (5mins and adjustable) BURNER LEAK TEST FAILED lamp illuminates on the local panel
and TEST IN PROGRESS lamp goes off.
 If the pressure holds above the lower set point during the depressurisation period the test has been
successful, the TEST IN PROGRESS lamp goes off and BURNER LEAK TEST CLEAR lamp
PRE PURGE
 Once pilot and main fuel gas header leak test is successfully completed the pre purge of furnace
box is carried out by running the FD fans 010-K-001A/B.
 Confirm the fire box chamber is free from any combustible gases by collecting flue gas samples if
require continue purging till the glue gas sample found free of combustible gases.
PILOT BURNER IGNITION
 Press push button HZS-1802&HZS-1092 for CCH2 on the local panel to open pilot block valves.
A lamp on the local panel indicates PILOT BLOCK VALVES OPEN (010-XZL-1007&1007 for
10-F-201).
 Insert the igniter and initiate spark, simultaneously open the PG S/D valves of the pilot gas line by
pressing PILOT#1 on the local panel.
 BMS allows opening the pilot isolation S/D valves in open position for 10 seconds. If the flame
detector senses the flame, the B/Vs will remains open otherwise it closes the S/D valves.
 The lamps on the local panel indicate flame status PILOT# 1ON or PILOT#1 OFF.
 Similarly light up other pilot burners.
MAIN BURNER IGNITION (FUEL GAS)

Page 426 of 592

Doc. No:
 Before opening fuel gas header S/D valves ensure that all individual burners’ isolation BVs are
kept fully closed.
 Press push button (010-HZS-1804&1904 for CCH2) on the local panel to OPEN FUEL GAS S/D
valves (XZV-1022/1049/1050 and XZV-1522/1549/1550).
 A lamp on the local panel indicates FUEL GAS B/V OPEN.
 Now the fuel gas burners can be lighted manually by opening 010-PV-1166(PV-1666 for 10-F-
201) and local isolation B/V at the firing platform.
 Once stable flame is observed the other burners can be taken on as per the requirement.
FUEL OIL BURNERS
 Ensure ALL individual burners fuel oil and atomizing steam isolation B/Vs are kept fully closed
near the firing platform.
 Establish Fuel oil circulation through the fuel oil header by opening the shutdown vales on the FO
supply and return header and Fuel oil control valve.(XZV-1024&1026 for CCH1 and XZV-1524
&1526 for 10-F-201) (PIC-1161&1561)
 Open PDIC-1162 &1562, atomizing steam to burners and put the PDIC on Auto at 2.1 Kg/cm2
differential pressure.
 Open individual FO/ATM steam valves (010-XZV-1046/1057 A-P for CCH1 and XZV-1546/1557
for 10-F-201 using push buttons in the local panel.(010-HZS-9302 A-P for CCH1 and XZS- 9332
A-P for 10-F-201).
 First open atomizing steam to the individual burner, slowly open fuel oil isolation B/V till the
burner catches flame.
 Adjust the burners B/V opening, PDIC and primary air to get a proper flame.

Page 427 of 592

Doc. No:

Page 428 of 592

Doc. No:
b) VACUUM HEATER (010-F-002)

The heater startup sequence is controlled by BMS logic and monitored from the BMS display in the
field. After taking all departmental clearances heater should be visually inspected prior to proceeding
with start-up.
The heater start up sequence is comprised of the following states.
1. Ensuring Shut down condition
2. Permissive for Idle condition
3. PG and FG header leak test and Pre-purge
4. Pilot ignition
5. Main burner ignition.
Shut down condition: The heater is considered to be in shut down state when both pilot and main fuel
gas and fuel oil burner headers are shut down. The heaters enter the shutdown state when any of the
following are active.
1. Loss of idle state permissive
2. Heater emergency switches
3. Time out shut down (pilot ignition time exceeded)
IDLE CONDITION: To leave the shutdown state, BMS advances the heater logic to idle state if:
1. The heater shutdowns are clear
2. All the idle state permissive are met
3. MCR operator conforms that all the relevant interlocks are reset to the field operator.
Permissive list for idle condition

 Heater emergency switches are not activated
 Pilot shutdown flag is cleared
 Main shut down flag is cleared
 No pilot/main flames are detected.
 All pilot flame rods and main flame scanners are healthy
 All pilot header B/V closed(limit switches activated for CLOSE position)
 The pilot header bleed valves OPEN.
 The Main fuel gas header B/Vs CLOSED
 The main fuel gas header bleed valves OPEN
 The main fuel oil supply header B/V closed
 The main fuel oil return B/V closed
 The main stack damper 010-PV-3118.

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When the above permissive are maintained (idle state),the BMS can advance the heater logic to the
PRE PURGE state by pressing 010-HZS-9341 from the MCR (ESD Panel) for PRMISSION TO
START LEAK TEST which will be indicated by a lamp in the local panel (010-XZL-3003)
PERMISSIVE
TAG NO. DESCRIPTION CONDITION
HZS-3001A HEATER EMERGENCY S/D SWI SWITCH NOT ACTIVATED



XZV-3045 M PILOT INDIVIDUAL S/D VALVE OF BURNER -13 CLOSE


Page 430 of 592

Doc. No:
XZV-3045 Q PILOT INDIVIDUAL S/D VALVE OF BURNER -17 CLOSE
XZV-3045 R PILOT INDIVIDUAL S/D VALVE OF BURNER -18 CLOSE
XZV-3045 S PILOT INDIVIDUAL S/D VALVE OF BURNER -19 CLOSE
XZV-3045 T PILOT INDIVIDUAL S/D VALVE OF BURNER -20 CLOSE
XZV-3048 MAIN FUEL GAS D/S S/D VALVE OF BLOCK BLEED CLOSE
XZV-3049 BLEED OPEN
MANUAL BURNNER CLOSE

ESTABLISHED DETECTED
IF THE ABOVE CONDITIONS SATISFIED THEN PRESS HZS 9341 PERMISSION FOR LEAK TEST

Page 431 of 592

Doc. No:
LEAK TEST FOR PILOT AND MAIN FUEL GAS
 Leak test shall be carried out with Nitrogen gas.

 Press start permissive leak test button 010-HZS-3101 from Local panel to start leak test.
 Now XZV-3057 (nitrogen S/D valve) will open and pressurization of pilot gas header will start.
 Illumination of 010-XL-3004 lamp on the local panel indicates PILOT LEAK TEST IN
PROGRESS.
 If the downstream pressure fails to reach the upper set point 0.95Kg/Cm2 within the pressurization
period(2 mins & adjustable)the BMS switches the leak test nitrogen B/Vs to the closed position,
PILOT LEAK TEST FAILED ( 010-XL-3005) indication lamp illuminates on the local panel and
the TEST IN PROGRESS lamp on the local panel goes OFF.
S/D valve (XZV-3057) to the closed position, the test in progress lamp remains ON and
depressurization timer starts.
 If the downstream pressure falls below the lower set point 0.55Kg/cm2 during the depressurization
period BURNER LEAK TEST FAILED lamp illuminates on the local panel and the TEST IN
PROGRESS lamp goes off.
 IF the pressure holds above the lower set point during depressurization period the test has been
successful then the TEST IN PROGRESS lamp goes off and PILOT LEAK TEST CLEAR lamp
MAIN FUEL GAS HEADER LEAK TEST
 Press 010-HZS-3103 on the local panel to start main FG leak test.

 The BMS switches nitrogen S/D valves XZV-3047 to the open position for a limited period.
 A lamp on the local panel indicates BURNER LEAK TEST IN PROGRESS.
 If the downstream pressure fails to reach the upper set point 1.85Kg/cm2 within the pressurization
period (5minutes and adjustable) the BMS switches the nitrogen valve to closed position. (XZV-
3047).
 BURNER LEAK TEST FAILED lamp on the local panel illuminates and the TEST IN PROGRESS
indication lamp goes off.
valves to closed position, the TEST IN PROGRESS lamp remains ON and the depressurization
timer starts.
 If the downstream pressure falls below the lower set point 0.35 Kg/cm2 during the depressurization
period (5mins and adjustable) BURNER LEAK TEST FAILED lamp illuminates on the local panel
and TEST IN PROGRESS lamp goes off.

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 If the pressure holds above the lower set point during the depressurization period the test has been
successful, the TEST IN PROGRESS lamp goes off and BURNER LEAK TEST CLEAR lamp
PRE PURGE
 Once pilot and main fuel gas header leak test is successfully completed the pre purge of furnace
box is carried out by running the FD fans 010-K-004 A/B.
 Confirm the fire box chamber is free from any combustible gases by analyzing oxygen content in
flue gas samples; if require continue purging till the glue gas sample found free of combustible
gases.
PILOT BURNER IGNITION
 Press push button HZS-3102 to open pilot S/D valves. A lamp on the local panel indicates PILOT
BLOCK VALVES OPEN (010-XZL-3007).
 Insert the igniter and initiate spark, simultaneously open the first isolation B/V of the pilot gas line
by pressing PILOT#1 on the local panel.
 BMS allows opening the pilot Gas S/D valves in open position for 10 seconds. If the flame detector
senses the flame, the valve will remains open otherwise it will closes the valve.
 The lamps on the local panel indicate flame status PILOT# 1ON or PILOT#1 OFF.
 Similarly light up other pilot burners.
MAIN BURNER IGNITION (FUEL GAS)
 Before opening fuel gas header (after light up of at least one pilot burner) S/D valves ensure that
all individual burners’ isolation BVs are kept fully closed.
 Press push button 010-HZS-3104 on the local panel to OPEN FUEL GAS S/D valves (XZV-
3026/3048).
 A lamp on the local panel indicates FUEL GAS B/V OPEN.
 Now the fuel gas burners can be lighted manually by opening 010-PIC-3079 and local isolation
B/V at the firing platform.
 Once stable flame is observed the other burners can be taken on as per the requirement.
FUEL OIL BURNERS
 Ensure ALL individual burners fuel oil and atomizing steam isolation B/Vs are kept fully closed
near the firing platform.

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 Establish Fuel oil circulation through the fuel oil header by opening the shutdown vales on the FO
supply and return header and Fuel oil control valve.(XZV-3023&XZV-3024) .
 Open PDIC-3085, atomizing steam to burners and put the PDIC on Auto at 2.1 Kg/cm2 differential
pressure.
 Open individual FO/ATM steam valves (010-XZV-3044/3045 A-T) using push buttons in the local
panel.(010-HZS-9333 A-T)
 First open atomizing steam to the individual burner, slowly open fuel oil isolation B/V till the
burner catches flame.
 Adjust the burners B/V opening, PDIC and primary air to get a proper flame.
For OEM manual on CDU (010-F-101/201) and VDU heater (010-F-002), refer to annexures at the end of
the manual.

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CHAPTER-16
DCS, PLC, ADVANCE PROCESS CONTROL, CCTV &
ONLINE ANALYSERS

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16.1 GENERIC FUNCTIONAL DESIGN SPECIFICATIONS FOR INTEGRATED

CONTROL SYSTEM: DCS
1.0 PURPOSE
The Intent of this document is to define the standard Honeywell Experion PKS DCS hardware and
software requirements and all standard/common software application for the DCS system for 15
MMTPA Paradip Refinery.
2.0 HARDWARE
This section provide brief description about various DCS hardware components like C300 controllers,
various IO modules, FTA’s, Honeywell patented FTE Network etc.
2.2 SERIES C HARDWARE

DCS Controller is Series-C C300 controller. Series C hardware uses a common form factor where all
modules mount on input output termination assemblies (IOTAs). These IOTAs are mounted on a
common carrier assembly.
2.4 C300 CONTROLLER

C300 Controller employs an Input Output Termination Assembly (IOTA) and an electronics module
which mounts and connects to the IOTA.

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2.4 DCS INPUT OUTPUT MODULES

DCS Input / Output modules are C-Series AI/AO and PMIO DI/DO modules. All AI / AO / DI / DO
modules are in redundant configuration. Exception is System alarm related IOM, wherein if a
dedicated module is reserved for System alarm, the same will be configured in non-redundant
configuration. Series C I/O modules are similar in construction to that of C300 controller, Series I/O
are used for all analog input / output related signals. Series C I/O’s communicate with the C300
Controller through one of the IOLINK’s out of two available links in C300 controller.
2.4 PMIO
Honeywell Process Manager I/O provides robust and compact I/O Configuration for Critical Process
applications. The Process Manager Input / Output sub system (PMIO) offers highly flexible functions
for both data monitoring and control. All DCS DI / DO are PMIO type IO modules. The PMIO modules
are placed in a 15 Slot PMIO Rack and these I/O’s communicates with the Controller through
IOLINK’s in C300 controller.
2.5 NETWORKING
2.5.1 NETWORK STRUCTURE
The Paradip Refinery project Network mainly consists of 4 Levels. The highest level is the existing
Business Information Network and is the un-trusted network. The BIN contains few nodes that require
communication with lower level networks.
2.5.2 PLANT NETWORK LEVELS
The following table briefly describes these levels:
2.5.3 FAULT TOLERANT ETHERNET (FTE)

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Fault Tolerant Ethernet (FTE) is dedicated to the process control functionality - providing not only
fault tolerance, but fast response, determinism, and the security required for industrial control
applications. Fault Tolerant Ethernet (FTE) is a single network topology with redundancy. The FTE
driver and the FTE-enabled components allow network communication to occur over an alternate route
when the primary route fails. Each FTE node is connected twice to a single LAN through the Network
Interface Card (NIC) as shown in the following figure.
3.0 SOFTWARE
Intent of this section is to provide brief description about DCS software “Experion Process knowledge
system (EPKS) Release R400” and its engineering components like configuration studio, control
builder, and quick builder etc.
3.1 EXPERION PKS SYSTEM INTRODUCTION
Experion PKS is an open control system that expands the role of distributed control. Experion PKS is
a powerful, open Microsoft window Server 2008 based system.
Experion PKS features include sophisticated human-machine interface. Honeywell HMI Web
Technology provides an advanced user interface HMI capabilities based on an open industry standard
HTML file format and Web Browser Access, Tightly integrated databases, engineering tools, and
control applications. An open, deterministic, high-speed control network communications system for
predictable and repeatable control linking servers, controllers, and remote I/Os. A single
controller/control platform for regulatory, sequential, and fast logic control, Redundancy support for
controllers, Control firewall, IO modules, C-FIM, servers, networks, Distributed System Architecture
(DSA) that integrates multiple servers into a single operational system, Support for interfaces to wide
variety of third-party controllers and protocols.
3.2 DISTRIBUTED SYSTEM ARCHITECTURE (DSA)
The Distributed System Architecture (DSA) option enables integration of multiple Experion servers
into a single operational system.
3.3 ASSET SEGREGATION (AREA CLASSIFICATION)
The operator’s view of the process as a whole is divided into Areas/Assets corresponding to process
sub-system or entire sections of the plant. Each Area/Asset will contain a set of tags. An area is a
relatively small portion of the process which is a logical grouping of tags related to a particular section
of the plant. The section of the plant may be process based or location based.

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3.4 EXPERION PKS DCS SOFTWARE COMPONENTS:
The Experion PKS software package comprises of software modules as described in this section.
(These software tools are basically Software engineering modules, specifically used for DCS logic
building by using Control Builder application and DCS 3rd party SCADA Tag building by using Quick
builder application.
3.4.1 CONFIGURATION STUDIO:
Configuration Studio provides a central location from which user can configure Experion PKS system.
The individual tools required to configure parts of the system are launched from Configuration Studio.
3.4.2 CONTROL BUILDER
Control Builder is a graphical object-oriented development software package, supporting Experion

C300 Controller system design, documentation and monitoring. It provides a comprehensive set of
tools for handling I/Os, continuous logic, motor, sequential, batch and advanced control functions
through a library of Function Blocks (FBs). FBs are basic objects provided by Honeywell to execute
different control functions. Each block supports parameters that provide an external view of what the
block is doing. FBs interconnect via “soft wires” to construct control applications or strategies.
Function Blocks are grouped together and contained in Control Modules (CMs) and in the case of
sequential FBs; Sequential Control Modules (SCMs) are present. SCMs greatly simplify batch logic
implementation by sequencing a group of process equipment through a series of distinct steps to
accomplish one or more process tasks. CMs and SCMs act as “containers” for Function Blocks. This
is a tool for creating, organizing, and checking out control strategies.
3.4.3 QUICK BUILDER:
Quick Builder is used for configuring Stations, printers, controllers other than the Experion PKS
Hybrid Controller, and points (SCADA tags) on those controllers. It is a graphical tool for defining the
hardware items and points in the system.
3.4.4 HMI WEB DISPLAY BUILDER:
HMI Web Display Builder is a specialized drawing application that enables user to create its own
(custom) displays for Station. Custom displays allow user to present information in a sophisticated and
user-friendly manner — well-designed custom displays make it easier for operators to visualize
complex processes, and reduce the probability of operator errors.
4.0 SYSTEM INTERFACE DETAILS

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Experion PKS is provided with a very powerful and robust supervisory control infrastructure which
supports a huge variety of drivers and interface types to integrate the system with third party devices.
On the project there will be a number of 3rd party vendor systems that will be required to interface
with the Honeywell Experion PKS system via communication links. These communication link
interfaces will be provided by either a MODBUS or OPC interface. The MODBUS links will be either
MODBUS ‘RTU over Ethernet’ or MODBUS ‘TCP’. (Default Case Modbus RTU will be preferred
communication link)
5.0 SYSTEM SIZING
The Experion Process Knowledge System (PKS) is Honeywell’s unified control system for process,
business, and asset management that helps industrial manufacturers increase their profitability and
productivity. Experion takes customers well beyond distributed control system (DCS) functionality
with an advanced automation platform solution and innovative application integration to improve
business performance and peace of mind.

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6.0 APPLICATION CONFIGURATION
6.1 GENERAL
This section mainly covers IO Assignment philosophies, DCS FBD methodology - Typical database
hierarchy sample Function blocks details, naming philosophy for DCS TAGS, Typical loop details
(Open Loop, Close Loop – Simple, Simple cascaded, Split range, close Loop with Interlock etc)
Sequence Implementation etc.
6.2 IO ASSIGNMENT PHILOSOPHY
6.3 DCS FBD METHODOLOGY
6.4 FUNCTION BLOCKS
6.5 IO FUNCTION BLOCKS IO
Function blocks used to transfer input and output signals to & from the I/O modules and the control
modules for indication, alarming, regulatory control, automated control logic. Included in this section
are the parameters for configuration of the Input / Output Module (IOM) channel as well as the Control
Module (CM) channel function block (FB).
6.7 REGULATORY CONTROL BLOCKS
6.7 REGULATORY CONTROL BLOCKS
6.7.1 PID BLOCK
The PID block is a regulatory control block that operates as a proportional-integral-derivative (PID)
controller. The PID block has two analog inputs - a process variable (PV) and a set point (SP). The
difference between PV and SP is the error and this block calculates a control output (OP) that should
drive the error to zero. By default, 0% indicated on the DCS HMI will represent valve closed, and
100% will represent valve open position, regardless of control valve action. Accordingly PID, OP will
be mapped in HMI. The output signal from DCS will be reversed for fail open valves and will be kept
direct for fail close valves. PID Function block supports following equations.
Equation A - Proportional, Integral, and Derivative on error
Equation B -- Proportional and Integral on error and Derivative on changes in PV.
Equation C -- Integral on error and Proportional and Derivative on changes in PV.
Equation D -- Integral only

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Equation E -- Proportional only; this equation supports the following two options that affect CV:
Output bias processing which adds fixed and floating bias to unbiased CV Reverse-control action
causes the sign of the unbiased CV to be reversed.
For Paradip project, Equation B will be used mainly as it eliminates derivative spikes in control action
that occur with quick changes in the set point. The PID block may be used in a single control loop or
with multiple PIDs in a cascade strategy. In this Project, the mode attribute is pinned to normal mode
attribute which is operator. Mode is fixed as manual or auto by pinning the modeflcas to eswfl.auto.
1. MASTER SLAVE PID
Cascade loops are configured using two CMs. A slave PID is configured as a simple PID with the
exception that cascade mode is enabled. The master PID loop output drives the set-points of the slave
loops.
2. SPLIT RANGE PID
A Split range PID is configured using three CMs. A master PID has an additional fanout function block
which splits the output to the two slaves. Each Slave has an auto manual block that calculates the gain,
bias and input limits to control the split range.
6.7.2 OVERRIDE SELECTOR (OVRDSEL)
This function block provides override feedback data to every block in an upstream cascade control
strategy. Also provides bypass processing, control initialization, and override feedback propagation. It
accepts up to four inputs (primaries) and selects the one with the highest or lowest value.
6.7.3 RATIO CONTROL (RATIOCTL)
The RATIOCTL block accepts the actual value of the controlled flow (X1), the actual value of the
uncontrolled flow (X2) and the target ratio between the flows (SP), and calculates the target value of
the controlled flow (OP) and the actual ratio between the flows (PV) as outputs. This block is typically
used to control one flow as the ratio of another.
6.7.4 FAN OUT BLOCK (FANOUT)
The FANOUT regulatory control block provides "bumpless" transition for each output after
initialization or mode changes. This FB is always required when controlling more than one analog
outputs using one PID controller. The FANOUT block can have up to 8 secondary blocks. In this
project the FANOUT block will be “locked” in Cascade mode and will not be available to the operator
via HMI displays. The FANOUT outputs are connected to the final control analog outputs through
AUTOMAN blocks.

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6.7.5 SWITCH BLOCK (SWITCH)
The SWITCH block accepts up to eight initializable inputs and operates as a single-pole, eight-position
rotary switch. The switch position may be changed by the operator, a user program, or another function
block. The inputs can be from any regulatory control blocks. (Like PID, AUTOMAN, FANOUT etc...)
6.8 DCS TYPICAL LOOP DETAILS
This section describes mainly how the functional schematic provided by customer (EPCm’s) will be
implemented in DCS system (Application implementation) for typical loops etc. This section will get
revised based on the prototype testing (Held separately to finalize various applicable templates)
6.9 NAMING PHILOSOPHY FOR DCS TAGS
This is the tagging convention to be implemented at the control system that will be Displayable at the
face plate. UUUFFFFFFNNNNMM
6.10 NAMING PHILOSOPHY FOR DCS SYSTEM HARDWARE
This section describes the naming convention for Controller, IO LINK and Modules being
implemented at the DCS control system. 6.10.1 NAMING CONVENTION FOR C300
CONTROLLER UUU_CPXXY (Controller Naming) UUU_CEXXY (Controller Execution Block
Naming)

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7.0 OPERATOR INTERFACE
This section briefly describes about Station, basic display layout, various features available (Windows,
navigation, diagnostics etc) & alarm management. Details are part of OPERATOR INTERFACE FDS
(Doc No: D10T618-101-36).
7.1 INTRODUCTION TO EXPERION STATION
Experion is a sophisticated management and control system that: Displays system data in a manner
that user can easily understand, Allows user to control your system by sending appropriate commands,
Automatically performs scheduled tasks, Notifies user of system activities, including alarms and
system events, Produces comprehensive reports. A Station is, in effect, a set of 'control panels' through
which operators and engineers can monitor and control plant or system. (Station is a separate Experion
program that runs on standard computers, as well as on the server.) Station presents information as a
series of displays—each display is a 'control panel' that shows a particular set or type of information,
and has an appropriate set of controls, such as 'buttons' and 'scroll bars'. There are two basic types of
display System. These are supplied with Experion and show information in a standardized manner.
For the most part, system displays consist of lists and 'electronic forms' containing system
configuration details Custom. These have been created specifically for user system, and make it much
easier to interpret and control system activity, often making use of sophisticated graphics, including
animations.
7.2 ALARM MANAGEMENT
The Station application provides an Alarm Summary display that lets user view all the current and
unacknowledged alarms in the system or just those alarms with configured priority level of high and/or
urgent, or just those assigned to a given area. While the Alarm Summary display is the focal point for
viewing alarms, individual alarms can appear on any display including Detail, Group, Trend, and user
built schematics. By default, the Alarm Summary shows all alarms, with the newest alarm at the top.
Alarm Summary view can be changed by applying filters and sorting the summary. Filtering the Alarm
Summary allows showing alarms that match the filter criteria and hide alarms that do not match the
filter criteria. For example, the Alarm Summary can be filtered to show alarms of a particular priority
only, or it can be filtered to show alarms for a particular area only. The Alarm Summary can be filtered
by any column in the summary.
Some of the important tabs on Alarm summary page are as follows: -
 Date & Time- It shows the time of occurrence of alarm. Filtering at this time can allow us to see
alarms for the particular time in the past
 Area- Area tab shows the area / assets of the alarm.

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 Source- It typically shows the name of the control module from which the alarm state has
generated.
 Condition- It shows the alarm condition like level low, motor trip etc.
 Priority- It shows the priority of the alarm like URGENT, HIGH, LOW, JOURNAL etc.
Description- It shows the description of the control module from which the alarm has generated.
Value- It shows value at the time of alarm
 Alarm Colours associated with their priority: (Urgent Priority- Red, High priority- Yellow, Low
Priority- Cyan)
8.0 HISTORY & TRENDING SPECIIFCATION
History Collection Each point used in the Experion Server can be configured for History Collection to
enable trending of old data. The server will store the point parameters at pre-determined intervals
according to the following choices for history collection: This process is known as history collection
and archiving. The Number of point parameters for each type can be adjusted to maximum.
8.1 TREND
A trend object presents information in a graphical manner, and can be configured in numerous ways.
The main components of Trend are chart area, axis, toolbar and legend.
8.1.1 TREND TYPES Five types of trends can be configured:

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8.7 TREND DISPLAY
Trend displays are standard Station displays that provide a way of viewing historical data for points.
It is advised, to configure the default trend points in their respective CM itself. Trends are configured
from the station with path. A maximum of 32 points can be configured in a trend (For PDRP Project,
the no of parameters shall be restricted to 8-12). A trend display shows changes in point parameter
values over time. Each trend is identified by a number, and generally has a descriptive title.
Trends can display data in several ways, including:
• Line graphs (the default)
• Bar graphs
• Numerical list of historical data
• X-Y plot of the value of one point against another (that is, one point on the x-axis and the other
on the y-axis)
1) To call up a trend by choosing it from list of trends: 1. Select View > Trend Summary to see the
list of trends. 2. Select a trend.
2) To call up a trend whose number users know: 1. Click the (Trend) toolbar button. 2. Type the
trend's number in the Command zone and press ENTER.
TREND CONFIGURATION
TO CONFIGURE A NEW TREND:
1. In the Configuration Explorer of Configuration Studio, click Trends and Groups.

2. Click the Configure trends task. The Trend Configuration Summary display appears in the System
Display tab in Configuration Studio.
3. In the Trend Summary display, click an empty title. This opens the Trend Configuration display.
4. In the Title box, type the name of the trend.
5. From the Trend Type list, select the type of trend user want to configure.
6. In the Sample Interval box, select the desired history interval from the list (for example, 1-minute
snapshots, 6-minute averages, and so on).
7. In the Duration box, select the period for which user want to see data.
8. Select the Multi-Range check box if user wants to set the range for each point individually.
9. Select the Percent check box if user wants the scale to be shown as a percent. Clear the check box if
user want the scale to be shown in engineering units.
10. In the Trend Range box, type the range user want to display. Note that this is for display only and does
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11. If user wants to prevent operators from changing the configuration of the trend, select the MNGR or
ENGR security level required to change traces check box.
12. Enter the point ID of each point user want to add to the trend.
13. From the Parameter list, select the point parameter to be trended for each point. If user the parameter
is not available in the list, select the Alpha-numeric check box and type the parameter.
14. To show or hide the trend for a particular point, select or clear the check box for that point. This can
reduce the complexity if a particular trend is obscured.
15. In the History offset box, type the date and time if a history offset is required. Otherwise, user can
leave the box blank.
16. Click View Trend to call up the Trend display in which user can change details interactively for this
trend.
9.0 DIAGNOSTICS
This section provides guidance and background information about the causes and Remedies for failures
which may occur in the C300 Controller
10.0 SYSTEM BACKUP
Regular Server backups are essential in minimising the downtime of a computer should it malfunction.
The time taken to restore from a failure is minimised if recent and relevant backups are immediately
available. There will be three types of backups performed on each Server, their size and frequency
varying such that the most important or frequently changing data is backed-up the most often. Once a
week the most recent backups is written to CD/DVD and archived. The weekly backup can be used
for restoration. Occasionally, after events such as hardware/software upgrades or major configuration
changes an image of the entire hard disk will be created. This image can be used to restore a Server
from scratch should it suffer from a catastrophic failure.
11.0 REMOTE ENGINEERING
Remote engineering is basically a facility of accessing DCS engineering application like control
builder or quick builder application from individual group engineering database In PDRP project, all
groups (Based on Group-2/3 as defined in DCS Unit Segregation) are provided with dedicated
engineering station for associated DCS engineering / configuration. Apart from the above, each control
room is provided with one Master Engineering Server, from where user can access to specify local
(SRR) engineering for carrying out engineering / configuration. Local Engineering database is also
backed up on this Master Engineering server. Master engineering client is provided with multiple
clients. Assignment of these clients to various Control Groups shall be done during detail engineering.

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12.0 SYSTEM ONLINE DOCUMENTATION
All DCS nodes will be installed with online DCS documentation, most applicable online
documentation will be “Experion knowledge builder” application. This contains in depth installation
and configuration details about all hardware supported by Experion system and in depth operator
guidance is provided for uses of engineering application like control builder, quick builder and HMI
web display builder etc. Control builder application will also have its own online library which
basically details about logic building, online logic viewing and printing etc. When the process is
running, the identical control module configuration forms used in engineering the control strategy can
be viewed from the Operator Station to provide additional information to the Operator.
16.2 GENERIC FUNCTIONAL DESIGN SPECIFICATIONS FOR OPERATOR INTERFACE
1.0 PURPOSE
The purpose of this document is to outline the specific configuration of the Honeywell Stations, with
regards to the Human Machine interface for the IOCL, Paradip Refinery Project.
2.0 OPERATOR INTERFACE

The primary operator interface in each console will be the DCS HMI workstation for which this
document is primarily intended. However each operator console also contains one or more
Hardwired Console stations and one or more ESD HMI workstations from which certain operator
commands only can be executed.
2.1 HMI WINDOW AND ITS FUNCTIONALITY
Station is a client application that collects data from various Experion sources and presents to users
through HMIWEB graphics. It has a set of ‘control panels’ through which the system is monitored
and configured. Figure below shows the Station’s layout.
2.3 ABOUT PERIPHERALS CONTROLS
This section, covers brief description about HMI (DCS / ESD / FDAS) peripherals controls.
2.3.1 TRACK BALL CONTROL
In general, the operator input on an operator station will be primarily through the Left-Button-Click
of the pointing device. The table below defines the common TRACK BALL behaviour for all
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Trackball event Object reaction Remarks
Left-Button-Click Point related shapes: Activate Point related shapes show a “hand” symbol
point faceplate or popup when a target is present to invoke a faceplate.
window Navigation related
objects: Invoke another display
Right-Button- Activate shortcut menu When the shortcut menu is invoked, the focus
Click will be forwarded to an object inside the shapes,
which has a point database connection. By doing
so, the current selected point will be shown in
stations message zone and the functions detail
display, trend etc, will be related to the current
selected point.
Left-Button- Point related shapes: Not Activate point detail display

Double Click applicable, since the single click
invokes a faceplate (unless
otherwise configured). Non-
shape objects with point
database connection (e.g. a level
bar, or a parameter in a
faceplate): the detail display will
be invoked
TRACK BALL - When the track ball pointer is

over over the object which is having
tooltip, the tooltip will get
displayed.
2.3.2 KEYBOARD CONTROLS of OEP (Operator Entry Panel)
Operator Entry Panel
The OEP keyboard has a set of preconfigured keys which invoke specific actions or commands.
There is also a set of keys, which user can customize to invoke actions and commands, and control
the LEDs, referred to as relegendable keys.

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DEFAULT ASSIGNED KEY FUNCTION FOR OEP KEYBOARD ARE LISTED BELOW
Calling up system displays
To call up the Press
Alarm Summary display ALM SUMM
System Status display SYST STATS
Message Summary display MSG SUMM
Console Status detail display CONS STATS
System Menu display SYST MENU
Point detail display for the selected object. If there is no associated point detail DETAIL
display, pressing the key calls up the point search display.
Group Trend display for the selected objected. If there is no associated Group UNIT TREND
Trend display, pressing the key invokes the Group Trend command and requires
a Group Trend number to be entered.
Group display for the selected object. If there is no associated Group display, GROUP
pressing the key invokes the Group command and requires a Group number to be
entered.
Trend for the selected object. If there is no associated Trend, pressing the key TREND
invokes the Trend command and requires a Trend number to be entered.
Group history for the selected point with the default interval. If there is no HOUR AVG
associated Group History, pressing the key invokes the Group History command
and requires a Group History number to be entered.

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Calling up other displays
To call up Press
A display based on its name or number SCHEM
The next display upwards (Graphic page navigation forward display) Based on PAGE BACK
Process Flow
The next display downwards (Graphic page navigation backward display) Based on PAGE FWD
Process Flow
Navigate forward and backward between displays that user has previously called up. PRIOR DISP.
DISP BACK.
DISP FWD.
The display associated with the selected object ASSOC DISP
Copy the current display to the first associated Station DISP SET
Print the current display PRINT DISP
Help (calls up HMI Help. (Like how to operate the station, how use station menus HELP
etc)
Changing focus
The term 'focus' used here means selecting a display object so that it will receive Keyboard input. For
example, if user wanted to move the focus to the next box so that user could change its value, then user
would use the Tab arrow keys.
Calling up other displays
To change focus to Press
Move the focus to any selectable object or editable box in the display TAB arrow keys
De-selects the object and cancels any uncommitted change. CLR ENTR

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Controlling points, issuing commands and entering data
To Press
Acknowledge/silence an alarm or message. (Note that in the case of a confirmable ACK

message, user cannot confirm it by pressing ACK twice. user must first press ACK
and then MSG CONFM.)
Silence all audible alarms SIL
Confirm a confirmable message MSG CONFM
Clear the selected message on the Message Summary. Depending on how user MSG CLEAR
system is configured, this button can also be used to clear the whole page of
messages if no individual message is selected on the Message Summary.
Lower the value of the selected object by 1% (default setting) LOWER
Lower the value of the selected object by 10% (default setting) FAST LOWER
Raise the value of the selected object by 1% (default setting) RAISE
Raise the value of the selected object by 10%(default setting) FAST RAISE
Select the OP of the selected object OUT
Select the SP of the selected object SP
Set the mode of the selected point to automatic AUTO
Set the mode of the selected point to manual MAN
Set the mode of the selected point to manual NORM
Clear an incorrect operator entry CLR ENTR
3.0 GRAPHIC ENVIRONMENT STANDARD
This section details, brief description about station (HMI) menus and toolbars
3.1 MENUS
Like any other windows application, it has menus, a toolbar and the display area. User can select
commands from the Station’s menu in the same way as in other applications.

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3.2 TOOLBAR
The Station toolbar provides speedy access to frequently used menu commands.

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3.3 MESSAGE ZONE / COMMAND ZONE
COMMAND ZONE
On the Station menu-toolbar screen capture, the single line text area with the label ‘Command’ next to
zoom control is called the Command Zone. Command Zone is a powerful tool to carry out many
tasks, including call up of displays. Just type the name of the display to be called up (or command to
be executed) in Command Zone and press Enter.
The following are some of the tasks that can be commanded from the command zone:

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 Call up a point detail display

 Call up custom display
 Call up a group display
 Call up a trend display.
A complete reference to commands is available in “Entering the Commands in Command Zone”
subsection under “About Station’s Layout” section of Operators’ Guide in Knowledge Builder. The
Command zone retains a history of the last 20 commands that user entered since logged on. User can
pick frequently used commands from the list. The command zone commands are not case-sensitive.
MESSAGE ZONE
The station displays explanatory messages in the message zone. For example, if you acknowledge an
alarm whose cause still exists, “The alarm has been acknowledged but has not returned to normal”
shall appear in the message zone as shown in Figure.
STATUS LINE / ALARM LINE
The status bar (also called status line) provides an overview of your system’s status.
FIGURE: STATUS BARS
The Status Line summarizes system status. The following table describes each part of the status Line,
starting from the left.
FIELD DESCRIPTION
Indicates if there are any alarms, as well as their status
· Blank: No alarm
· Flashing according to the alarm priority colors: At least

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FIELD DESCRIPTION
one unacknowledged alarm
· Not flashing according to the alarm priority colors: There is at least one
alarm, but they have all been acknowledged.
Click the field to call up the Alarm Summary, which lists each alarm.
Indicates whether there are any system alarms, as well as their status, for
example, failed communication links between the server and other devices
(such as channels, controllers, and so on):
· Blank: There are no system alarms.
· Flashing Cyan: At least one unacknowledged system alarm.
· Cyan (not flashing): There is at least one system alarm, but they
· have all been acknowledged
Click the field to call up the System alarm summary, which lists each system
alarm.
Indicates whether there are any messages, as well as their status:
· Blank: No messages.
· Flashing green: At least one unacknowledged message.
· Green (not flashing): There is at least one message, but they
· have all been acknowledged.
Click the field to call up the Message Summary, which lists each message.
Server ID: The computer name of the server to which the Console Station is
connected.
A red LED appears if the server is unavailable.
A yellow LED appears when the Console Station is synchronizing with the
server.
Console Station ID: Visible on a Console Station only. The computer name of
the Console Station you are logged on to.

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FIELD DESCRIPTION
Console Station number: The number of the Station you are logged on to.
(Most systems have more than one Station.) The number is in the format
CStn01-n, for example CStn01-1.
Station security level. Currently set to Operator, station security allows

restricting of various controls and elements to higher security levels. Possible
values include engineer and manager.
4.0 GRAPHIC HIERARCHY
4.1 TYPES OF GRAPHICS
The primary operator interface in each console will be the DCS HMI workstation for which this
document is primarily intended. Following are the broad categories of HMI;
 DCS HMI
 ESD HMI
 HARDWIRED CONSOLE
 FDAS HMI (Located in Engineering Room)
DCS Process Graphics are accessible as ‘single window concept’ through standard navigation for all
units associated with the console. Other unit graphics available but called up indirectly.
4.2 LEVELS OF GRAPHICS
LEVEL 0: REFINERY OVERVIEW
LEVEL 1: CONSOLE OVERVIEW DISPLAY
LEVEL 2: PROCESS UNIT OVERVIEW DISPLAYS
LEVEL 3: PROCESS UNIT DETAIL DISPLAYS
LEVEL 4: EQUIPMENT DISPLAYS
16.3 GRAPHIC DETAIL:
5.1 GRAPHIC BUILDER

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A HMI web display builder is the application which is used for building all HMI related graphics
(DCS / ESD / FDAS HMI’s)
5.2 COLOUR OBJECT LIBRARY
This section details about line colours (process line colours), static, dynamic object library and text
sizes used in graphic development of Paradip project.
5.2.1 LINE COLOURS
PROCESS STREAM COLOURS
S. No. DESCRIPTION LINE COLOR
1. Crude / Flashed Crude

(3PIX)
2. Fuel Gas / Off Gas

(2PIX)
3. Sour Gas / Tail Gas / Flue Gas

(2PIX)
4. Hydrogen / Make Up Hydrogen / Hydrogen Rich

(3PIX)
Gases
5. Recycle Gas / Recycle Compressor ( Suction And

Discharge Circuit) / Quench Gas (3PIX)
6. Propane / Butane / Iso Butane / LPG / Propylene (3PIX)
7. Isomerate/ Alkylate/ Gasoline/ Reformate / Full (3PIX)

Range Naphtha / FCC Gasoline
8. Light Naphtha / Naphtha / FCC Light Naphtha

(3PIX)
/Stabilized Naphtha / Unstabilized Naphtha / Heart
Cut Naphtha / Heavy Naphtha
9. Kerosene / ATF / Sponge Oil (3PIX)
10. Diesel/LAGO (LIGHT ATM GAS OIL)/HAGO (3PIX)

(Heavy ATM Gas Oil)/Cycle Oil / LCGO (Light
Coker Gas Oil) / Flushing Oil/Fuel Oil/Purge
Oil/Vacuum Diesel

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11. VGO (Light Vacuum Gas Oil / Heavy Vacuum (3PIX)

Gas Oil ) / HCGO (Heavy Coker Gas Oil) /
Vacuum Slop
12. ATM Residue / Vacuum Residue / VR / Coke (3PIX)
13. Lean Amine / Rich Amine (3PIX)
14. Sulpur Dioxide / Sour Water (3PIX)
15. Sulphuric Acid / Fresh Acid / Spent Acid (2PIX)
16. LP Flare (2PIX)
17. HP Flare (3PIX)
18. Sulphur (4PIX)
19. Slop / Light Slop / Heavy Slop / CBD (2PIX)
20. Lube Oil (2PIX)
UTILITIES LINE COLOURS
1. CWS / CWR / Service Water / Tempered Water / (2PIX)

Drinking Water / Raw Water / Fire Water / CRWS
2. Demin Water / Boiler Feed Water / Process Water (2PIX)

/ Condensate / Steam Condensate / Stripped Water
3. LP Steam (2PIX)
4. MP Steam (3PIX)
5. HP Steam (2PIX)
6. HHP Steam (3PIX)

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7. Plant Air / Service Air / Instruement Air (2PIX)

/Decoking Air
8. Nitrogen / Inert Gas (2PIX)
9. Caustic / Fresh Caustic / Spent Caustic (2PIX)
10. Catalyst / Chemicals CI (Corrosion Inhibitor) / (2PIX)

Ammonia / Chlorine / Antifoam / DMDS /
Morpholin / Refrigerent /Other Chemicals)
11. OWS / SS (2PIX)
5.2.2 TEXT SIZES
The text Fonts and Style were listed in below table:
S. No. Text Type Color Font Style Size
1 Display Title Black Arial Bold 14
2 Tag name Cyan Arial Regular 10
3 Engineering Unit Pale-goldenrod Arial Regular 10
4 General Text White Arial Regular 10

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5.2.3 DYNAMIC OBJECT LIBRARY

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5.3 POINT DETAIL DISPLAY
5.3.1 CONTEXT MENU
All shapes used for point/parameter presentation, such as pumps, valves, controllers etc (not navigation
objects and bar graphs), provide shortcut menu functionality. The Shortcut menu appears upon right-
clicking of a shape.
The Shortcut menu provides the following options:

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 Acknowledge Alarm : This option allows acknowledgment of the alarms of the current selected
point
 Detail: This option will invoke the detail display for the current selected point
 Trend: normally invokes the first trend group in which the current selected point appears. If a point
is not configured in a trend group, the system will ask the operator for a trend group number.
 Group: Normally invokes the first group in which the current selected point appears. If a point is
not configured in a group, the system will ask the operator for a group number.
 Associated Display: invokes the associated display for the current selected point. If no associated
display has been configured, a warning will appear in the message zone “No associated display”.
The Shortcut menu will disappear after one of the options has been selected, when the operator clicks
outside the Shortcut menu or presses the escape button on the keyboard, or after the timeout period of
10 seconds (standard Microsoft Windows behavior).Display Navigation
5.3.2 GROUP DISPLAYS
There shall be a number of predefined and preconfigured Group Displays (containing at least 8
Faceplates), mainly around more complex process equipment, to provide the operator with a grouped
overview of important control parameters.
When calling up a group display in Station, operator can use:
 Standard navigation methods

 Custom navigation methods
STANDARD NAVIGATION METHODS: - Standard navigation methods require no configuration.
They are listed below because you might want to use them when checking a group configuration or
display.
The following standard methods can be used to call up a group display:
 Go to the Group Summary display click the name of a specific group to call up. When the
Group Configuration display for a specific group is displayed, click the View Group link to
view the group.
 Click the Group icon on the Station toolbar and type a group number in the Station command
zone and press ENTER.
 Press F6 to call up a group by number.
 In Station's Command Zone, type the GRP command and the number of the group you want to
display then press ENTER.
 In any Group display, change the current number in the Group box to the number of another
group to display. Alternatively, choose another group from the list of titles at the top of the
display.

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5.3.3 CUSTOM NAVIGATION METHODS
Alternatively, the following custom call-up methods can be used to provide a quick and easy way of
calling up a display:
User-defined Station function keys
Push-button objects on a custom display
5.3.4 TREND DISPLAYS
All "analogue" measured process variables, both DCS and ESD based, shall be configured in
predefined and preconfigured Trend Displays (containing each at least 8 pens).
6.0 TYPICAL REPORTS
1. Material Balance Report

2. Critical Equipment Monitoring Report
3. Shift Log Report
4. Daily Log Report
5. Running Hours Report
16.4 ALARM MANAGEMENT
Two types of Alarm are broadly classified (Processed) in the system.
1) Process alarm
2) System alarm
Process alarm: - An alarm is generated whenever an abnormal condition occurs. Alarms are typically
associated with points—for example, the value of an analog point representing a temperature sensor,
may be above or below the acceptable range. These types of alarms are known as 'process' alarms
because they are associated with the process you are monitoring and are displayed only on the Process
Alarm Summary of HMI’s.
The Alarm box in the Status Bar flashes red if there are any unacknowledged alarms.
System alarm: - Alarms may also be generated when any important event occurs, such as a
communications failure. These types of alarms are known as 'system' alarms because they are

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associated with components that form your system. These alarms are displayed on the System Status
display of HMIs.
The System box in the Status Bar flashes cyan if there are any unacknowledged system alarms.
Priority Assignment RESPONSE COMMENT
Urgent (U) 1. Any Alarm indicating a failure of Immediate 1. Extreme risk to personnel,
(Critical) safety critical equipment, production, major equipment,
endangerment to personnel or damage or the environment.
to plant or the environment.
2. Many of these will be
2. Any FDAS alarm annunciated on the Hard
Wired Console
HIGH (H) Any Alarm which is pre- alarm for 1-5 Minutes 1. High risk situation will
(Warning) S/D. First out alarms indicating the progress to an emergency
cause of a shutdown or trip. situation if NOT corrected.
2.Some of these may be
annunciated on the HWC
LOW (L) 1. Any Alarm that requires operator 5-30 Minutes Condition needing attention
(Advisory) action, Indicates loss of control or soon.
essential data.
2. Any alarm that requires service /

maintenance action. (Including
DCS/ESD hardware failures)
3. First out alarm from a package
JOURNAL 1. Indicates loss of non- essential data. - An event recorded in disk file,
(J) (Log Individual alarms that are shown to the NO operator action required.
only) operator as a common alarm.
2. Alarms indicating that equipment

has been shut down by the safety
system.
3. Alarms that are duplicates of other

alarms

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16.5 List of Online Analyser
SL. No Tag No Type Description
1 010-AT-1003 Oil Deslater effluent outlet analysis at 010-E-152
2 010-AT-1007 Oil Deslater effluent outlet analysis at 010-E-252
3 010-AT-1008 pH At CDU Sour Water Pump, 010-P-011A/B
4 010-AT-1002 Oxygen CDU Heater (010-F-101) Arch Area
5 010-AT-1502 Oxygen CDU Heater (010-F-201) Arch Area
6 010-AT-1001 CO/O2 CDU Heater Flue Gas Stack (010-SK-001)
7 010-AT-1004 SOx CDU Heater Flue Gas Stack (010-SK-001)
8 010-AT-1006 NOx CDU Heater Flue Gas Stack (010-SK-001)
9 010-AT-1009 VOC CDU Heater Flue Gas Stack (010-SK-001)
10 010-AT-1010 PM CDU Heater Flue Gas Stack (010-SK-001)
11 010-AT-3001 Oxygen VDU Heater (010-F-002) Arch Area
12 010-AT-3002 NOx VDU Heater Flue Gas Stack (010-SK-002)
13 010-AT-3003 SOx VDU Heater Flue Gas Stack (010-SK-002)
14 010-AT-3005 CO/O2 VDU Heater Flue Gas Stack (010-SK-002)
15 010-AT-3007 PM VDU Heater Flue Gas Stack (010-SK-002)
16 010-AT-3008 VOC VDU Heater Flue Gas Stack (010-SK-002)

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Advanced Process Control in AVU

Details of APC in AVU is given as annexure at the end of the manual

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CHAPTER-17
UTILITY & AUXILIARY NETWORKS

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17.1 UTILITIES
Utility / Auxiliary system consists of Power, water, stream, air, fuel oil, fuel gas, flare, blow down,
special drainage, effluent, flushing oil etc. Brief description of the facility provided for each system is
described below.
UTILITIES CONSUMPTION & GENEREATION:
UTILITY UOM Consumption
Cooling water M3/hr 11314
Fuel Gas MT/hr 21.3
Fuel Oil MT/hr 25.7
Instrument Air NM3/hr 4387
Plant Air NM3/hr 1300
Nitrogen NM3/hr 65.3
BFW MT/hr 74.3
Installed Power of Motors MW 18.8
HP Steam Consumption
MT/hr 26.6
(@ 40.0 kg/cm2 g & 390º C)
MP Steam Consumption
MT/hr 85.2
(@14.0 kg/cm2 g & 290º C)
LP Steam Consumption
MT/hr 77.9
(@ 4.0 kg/cm2 g & 175º C)
Fuel Gas Generation MT/hr 11.2
MP steam Generation MT/hr 62.5
LP steam Generation MT/hr 34.7

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17.2 INSTRUMENT AIR (PID: 010-9401)

To cater to the requirements of dry/clean air for instrument, 4" header is provided with a gate valve &
spectacle blind at the battery limit. Various tapings from the instrument air header have been taken to
supply air to individual instruments. . At battery limit PG 7614 & PI 9019 with DCS indication is
provided.
Instrument Air Condition & Specification:
INST. AIR UNIT MIN NOR MAX MECH.

PARAMETERS DESIGN
Pressure kg/cm2 (g) 4.5 7 8 10.5
Temperature ºC Ambient 40 50 65
Dew Pt. ºC (-) 40 at atmospheric pressure.
Oil Content PPM Nil (oil Free)
17.3 PLANT AIR/SERVICE AIR (PID: 010-9401)

A 6” Plant air header is provided with gate valve & spectacle blind at battery limit. Plant Air header is
distributed throughout the unit. At battery limit PG 7769 & PI 9025 with DCS indication is provided.
Plant air is distributed in all sections of the unit.
Plant Air Condition & Specification:
PLANT AIR UNIT MIN NOR MAX MECH

PARAMETERS DESIGN
Pressure Kg/Cm2 (g) 4 7 8 10.5
Temperature ºC 40 40 50 65
Dew Pt. ºC Saturated
Oil Control PPM Nil (oil Free)

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17.4 STEAM SYSTEM

A) HP (HIGH PRESSURE) STEAM (PID 010-9101)
HP steam is made available at battery limit of AVU through 8” header. A double block valve is
provided at the battery limit. The sole user of the HP steam in the unit is VR steam driven pump
(010-P-025A HP-MP).At battery limit PG 7467 & TG 9006 are provided for the local indication
and DCS indication of pressure (PI 9101), temperature (TI 9007 ) & flow (FI 9002) are also
provided.
HP Steam Condition:
HP STEAM UNIT MIN NOR MAX MECH

DESIGN
Pressure Kg/Cm2 (g) 39 40 42 46
Temp ºC 380 390 400 427
B) MEDIUM PRESSURE (MP) STEAM (PID 010-9101)

MP steam is made available in the unit through a 24” header with a gate valve with provision of
spacer for blinding at the battery limit with PG-9561 & TG-9004 for local indication. PI-9008, TI-
9005 & FI-9001 for indication of pressure, temp. & flow in the control room.
MP STEAM HEADER IS FEEDING TO DIFFERENT SECTIONS:
I. CDU Furnace Train-1 (010-F-101)
 Emergency steam
 Decoking steam
 Steam to individual soot blowers
 Atomising steam
II. CDU Furnace Train-2 (010-F-201)

 Emergency steam
 Decoking steam
 Atomising steam
III. Vacuum Furnace (010-F-002)

 Emergency steam
 Decoking steam

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 Coil purging steam (Turbulising steam)
 Atomising steam
IV. Vacuum Ejectors 010-EJ-001 A/B/C, 002 A/B/C, 003 A/B/C
MP Steam Condition:
MP STEAM UNIT MIN NOR MAX MECH

DESIGN
Pressure Kg/Cm2 (g) 12.5 14 15 18
Temp ºC 210 290 305 350
C) LOW PRESSURE (LP) STEAM (PID 010-9102):
LP steam is supplied to the unit through a 20” header having a block valve with provision of spacer for
blinding at B/L. Pressure gauge & temperature gauge PG-7486 & TG-9014 are provided for local
observation. PI-9027, TI-9013 & FI-9006 are provided to indicate pressure, temperature & flow
respectively on the control panel. The LP steam is distributed to different sections of the unit Viz.:
A. Snuffing (box purging) steam to heaters 010-F-101, 010-F-201 & 010-F-002.

B. Manifolds to pump house, desalter, Train-1 & Train-2 & hose station at various locations of
the unit are provided.
C. Connection provided in columns and vessels for use as utility steam.
D. LP steam is also used as Stripping steam to CDU, VDU, Kerosene Stripper, and LAGO Stripper
& HAGO Stripper.
E. LP steam connections are provided in utility stations located across the unit.
LP Steam Condition:
LP STEAM UNIT MIN NOR MAX MECH

DESIGN
Pressure Kg/Cm2 (g) 3.3 4 5 7
Temp ºC 146 175 190 240

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D) STEAM GENERATION:
MP Steam generation:
Saturated MP steam is getting generated from MP steam generators i.e. 010-E-149 (HVGO/MP
Steam generator) @ 17.0 Kg/cm2 (g) & 229º C and from CDU & VDU waste heat boilers (010-
WHB-001/002) @ 17.0 Kg/cm2 (g) & 206º C. Saturated steam gets superheated in the convection
coil of CDU & VDU furnace and the MP superheated steam generated from 010-PT-025A (vacuum
residue turbine driven pump HP to MP) is routed to MP steam header.
LP Steam generation:
Saturated LP steam is generated from 010-E-150(HVGO/LP Steam generator), 010-E-151/251A-
C (Vacuum Residue/LP Steam generator) at 5.0 Kg/Cm2 (g) and 190º C gets superheated in the
convection coil of CDU & VDU furnace and routed to the LP steam header.
17.5 COOLING WATER SYSTEM (PID 010-9204):
Two cooling water headers are provided with a two butterfly block valves at the B/L each. One
header of line size 48” supply water to Pump house, coolers, sample coolers, ejectors, furnace etc.
provided with PG-9362 & TG-9038 are provided for local indication. PI-9058, TI-9040 & FI-9019
indicate at the B/L condition on the control panel. The return header is also provided with a butterfly
valve with TG-9037, PG-9363 are provided for local indication and TI-9039 indicate at the B/L
condition on the control panel.
Second header of line size 30” supply water to Pump house, coolers, sample coolers, Compressors,
etc. provided with PG-360 TG-9009 are provided for local indication. PI-9015, TI-9010 & FI-9003
indicate at the B/L condition on the control panel. The return header is also provided with a butterfly
valve, TG-9011, PG-9361 for local indication and TI-9012 indicates the condition on the control
panel.
Cooling Water Condition:
COOLING UNIT MIN NOR MAX MECH

WATER DESIGN
Supply Pr. Kg/Cm2 (g) 4.5 5.5 6.5 8
Return Pr. Kg/Cm2 (g) 2.5 3.0 3.5 8
Supply Temp. ºC - 35 35 65
Return Temp. ºC - 44 44 65

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17.6 SERVICE WATER SYSTEM (PID 010-9201):

Service water is made available throughout the unit via 6” header with a butterfly valve & spectacle
blind is provided in the unit. At battery limit PG 7353 is provided for local indication and PI-9011
for pressure indication in DCS. Service water connections are provided in all utility station,
analyzer house & in furnaces.
17.7 DM WATER (PID 010-9205):

2” header is provided with block valve & spectacle blind and PG 7383 is provided for local
indication at the B/L. DM water is used for preparation of phosphate solution for injection into
steam drum.
17.8 DRINKING WATER (PID 010-9205):

A 2” header is provided with a block valve & spectacle blind and PG 7406 is provided for local
indication at the B/L. Drinking water is used in safety showers located within the unit.
17.9 BFW (MP) SYSTEM (PID 010-9203):

MP boiler feed water is made available via 6” header. At battery limit block valve & spectacle blind
is provided. TG-9008 & PG-9521 are provided for local indication and DCS indication of pressure
is also provided by PI-9013.Following are the users of the BFW in unit:
 010-E-150(HVGO/LP Steam generator),

 010-E-151/251A-C (Vacuum Residue/LP Steam generator)
 010-E-149 (HVGO/MP Steam generator)
 010-WHB-001(CDU Waste heat boiler)
 010-WHB-002(VDU Waste heat boiler)
 010-DS-001(MP STEAM DESUPERHEATER CDU)
 010-DS-002(MP STEAM DESUPERHEATER VDU)
Boiler Feed Water (MP) Condition:
BFW (MP) UNIT MIN NOR MAX MECH

DESIGN
Pressure Kg/Cm2 (g) 28 28 30 40
Temp ºC 105 105 116 150

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17.10 FUEL SUPPLY SYSTEM:
A) FUEL OIL (PID 010-9551):

Fuel oil is supplied to the unit via a 4” header provided with a double block valve & spectacle blind.
At battery limit PG-7565, TI-9002, PI-9031, FI-9008 is provided for local as well as DCS indication.
A 4” return header is also provided with FI-9007, TG-9042, PI-9003 and PG-7564 at B/L. The main
consumers of the Fuel oil are following:
 010-F-101/201 - Crude Charge heater
 010-F-002 - Vacuum Heater
Fuel Oil Condition & Specification:
FUEL CONDITIONS UNIT MIN NOR MAX DESIGN

Supply header pressure kg/cm²g 8 10.0 11.0 15.0
Pressure available at burner kg/cm²g 5.5 8 11.0 15.0
Return header pressure kg/cm²g 2.0 2.5 3.0 15.0

Temperature at burner °C Ambient 40 40 65.0
FUEL QUALITY UNIT MIN NOR MAX DESIGN

Specific gravity SG 0.962
Lower heating value (LHV) kcal/kg 9480
Viscosity @ 40 °C cP 8.7
Pour point °C 8 max
Flash point °C >66
Sulphur content ppmw 2500 max
Vanadium content ppm wt 2 max
Nickel content ppm wt 1 max
Iron content ppm wt 0.5 max
Nitrogen content ppm wt 60 max
AROMATICS CONTENT
Diethyl Benzene ppmw 110
C11+ Aromatics wt% 5.38
Tetramethyl wt% 1.29
C/H ratio 8.8

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B) FUEL GAS SYSTEM (PID 010-9501):

A. FUEL GAS EXPORT:
Fuel gas generated from De-ethaniser O/H receiver (010-V-009), Recontractor Drum (010-V-007)
and NHT unit is being treated in Amine Absorber (010-C-010) before it put to export header. The
fuel gas which is generated in De-propaniser O/H receiver (010-V-010) is directly feed to the fuel
gas export header. A 14’’ fuel gas header is provided with block valve & spacer and PI-9059, FI-
9020, PG-7727 at B/L for indication.
B. FUEL GAS IMPORT:
Fuel Gas in AVU is made available via 12” header with a block valve and spacer at B/L. Fuel gas
line is electrical traced upto the fuel gas KOD of furnace. At the battery limit PG-7747, PI-9023
& FI-9005 are provided for local and DCS indication.
Tapping to the following equipments in the unit are provided.
1. 010-C-001/010-C-007
2. 010-V-005/010-V-020/010-V-019/010-V-610/010-V-611/010-V-612/010-V-613/010-V-614
3. 010-V-004(Fuel Gas KOD)
4. Purging for LP Flare header, Acid Gas Flare header ,C-001 PSV and C-007 PSV
Fuel Gas Condition &Specification:
FUEL CONDITIONS UNIT MIN NOR MAX DESIGN

Supply pressure (consumer) kg/cm²g 3.2 3.9 4.2 6.0
o
Supply temperature (consumer) C Ambient 40 55 65
Supply pressure (producer) kg.cm2g 4.5 5.0 5.0 6.0
o
Supply temperature (producer) C Ambient 40 50 65
QUALITY Units Value

FUEL TYPE Full Refinery Fuels Refinery Fuel Gas
Net calorific value (LHV) kcal/kg 11,070 11716 ---
Molecular weight - 20.1 21.1 ---
Composition
H2S vol% 0.005 - 0.005
H2 vol% - 13.15 23.70
CO vol% 4.0 - 0.30

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N2 vol% 0.7 - 5.70

O2 vol% - - 0.20
C1 vol% 80.48 38.95 30.30
C2= vol% - 31.99 16.9
C2 vol% 7.7 13.64 15.80

C3= vol% - - 3.5
C3 vol% 4.48 1.29 0.60
C4= vol% - - 0.1
C4 vol% 2.4 0.98 1.20
C5+ vol% 0.22 - 1.20
C6+ vol% 0.02 - -

H2O vol% - - 0.6
17.11 FLARE SYSTEM (PID 9303, 9304 & 9310):
 Safety valves are an essential feature for all pressure vessels {Control or check system of safety
valves is adopted; as a set pressure 5% less than the design pressure but not less than 1 Kg/Cm2
(g) below the design pressure}
 These safety valves discharge into the 42”LP flare header running through the AVU. Before it
joined with the refinery flare header it enters to flare KOD (010-V-301) where liquid if any is
separated from the flare gas. At the battery limit of the LP flare header FT 9018, PT 9018 & TT
9043 is provided with DCS indication.
 The Acid gas flare header enters inline condensate pot .The liquid is drained to ABD via
ON/OFF control valve XV-9026.The acid gas is exported to refinery acid gas flare header.
17.12 CLOSED BLOW DOWN SYSTEM (CBD)-(PID 010-9610, 9611, 9612, 9613, 9614)
Five nos. of underground CBD vessels are provided through out the unit to drain liquid hydrocarbon
from the exchangers, vessels, pipelines & pumps during an emergency or scheduled shutdown of
the unit. CBD vessels are provided in following areas:
Area/Location Vessel No. Pump No.

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Heat Exchanger Train-1 010-V-610 010-P-610

Heat Exchanger Train-1 010-V-611 010-P-611
CDU Area 010-V-612 010-P-612
VDU Area 010-V-613 010-P-613
Naphtha Stabilizer Area 010-V-614 010-P-614
Each CBD is provided with 2”steam coil. LI, TI, PI & FI indicate level, temperature & pressure in
the control room. PG is provided to measure the pressure locally. Liquid fill CBD vessel will be
pumped out by vertically mounted centrifugal pump which is interlocked with level switch. In case
of pump failure i.e. pump fails to start automatically, LAH or LAL will activate an alarm in the
control room of high level or low level respectively. Discharge of the all five CBD’s pumps joined
into an 8” header before it goes to OSBL wet slop tank storage (203-TK-026).
17.13 AMINE BLOW DOWN SYSTEM (PID 010-4002 & 4004)

Lean Amine solution is being used to treat the fuel gas generated from AVU & NHT unit in
Amine Absorber (010-C-010) & Sour gas from hot well and oxidizer vent gas from SR LPG is
being treated in LP scrubber (010-C-009). To drain the amine solution from pump, vessels &
column amine blow down system is provided. The system consists of one underground vessel
(010-V-018) & a vertical submersible pump (010-P-034).
17.14 FLUSHING OIL SYSTEM (FLO) - (PID 010-9551):
An elaborate arrangement of flushing for equipments & lines etc. is available in the unit. 6” header
with double isolation & spectacle blind at B/L is provided with PG-7716, TI-9026, and PI-9035 at
B/L. Flushing oil is supplied to the following equipment for flushing:
Type of Tag No of the Equipments

equipment
Pump 4” FLO line at common suction of 010-P-004A-C
4” FLO line at common suction of 010-P-006A-B
2” FLO line at individual pump suction of 010-P-030A-B
2” FLO line at individual pump suction of 010-P-007A-C
Exchangers 010-E-102/202, 010-E-103/203, 010-E-104A-D/204A-D
010-E-106/206, 010-E-107/207, 010-E-108/208, 010-E-117/217
010-E-119/219, 010-E-122A-D/222A-D, 010-E-123/223
010-E-124A-C/224A-C, 010-E-126/226, 010-E-128/228

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Type of Tag No of the Equipments

equipment
010-E-129/229, 010-E-131/231, 010-E-132/232, 010-E-118/218A-D
010-E-127A-K/227A-K, 010-E-149, 010-E-150, 010-E-039A-B, 010-E-151A-
C/251A-C
Vessels 010-V-019 & 010-V-020
Columns 010-C-001
4” FLO connection in 010-C-007 with vacuum residue quench line
Strainers 010-STR-001A-B, 010-STR-002A-B,
010-STR-003A-B, 010-STR-004A-B & 010-STR-005A-B
Air Coolers 010-AC-015
Furnace 6” FLO connection to 010-F-101/201 & 6” FLO connection to 010-F-002
Connection of 6” FLO connection at battery limit
FLO in other 2” FLO connection at AR line each at train-1 & train-2 only for start-up/VDU
major Locations bypass case
2” FLO connection at start up recycle line.
FLO connection to LG, LT associated with 010-C-001
FLO connection to LT associated with 010-C-007
Unless and otherwise specified all the FLO connection are 2”.

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17.15 Feed & Product Storage Facility:
Feed & Product

Source/ Destination Tank Nominal Temp. Press.
Stream
Capacity (m3) (OC) (kg/cm²g)
Crude Tank
Crude Tank 59,555 35 30.0
(201-TK-001 to 011)
LPG Bullets
C3 LPG 3,130 40 16.0
(205-V-003 to 009 /012/013/014)
LPG Bullets
C4 LPG 3,130 40 17.0
(205-V-003 to 009 /012/013/014)
NHDT Feed Tank

28,852 40 5.5
(203-TK-001/002)
SR Naphtha
GT Tank
6,015 40 5.5
(110-TK-001/002))
DHDT Feed Tank

Kerosene 28,852 40 6.0
(203-TK-005/006)
DHDT Feed Tank (203-TK-005/006) 28,852

VR Tank (203-TK-007/008) 30,763 60 6.0
Atmospheric Gas
Flushing Oil Tank(126-TK-001) 6,783
Oil
HSFO Tanks (105-TK-001/002/003) 10,840
60 6.0
GT Diesel Tanks (110-TK-004/005) 6,015
Vacuum Diesel Storage Tank (203-TK-005/006) 28,852 60 3.0
VGO+HVGO VGO HDT Feed Tank (203-TK-010/011) 72,007 60 6.0
VR Tank (203-TK-007/008) 30,763 190 12.0

Vacuum Residue
HSFO Tank (105-TK-001/002/003) 10,840 190 12.0

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CHAPTER-18
BLIND LIST

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18.1 LIST OF CLOSED SPECTACLE BLIND
Blind size
Sl. No. P&ID No. Line no. Blind Position (Normal)
mm
1 010-6001 10-OWS-010-1106-A2AP-NI 10 Closed spectacle blank
3 010-1004 20-CBD-010-1184-D2AP-PP 20 Closed spectacle blank
7 010-1005 20-OWS-010-1175-D2AP-PP 20 Closed spectacle blank
13 010-1010 20-CBD-010-1061-B1AP-PP 20 Closed spectacle blank
14 010-1010 20-OWS-010-1067-B1AP-PP 20 Closed spectacle blank
19 010-1010 20-FLP-010-1037-B1AP-PP 20 Closed spectacle blank

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Doc. No:
Blind size
mm
22 010-1017 20-SL-010-1005-A1AS-IH 20 Closed spectacle blank
23 010-1018 20-OWS-010-1054-A2AQ-PP 20 Closed spectacle blank
24 010-1018 20-CBD-010-1052-A2AQ-NI 20 Closed spectacle blank
29 010-1018 20-FLP-010-1031-A2AQ-PP 20 Closed spectacle blank

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Blind size
mm
44 010-1021 20-FLP-010-1025-B2FP-IT 20 Closed spectacle blank
46 010-1021 20-CBD-010-1042-B2FP-IT 20 Closed spectacle blank
62 010-1024 20-P-010-1447-B1AP-NI 20 Closed spectacle blank
65 010-1025 20-OWS-010-1033-B2FP-IT 20 Closed spectacle blank

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Doc. No:
Blind size
mm
66 010-1025 20-OWS-010-1032-B2FP-IT 20 Closed spectacle blank
69 010-1026 20-OWS-010-1185-A4AR-NI 20 Closed spectacle blank
70 010-1027 20-FLP-010-1062-B2AQ-NI 20 Closed spectacle blank
74 010-1027 20-CBD-010-1049-B2AQ-NI 20 Closed spectacle blank
75 010-1027 20-OWS-010-1051-B2AQ-NI 20 Closed spectacle blank
78 010-1027 20-FLP-010-1029-A4AR-NI 20 Closed spectacle blank
80 010-1035 20-FLP-211-0048-B1GP-IH 20 Closed spectacle blank
82 010-1035 20-FLP-010-9316-B1AP-NI 20 Closed spectacle blank
84 010-1037 20-OWS-010-1047-B38P-IT 20 Closed spectacle blank
85 010-1037 20-CBD-010-1047-B38P-IT 20 Closed spectacle blank

Page 486 of 592

Doc. No:
Blind size
mm
90 010-1040 20-CBD-010-1652-A2AQ-PP 20 Closed spectacle blank
91 010-1040 20-CBD-010-1657-A0LV-PP 20 Closed spectacle blank

Page 487 of 592

Doc. No:
Blind size
mm
111 010-1041 20-OWS-010-1057-B2AQ-PP 20 Closed spectacle blank
114 010-1041 20-OWS-010-1056-B2AQ-PP 20 Closed spectacle blank
117 010-1041 20-FLP-010-1035-B2AQ-PP 20 Closed spectacle blank

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Doc. No:
Blind size
mm
144 010-2007 20-FLP-010-2052-B2GQ-NI 20 Closed spectacle blank

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Doc. No:
Blind size
mm
160 010-2010 20-FLP-010-2050-B1GP-NI 20 Closed spectacle blank
165 010-2011 20-P-010-4080-B1GP-NI 20 Closed spectacle blank
166 010-2013 20-P-211-4078-B1GP-NI 20 Closed spectacle blank
169 010-2013 20-OWS-010-2016-B1GP-NI 20 Closed spectacle blank

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Doc. No:
Blind size
mm
196 010-3004 20-P-010-3304-D382-IT 20 Closed spectacle blank

Page 491 of 592

Doc. No:
Blind size
mm
199 010-3005 20-P-010-3309-D0L2-IT 20 Closed spectacle blank
200 010-3005 20-P-010-3305-D0L2-IT 20 Closed spectacle blank
201 010-3006 20-P-010-3133-B4F2-IT 20 Closed spectacle blank
202 010-3006 20-P-010-3152-B4FV-IT 20 Closed spectacle blank
205 010-3006 20-P-010-3149-B2FP-IT 20 Closed spectacle blank
210 010-3011 20-CBD-010-3082-B4AR-NI 20 Closed spectacle blank
211 010-3011 20-OWS-010-3084-B4AR-NI 20 Closed spectacle blank
214 010-3012 20-P-010-3166-B2AP-IT 20 Closed spectacle blank
219 010-3035 20-CBD-010-3209-A0L2-PP 20 Closed spectacle blank

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Blind size
mm
220 010-3035 20-CBD-010-3183-A2A6-PP 20 Closed spectacle blank
221 010-3035 20-FLP-010-3024-A2A6-PP 20 Closed spectacle blank
222 010-3035 20-FLP-010-3023-A2A6-PP 20 Closed spectacle blank
223 010-3035 20-CBD-010-3208-A2A6-PP 20 Closed spectacle blank
225 010-3035 20-CBD-010-3185-A0L2-PP 20 Closed spectacle blank
226 010-4003 20-AM-010-4024-A4AR-NI 20 Closed spectacle blank
230 010-6002 20-FLP-010-2128-A2GQ-PP 20 Closed spectacle blank
232 010-6002 20-FLP-010-2126-B1GP-PP 20 Closed spectacle blank
233 010-6002 20-FLP-010-2127-B1GP-PP 20 Closed spectacle blank
235 010-6002 20-FLP-010-2130-A1GP-NI 20 Closed spectacle blank
237 010-6002 20-FLP-010-2132-B4AR-NI 20 Closed spectacle blank
239 010-6002 20-FLP-010-2134-A1AP-NI 20 Closed spectacle blank
240 010-6013 20-CBD-010-6005-B2AP-NI 20 Closed spectacle blank
241 010-6013 20-OWS-010-6154-B2AP-NI 20 Closed spectacle blank

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Blind size
mm
245 010-9310 20-OWS-010-9306-A2AQ-NI 20 Closed spectacle blank
249 010-2001 25-N-010-2001-A2AQ-NI 25 Closed spectacle blank
253 010-3012 25-P-010-3134-B2A2-IT 25 Closed spectacle blank
254 010-3012 25-P-010-3602-B2A2-IT 25 Closed spectacle blank

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Blind size
mm
273 010-2001 40-N-010-2000-A4AR-PP 40 Closed spectacle blank
274 010-2002 40-N-010-2005-A4AR-PP 40 Closed spectacle blank

Page 495 of 592

Doc. No:
Blind size
mm
287 010-1001 50-FLO-010-1033-B1AP-NI 50 Closed spectacle blank
288 010-1001 50-CBD-010-1195-B2AP-IT 50 Closed spectacle blank

Page 496 of 592

Doc. No:
Blind size
mm
317 010-1011 50-FLO-010-1012-B2FP-NI 50 Closed spectacle blank
322 010-1011 50-CBD-010-1205-B4AV-PP 50 Closed spectacle blank
324 010-1012 50-FLO-010-1027-B4AV-NI 50 Closed spectacle blank
329 010-1013 50-OWS-010-1003-A2AD-NI 50 Closed spectacle blank

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Doc. No:
Blind size
mm
330 010-1013 50-SL-010-1012-A2AD-IH 50 Closed spectacle blank
331 010-1013 50-FLP-010-1088-A2AD-NI 50 Closed spectacle blank
332 010-1013 50-FLP-010-1088-A2AD-NI 50 Closed spectacle blank
335 010-1016 50-P-010-1212-A2AQ-PP 50 Closed spectacle blank
342 010-1026 50-CBD-010-1095-A4AR-NI 50 Closed spectacle blank
346 010-1027 50-SL-010-1013-A4AR-IH 50 Closed spectacle blank

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Doc. No:
Blind size
mm
352 010-1034 50-FLO-010-1020-D38P-NI 50 Closed spectacle blank
354 010-1034 50-CBD-010-1204-B38P-PP 50 Closed spectacle blank
361 010-1035 50-CBD-010-1095-B2AQ-PP 50 Closed spectacle blank
364 010-1037 50-FLO-010-1016-B38P-NI 50 Closed spectacle blank
370 010-1037 50-P-010-1299-B38P-IT 50 Closed spectacle blank

Page 499 of 592

Doc. No:
Blind size
mm

Page 500 of 592

Doc. No:
Blind size
mm

Page 501 of 592

Doc. No:
Blind size
mm
418 010-1134 50-CBD-010-1697-B38P-PP 50 Closed spectacle blank
431 010-2007 50-N-010-2013-A2GQ-NI 50 Closed spectacle blank
432 010-2008 50-FLP-010-2090-A2GQ-NI 50 Closed spectacle blank
435 010-2010 50-N-010-2014-A1GP-NI 50 Closed spectacle blank

Page 502 of 592

Doc. No:
Blind size
mm
441 010-3001 50-SL-010-3020-A2AL-IH 50 Closed spectacle blank
442 010-3001 50-OWS-010-3003-A2AL-NI 50 Closed spectacle blank
443 010-3003 50-OWS-010-3096-A1A4-IH 50 Closed spectacle blank
444 010-3003 50-FG-010-3005-A2A6-NI 50 Closed spectacle blank
447 010-3004 50-SM-010-3033-B1AS-IH 50 Closed spectacle blank
448 010-3004 50-FLO-010-3012-D382-NI 50 Closed spectacle blank
450 010-3004 50-CBD-010-3057-D38P-PP 50 Closed spectacle blank
456 010-3005 50-OWS-010-3075-D0LV-IT 50 Closed spectacle blank
457 010-3005 50-FLO-010-3001-D0L2-NI 50 Closed spectacle blank
458 010-3005 50-CBD-010-3065-D0LV-IT 50 Closed spectacle blank
459 010-3005 50-FLO-010-3003-D0L2-NI 50 Closed spectacle blank
460 010-3005 50-CBD-010-3067-D0LV-IT 50 Closed spectacle blank
461 010-3005 50-OWS-010-3077-D0LV-IT 50 Closed spectacle blank

Page 503 of 592

Doc. No:
Blind size
mm
462 010-3005 50-FLO-010-3136-D38P-PP 50 Closed spectacle blank
463 010-3006 50-CBD-010-3100-B2FP-PP 50 Closed spectacle blank
464 010-3006 50-OWS-010-3091-B4FV-PP 50 Closed spectacle blank
465 010-3006 50-SL-010-3018-B4FV-IT 50 Closed spectacle blank
468 010-3006 50-SL-010-3016-B2FP-IT 50 Closed spectacle blank
469 010-3006 50-FLO-010-3006-B4F2-NI 50 Closed spectacle blank
470 010-3006 50-FLO-010-3061-B4FV-NI 50 Closed spectacle blank
471 010-3006 50-SL-010-3015-B2FP-IT 50 Closed spectacle blank
472 010-3006 50-CBD-010-3101-B4FV-PP 50 Closed spectacle blank
475 010-3006 50-SL-010-3017-B4FV-IT 50 Closed spectacle blank

Page 504 of 592

Doc. No:
Blind size
mm
486 010-3006 50-FLO-010-3060-B4FV-NI 50 Closed spectacle blank
490 010-3007 50-OWS-010-3001-B2AS-IH 50 Closed spectacle blank
491 010-3007 50-OWS-010-3011-B2FP-PP 50 Closed spectacle blank
500 010-3010 50-P-010-3095-A2AQ-NI 50 Closed spectacle blank
501 010-3010 50-SL-010-3012-B2AQ-NI 50 Closed spectacle blank
502 010-3010 50-SL-010-3014-A4AR-NI 50 Closed spectacle blank

Page 505 of 592

Doc. No:
Blind size
mm
507 010-3012 50-SL-010-3081-B2AP-IT 50 Closed spectacle blank
508 010-3012 50-FLO-010-3096-B2A2-NI 50 Closed spectacle blank
512 010-3012 50-FLO-010-3095-B0J2-NI 50 Closed spectacle blank

Page 506 of 592

Doc. No:
Blind size
mm
538 010-3013 50-SL-010-3035-B2AP-IH 50 Closed spectacle blank
540 010-3013 50-SL-010-3036-B2AP-IH 50 Closed spectacle blank

Page 507 of 592

Doc. No:
Blind size
mm
554 010-3021 50-FLO-010-3101-A1AD-NI 50 Closed spectacle blank
571 010-3028 50-OWS-010-3069-A1AS-PP 50 Closed spectacle blank

Page 508 of 592

Doc. No:
Blind size
mm
585 010-3028 50-OWS-010-3099-B1AP-IT 50 Closed spectacle blank

Page 509 of 592

Doc. No:
Blind size
mm
596 010-3031 50-OWS-010-3105-B2A6-NI 50 Closed spectacle blank
597 010-3031 50-CBD-010-3196-B2A6-NI 50 Closed spectacle blank

Page 510 of 592

Doc. No:
Blind size
mm
631 010-4003 50-N-010-4003-A2AL-NI 50 Closed spectacle blank

Page 511 of 592

Doc. No:
Blind size
mm

Page 512 of 592

Doc. No:
Blind size
mm

Page 513 of 592

Doc. No:
Blind size
mm

Page 514 of 592

Doc. No:
Blind size
mm

Page 515 of 592

Doc. No:
Blind size
mm
727 010-6001 50-CBD-010-1160-D38P-NI 50 Closed spectacle blank
742 010-6001 50-CBD-010-1571-B4AV-NI 50 Closed spectacle blank

Page 516 of 592

Doc. No:
Blind size
mm
751 010-6001 50-CBD-010-1649-B4FV-NI 50 Closed spectacle blank
754 010-6001 50-CBD-010-1159-B2FP-NI 50 Closed spectacle blank

Page 517 of 592

Doc. No:
Blind size
mm

Page 518 of 592

Doc. No:
Blind size
mm

Page 519 of 592

Doc. No:
Blind size
mm

Page 520 of 592

Doc. No:
Blind size
mm

Page 521 of 592

Doc. No:
Blind size
mm
876 010-6002 50-P-010-2182-A1AP-NI 50 Closed spectacle blank
878 010-6002 50-P-010-2177-B2AP-PP 50 Closed spectacle blank

Page 522 of 592

Doc. No:
Blind size
mm
885 010-6002 50-P-010-2180-A4AR-NI 50 Closed spectacle blank
888 010-6013 50-CBD-010-6004-A2AP-NI 50 Closed spectacle blank
892 010-6014 50-FLO-010-6003-A2AP-NI 50 Closed spectacle blank
898 010-6014 50-CBD-010-6009-A2AP-NI 50 Closed spectacle blank

Page 523 of 592

Doc. No:
Blind size
mm
902 010-9303 50-N-010-9300-A2AQ-IT 50 Closed spectacle blank
908 010-9612 50-SL-010-9606-A2AQ-NI 50 Closed spectacle blank
911 010-9615 50-OWS-010-9600-A2AS-NI 50 Closed spectacle blank
914 010-1010 80-OWS-010-1011-A1AP-PP 80 Closed spectacle blank
915 010-1010 80-SL-010-1011-A1AP-IH 80 Closed spectacle blank
916 010-1010 80-CBD-010-1034-A1AP-PP 80 Closed spectacle blank
919 010-1017 80-CBD-010-1016-A38P-IT 80 Closed spectacle blank

Page 524 of 592

Doc. No:
Blind size
mm
924 010-1025 80-OWS-010-1012-A2FP-IT 80 Closed spectacle blank
929 010-1027 80-SL-010-1014-A4AR-IH 80 Closed spectacle blank
933 010-2004 80-CBD-010-2012-B1AP-IH 80 Closed spectacle blank
936 010-2006 80-SL-010-2003-B4AR-IH 80 Closed spectacle blank
938 010-2007 80-SL-010-2004-B1GP-IH 80 Closed spectacle blank
939 010-2009 80-SL-010-2005-B2GQ-NI 80 Closed spectacle blank
940 010-2010 80-SL-010-2006-B1GP-IH 80 Closed spectacle blank
942 010-2012 80-SL-010-2007-B1GP-NI 80 Closed spectacle blank
944 010-3003 80-CBD-010-3032-A382-PP 80 Closed spectacle blank

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Doc. No:
Blind size
mm
946 010-6013 80-FLO-010-6001-A2AP-PP 80 Closed spectacle blank
953 010-1004 100-WP-010-1031-D2AQ-IH 100 Closed spectacle blank
958 010-1012 100-P-010-1951-B2FP-IT 100 Closed spectacle blank
959 010-1016 100-FG-010-1008-A2AD-NI 100 Closed spectacle blank
960 010-1018 100-FLO-010-1004-A2AQ-NI 100 Closed spectacle blank
961 010-1020 100-FLO-010-1002-A2AP-NI 100 Closed spectacle blank
964 010-1104 100-WP-010-1531-D2AQ-IH 100 Closed spectacle blank

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Doc. No:
Blind size
mm
972 010-3003 100-FLO-010-3106-A4A2-NI 100 Closed spectacle blank
974 010-1001 150-FLO-010-3010-B1AP-IE 150 Closed spectacle blank
975 010-1027 150-WS-010-9467-A2AQ-NI 150 Closed spectacle blank
976 010-3011 150-P-010-3171-B4AR-NI 150 Closed spectacle blank
977 010-3011 150-WS-010-9468-A4AR-NI 150 Closed spectacle blank
978 010-3012 150-FLO-010-3100-A2A2-NI 150 Closed spectacle blank
981 010-1035 200-P-010-1482-B2AQ-NI 200 Closed spectacle blank
982 010-3004 200-CM-010-3048-B1AS-IH 200 Closed spectacle blank
Note: This list doesn’t includes the closed spectacle blank of Heaters

Page 527 of 592

Doc. No:
18.2 LIST OF OPEN SPECTACLE BLIND
Blind size Blind Position

Sl. No. P&ID No. Line no.
mm (Normal)
1 010-1006 20-OWS-010-1063-D2AQ-NI 20 Open spectacle blank
2 010-1006 20-OWS-010-1064-D2AQ-NI 20 Open spectacle blank
3 010-3006 20-P-010-3151-B4FV-IT 20 Open spectacle blank
4 010-3006 20-P-010-3149-B2FP-IT 20 Open spectacle blank
5 010-3010 20-FLP-010-3019-B2AQ-NI 20 Open spectacle blank
6 010-3010 20-FLP-010-3020-B2AQ-NI 20 Open spectacle blank
7 010-3012 20-P-010-3166-B2AP-IT 20 Open spectacle blank
9 010-3013 20-WCR-010-3042-A2AW-NI 20 Open spectacle blank
10 010-3013 20-WCS-010-3042-A2AW-NI 20 Open spectacle blank
15 010-9615 20-CL-010-9615-A2AS-PP 20 Open spectacle blank
17 010-1001 25-C-010-1000-D0LV-IT 25 Open spectacle blank
20 010-1010 25-P-010-1054-B1AP-IH 25 Open spectacle blank

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mm (Normal)
23 010-1016 25-C-010-1005-A0LV-PP 25 Open spectacle blank
32 010-1026 25-WP-010-1054-A4AR-NI 25 Open spectacle blank

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mm (Normal)
64 010-1037 25-P-010-1117-B38P-IT 25 Open spectacle blank

Page 530 of 592

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mm (Normal)
67 010-3007 25-C-010-3007-D0LV-NI 25 Open spectacle blank
80 010-4001 40-AM-010-4014-A4AR-NI 40 Open spectacle blank
83 010-1004 50-P-010-1194-B1AP-PP 50 Open spectacle blank

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mm (Normal)
87 010-1006 50-WP-010-1090-B2AP-NI 50 Open spectacle blank
88 010-1010 50-P-010-1330-A2AP-PP 50 Open spectacle blank
89 010-1013 50-FG-010-1003-A2AD-NI 50 Open spectacle blank
90 010-1016 50-C-010-1004-B1LV-PP 50 Open spectacle blank
91 010-1027 50-FLP-010-1139-A2AQ-NI 50 Open spectacle blank
92 010-1037 50-OWS-010-1024-B38P-IT 50 Open spectacle blank
100 010-2000 50-P-010-2110-A2AQ-NI 50 Open spectacle blank
101 010-2000 50-CBD-010-2011-A2AQ-NI 50 Open spectacle blank
102 010-2001 50-P-010-2087-A4AR-PP 50 Open spectacle blank
105 010-2004 50-P-010-2036-A2AQ-PP 50 Open spectacle blank
107 010-2007 50-P-010-2067-A2GQ-PP 50 Open spectacle blank
108 010-2009 50-P-010-2073-B2GQ-NI 50 Open spectacle blank

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mm (Normal)
111 010-2010 50-P-010-2085-A1GP-NI 50 Open spectacle blank
112 010-2011 50-FLP-010-2076-A1GP-NI 50 Open spectacle blank
113 010-2012 50-P-010-2103-B1GP-NI 50 Open spectacle blank
116 010-3003 50-C-010-3002-B1LV-NI 50 Open spectacle blank
117 010-3003 50-C-010-3001-A0LV-NI 50 Open spectacle blank
118 010-3003 50-N-010-3000-A2A6-NI 50 Open spectacle blank
119 010-3004 50-SH-010-3001-D1AS-IH 50 Open spectacle blank
120 010-3007 50-WB-010-3002-B2AS-IH 50 Open spectacle blank
121 010-3007 50-BD-010-3012-B2AS-IH 50 Open spectacle blank
126 010-3010 50-P-010-3139-B2AP-NI 50 Open spectacle blank
127 010-3011 50-P-010-3049-A4AR-NI 50 Open spectacle blank

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mm (Normal)
152 010-3028 50-SL-010-3064-A1AS-IH 50 Open spectacle blank

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mm (Normal)

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mm (Normal)
179 010-3030 50-P-010-3676-A2A6-IA 50 Open spectacle blank
180 010-3033 50-SM-010-3039-B1AS-IH 50 Open spectacle blank
182 010-4001 50-P-010-4006-A2AQ-IT 50 Open spectacle blank
183 010-4001 50-AM-010-4020-B2AL-IH 50 Open spectacle blank
184 010-4001 50-N-010-4002-A2AQ-NI 50 Open spectacle blank
186 010-4002 50-N-010-4001-A4AR-NI 50 Open spectacle blank
191 010-4003 50-P-010-0068-A2AN-IT 50 Open spectacle blank
194 010-9205 50-WDK-010-9002-S1RW-NI 50 Open spectacle blank
195 010-9205 50-WDM-010-9205-A0JV-NI 50 Open spectacle blank

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mm (Normal)
198 010-9610 50-FG-010-9600-A2AQ-NI 50 Open spectacle blank
210 010-1001 80-WP-010-1000-D2AP-IT 80 Open spectacle blank
211 010-1010 80-P-010-1203-B2AQ-NI 80 Open spectacle blank
212 010-1022 80-OWS-010-1001-A2AP-IH 80 Open spectacle blank
213 010-1023 80-OWS-010-1002-A2AP-PP 80 Open spectacle blank
214 010-1025 80-OWS-010-1012-A2FP-IT 80 Open spectacle blank
215 010-1025 80-P-010-1148-A2FP-IT 80 Open spectacle blank
216 010-1041 80-P-010-1321-B2AQ-IH 80 Open spectacle blank

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mm (Normal)
219 010-1101 80-WP-010-1500-D2AP-IT 80 Open spectacle blank
220 010-2002 80-P-211-2019-B4AR-NI 80 Open spectacle blank
221 010-2003 80-OWS-010-2002-A2AQ-NI 80 Open spectacle blank
222 010-2006 80-OWS-010-2005-A2AQ-NI 80 Open spectacle blank
223 010-2007 80-P-010-2028-B1GP-PP 80 Open spectacle blank
233 010-2012 80-OWS-010-2009-B1GP-NI 80 Open spectacle blank
234 010-2012 80-FG-010-2003-B1GP-NI 80 Open spectacle blank

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mm (Normal)
244 010-3003 80-P-010-3036-A0L2-IT 80 Open spectacle blank
260 010-4003 80-AM-010-4007-B2AL-IH 80 Open spectacle blank

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mm (Normal)
268 010-6013 80-FLP-010-6055-A2AP-PP 80 Open spectacle blank
273 010-6014 80-FLP-010-6056-A2AP-NI 80 Open spectacle blank
275 010-6014 80-P-010-6120-A2AP-IT 80 Open spectacle blank
277 010-6014 80-P-010-6122-A2AP-IT 80 Open spectacle blank
280 010-9310 80-SL-010-9610-A2AQ-IH 80 Open spectacle blank
281 010-9451 80-N-010-9451-A1AA-NI 80 Open spectacle blank

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mm (Normal)
291 010-1004 100-WP-010-1019-D2AQ-IH 100 Open spectacle blank
292 010-1004 100-WP-010-1095-D2AP-PP 100 Open spectacle blank
298 010-1006 100-WP-010-1002-D2AQ-NI 100 Open spectacle blank
300 010-1006 100-WP-010-1004-A2AQ-NI 100 Open spectacle blank
301 010-1022 100-P-010-1121-A2AP-IH 100 Open spectacle blank
304 010-1025 100-SL-010-1007-A2FP-IH 100 Open spectacle blank

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mm (Normal)
324 010-2008 100-WCR-010-2008-A2AP-NI 100 Open spectacle blank
325 010-2008 100-WCS-010-2005-A2AP-NI 100 Open spectacle blank
328 010-2008 100-P-010-2068-A2GQ-NI 100 Open spectacle blank

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mm (Normal)

Page 543 of 592

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mm (Normal)
352 010-3031 100-WP-010-3004-B2A6-NI 100 Open spectacle blank

Page 544 of 592

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mm (Normal)
374 010-6013 100-WCR-010-6063-B2AP-NI 100 Open spectacle blank
375 010-6013 100-WCS-010-6075-B2AP-NI 100 Open spectacle blank
010-9102 S-
378 100-CL-010-9102-A2AS-PP 100 Open spectacle blank
3
010-9401 S-
379 100-AI-010-9401-A1AA-NI 100 Open spectacle blank
2
380 010-9551 100-FO-010-9551-A1AD-NI 100 Open spectacle blank
381 010-9551 100-FO-010-9552-A1AD-NI 100 Open spectacle blank
385 010-9616 100-SL-010-9611-A1AS-PP 100 Open spectacle blank
386 010-9616 100-BD-010-9600-A2AS-PP 100 Open spectacle blank
387 010-9616 100-BD-010-3016-A2AS-PP 100 Open spectacle blank
390 010-1005 150-WP-010-1014-B4AV-PP 150 Open spectacle blank

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mm (Normal)
397 010-1007 150-WP-010-1025-B4AV-IH 150 Open spectacle blank
402 010-1008 150-WP-010-1008-B4AV-NI 150 Open spectacle blank
406 010-1017 150-P-010-1119-A2FP-IH 150 Open spectacle blank

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mm (Normal)

Page 547 of 592

Doc. No:

mm (Normal)

Page 548 of 592

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mm (Normal)
468 010-1107 150-WP-010-1525-B4AV-IH 150 Open spectacle blank
479 010-2011 150-WCR-010-2011-A2AP-NI 150 Open spectacle blank
480 010-2011 150-WCS-010-2007-A2AP-NI 150 Open spectacle blank

Page 549 of 592

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mm (Normal)
483 010-2016 150-P-010-2166-B4AR-PP 150 Open spectacle blank

Page 550 of 592

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mm (Normal)
523 010-3001 150-P-010-3137-A2AL-IT 150 Open spectacle blank
524 010-3001 150-P-010-3135-A2AL-IT 150 Open spectacle blank
525 010-3002 150-P-010-3017-D0LV-IT 150 Open spectacle blank

Page 551 of 592

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mm (Normal)
526 010-3003 150-P-010-3070-A0J2-IT 150 Open spectacle blank

Page 552 of 592

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mm (Normal)
551 010-4001 150-P-010-4021-A2A8-NI 150 Open spectacle blank
554 010-5010 150-WF-010-1088-A2AU-NI 150 Open spectacle blank
555 010-9201 150-WS-010-9201-A2AW-NI 150 Open spectacle blank
010-9401
559 150-AP-010-9401-A1AA-NI 150 Open spectacle blank
S-1
560 010-9551 150-FLO-010-9551-A1AD-NI 150 Open spectacle blank

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mm (Normal)
573 010-9615 150-SL-010-9612-A1AS-PP 150 Open spectacle blank
576 010-1006 200-WP-010-1001-A2AQ-PP 200 Open spectacle blank
588 010-1022 200-SL-010-1001-A2AP-IH 200 Open spectacle blank
590 010-1023 200-SL-010-1002-A2AP-IH 200 Open spectacle blank

Page 554 of 592

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mm (Normal)
591 010-1025 200-P-010-1119-A2FP-IH 200 Open spectacle blank
600 010-1034 200-P-010-3009-D38P-IT 200 Open spectacle blank

Page 555 of 592

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mm (Normal)
621 010-2005 200-P-010-2244-A1AP-NI 200 Open spectacle blank
624 010-2007 200-P-010-2057-B1GP-IH 200 Open spectacle blank
629 010-3001 200-P-010-4004-A2AL-IH 200 Open spectacle blank
634 010-3008 200-SL-010-3005-B1AS-IH 200 Open spectacle blank

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mm (Normal)
642 010-3033 200-P-010-3038-B2A6-NI 200 Open spectacle blank
646 010-4003 200-P-010-4004-A2AL-NI 200 Open spectacle blank
647 010-5010 200-WF-010-1087-A2AU-NI 200 Open spectacle blank
656 010-1006 250-WP-010-1001-B2AQ-PP 250 Open spectacle blank

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mm (Normal)
665 010-3003 250-P-010-3025-A0J2-IT 250 Open spectacle blank
667 010-3009 400-FLP-010-3009-A2A6-IH 400 Open spectacle blank
Note: This list doesn’t includes the open spectacle blank of Heaters
18.3 LIST OF OPEN SPACER

mm (Normal)
1 010-1026 200-P-010-1339-A4AR-PP 200 Open spacer

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mm (Normal)

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mm (Normal)
29 010-3019 200-SL-010-3025-B1AS-IH 200 Open spacer
30 010-3020 200-SL-010-3026-B1AS-IH 200 Open spacer
31 010-1001 250-P-010-1320-B2AP-IT 250 Open spacer
33 010-1002 250-P-010-1276-B2AP-IH 250 Open spacer
49 010-1011 250-P-010-3021-B4FV-IT 250 Open spacer

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mm (Normal)
52 010-1011 250-P-010-1061-B4AV-IT 250 Open spacer
54 010-1011 250-P-010-3027-B2FP-IT 250 Open spacer
58 010-1012 250-P-010-1073-B2FP-IH 250 Open spacer
59 010-1013 250-FG-010-1004-A2AD-IT 250 Open spacer
61 010-1016 250-P-010-1076-A2AP-IH 250 Open spacer
69 010-1024 250-P-010-1481-B1AP-NI 250 Open spacer
70 010-1024 250-P-010-1136-B1AP-NI 250 Open spacer
71 010-1024 250-WCS-010-1000-A2AP-NI 250 Open spacer

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mm (Normal)
72 010-1024 250-WCR-010-1000-A2AP-NI 250 Open spacer
74 010-1035 250-P-010-2017-B2AQ-NI 250 Open spacer
75 010-1035 250-P-010-2030-B2AQ-IH 250 Open spacer
76 010-1037 250-P-010-1302-B38P-IT 250 Open spacer

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mm (Normal)
109 010-2003 250-P-010-2010-A4AR-NI 250 Open spacer
110 010-2004 250-WCS-010-2002-A2AW-NI 250 Open spacer
111 010-2004 250-WCR-010-2003-A2AW-NI 250 Open spacer
115 010-2006 250-P-010-2115-A2AQ-NI 250 Open spacer

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mm (Normal)
116 010-3003 250-P-010-3059-A4A2-IT 250 Open spacer
117 010-3004 250-P-010-3100-D38P-IT 250 Open spacer
120 010-3005 250-P-010-3016-D0L2-IT 250 Open spacer
121 010-3005 250-P-010-3006-D0L2-IT 250 Open spacer
127 010-3011 250-P-010-3046-B4AR-NI 250 Open spacer
129 010-3030 250-SM-010-3042-B1AS-IH 250 Open spacer
133 010-4002 250-FG-010-4004-A2AD-NI 250 Open spacer
134 010-9303 250-FAG-010-9303-A2AQ-IT 250 Open spacer
135 010-9615 250-CL-010-9611-A2AS-PP 250 Open spacer

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mm (Normal)
159 010-1017 300-P-010-1173-A2FP-IT 300 Open spacer

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mm (Normal)
161 010-1024 300-P-010-1135-B1AP-PP 300 Open spacer
170 010-1034 300-P-010-1063-B4FV-IH 300 Open spacer

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mm (Normal)

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mm (Normal)
213 010-2005 300-P-010-2046-A1AP-NI 300 Open spacer
217 010-2010 300-P-010-2078-B1GP-IH 300 Open spacer

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mm (Normal)
238 010-3031 300-P-010-3637-B2A6-NI 300 Open spacer

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mm (Normal)
252 010-1008 350-WCS-010-1005-B2AP-NI 350 Open spacer
253 010-1008 350-WCR-010-1005-B2AP-NI 350 Open spacer
255 010-1017 350-P-010-1072-A2AP-IT 350 Open spacer
256 010-1017 350-SL-010-1005-A1AS-IH 350 Open spacer
262 010-1108 350-WCR-010-1505-B2AP-NI 350 Open spacer
263 010-1108 350-WCS-010-1505-B2AP-NI 350 Open spacer
267 010-2004 350-P-010-2031-A2AQ-PP 350 Open spacer

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mm (Normal)
270 010-2005 350-P-010-2106-B1AP-PP 350 Open spacer
271 010-3003 350-P-010-3078-A0J2-IT 350 Open spacer
272 010-3004 350-P-010-3099-D382-IT 350 Open spacer
273 010-3004 350-P-010-3007-D382-IT 350 Open spacer
274 010-3004 350-P-010-3008-D382-IT 350 Open spacer
275 010-3012 350-P-010-3078-B0J2-IT 350 Open spacer
285 010-9501 350-FG-010-9608-A2AD-NI 350 Open spacer

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mm (Normal)
299 010-1016 400-P-010-1088-A2AQ-IH 400 Open spacer
300 010-1017 400-SL-010-1005-A1AS-IH 400 Open spacer

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mm (Normal)
320 010-2000 400-P-010-2005-A2AQ-IT 400 Open spacer
331 010-3010 400-WP-010-3001-A2AQ-NI 400 Open spacer

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mm (Normal)
345 010-3033 400-P-010-3666-B2A6-IA 400 Open spacer

Page 574 of 592

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mm (Normal)
362 010-9310 400-FLP-011-9001-A2AQ-NI 400 Open spacer

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mm (Normal)
381 010-3003 450-P-010-3007-A382-IT 450 Open spacer
383 010-3006 450-P-010-3005-B4F2-IT 450 Open spacer
401 010-3003 500-P-010-3005-A4F2-IT 500 Open spacer

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mm (Normal)
402 010-3003 500-P-010-3144-A4F2-IT 500 Open spacer
403 010-3012 500-P-010-3003-B2A2-IT 500 Open spacer
416 010-1017 600-P-010-1108-A2FP-IT 600 Open spacer
418 010-1017 600-P-010-1198-A2AP-IT 600 Open spacer

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mm (Normal)
429 010-3003 650-SL-010-3004-A1A4-IH 650 Open spacer
430 010-3003 650-SL-010-3004-A1A4-IH 650 Open spacer
434 010-1001 750-P-010-1000-B1AP-IE 750 Open spacer
436 010-1017 750-P-010-1113-A38P-IT 750 Open spacer
010-9204
443 750-WCS-010-9204-A2AW-NI 750 Open spacer
S-1
010-9204
444 750-WCR-010-9204-A2AW-NI 750 Open spacer
S-1

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mm (Normal)
445 010-1017 900-P-010-1075-A38P-IH 900 Open spacer
446 010-1017 900-P-010-1575-A38P-IH 900 Open spacer
459 010-1016 1050-P-010-1082-A2AQ-PP 1050 Open spacer
463 010-3003 1200-P-010-3310-A2A6-IA 1200 Open spacer
010-9204
464 1200-WCR-010-9208-A2AW-NI 1200 Open spacer
S-2
010-9204
465 1200-WCS-212-9207-A2AW-NI 1200 Open spacer
S-2

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mm (Normal)
Note: This list doesn’t includes the open spacer of Heaters

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CHAPTER 19
STANDING INSTRUCTIONS

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Following instructions must be followed for safe operation of the AVU and its associated facilities:
A. General
1. AVU & SR-LPG Treatment Area and its associated facilities is declared as restricted area. Unauthorized
movement of vehicles / persons is not allowed in this area.
2. ‘Shift-In-Charge’ to report the plant conditions/ unit upsets/ tripping of critical equipment etc. to the
‘Unit-In-Charge’.
3. All the Shift Officers must sign the Instruction register after going through the Instructions given by the
Unit-in-charge.
4. Log of the previous shift, current log-book, Laboratory results should be signed by every ‘Shift-in-
charge’.
5. Reasons for deviation from instructions and corrective actions taken should be recorded in the ‘Shift-In-
Charge’ log book.
6. Shift-in-charge and Panel officer to ensure that the following records are maintained.
Documents to be Maintained
S.No. Description
1. Shift Officer Logbook

2. Laboratory Results Register
3. Steam /Hydrocarbon Leak Register
4. Interlock Bypass Register

5. Energising/Deenergising status in E-Lockout
6. Shutdown Joblist Register
7. Chemical /Lube Oil Consumption Record
8. PSV Checking Record
7. Field-in-Charge to countersign respective Engineering Assistant logbooks.

8. Shift-in-charge & Field-in-charge to routinely ‘pass on’ Plant-in-charge’s important instructions in
the Field instruction Book.
9. Shift-in-charge to ensure that ‘Activity Matrix’ jobs are strictly adhered to; its compliance to be
mentioned in SIC’s logbook.
10. Night Shift-in-Charge to note down all the jobs to be carried out the next day and issue Notifications
of the same.

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11. Normally, all job requests are required to be issued as SAP notifications.
12. Jobs which cannot be attended during Unit running are to be logged in the Shutdown jobs register.
13. Night Shift-in-charge to ensure that previous days’ DOR is prepared and updated on Intranet.
14. All Absentees shall be made ready for Time Office within forty-five minutes of the commencement
of the shift.
15. Shift changes are only allowed for extra-ordinary cases with the approval of PNM/CPNM.
16. Regularization of any attendance is normally not accepted, however as a special case, it can be done
only with approval of Unit-in-Charge.
17. No shift person shall leave the plant unless properly relieved or permitted by ‘Shift-In-Charge’ (in
case of staff) or by ‘Unit-In-Charge’ (in case of officers). However persons completing 16 hrs duty
shall be released by making alternative arrangements.
18. Any Unit personnel person going out of station should take the approval from ‘Unit-In-Charge’
before leaving the station.
19. Always Remove Shoes before entering the DCS Area.
B. SAFETY
1. Use proper Personnel Protective Equipment (PPEs) i.e. helmet, safety shoes, hand gloves while
working/ moving inside the unit. No person should be allowed to work in the area without proper
PPEs.
2. Use personal protective equipments as applicable while handling chemicals and for other unit
operations.
3. Fire of any nature & intensity must be immediately reported by Shift-in-Charge to F&S Control Room
and Unit-in Charge.
4. Ensure good housekeeping, proper illumination and cleaning of the operating area.
5. Ensure that all safety apparatus and first aid equipment are easily available and accessible. Operating
team must be properly trained in using them. Get the fire extinguishers charged/replaced immediately
after use.
6. Normally, the high point vents (HPV’s) and low point drains (LPD’s) must be capped or blinded with
their Isolation valve closed.
7. Oxygen/ hydrocarbon content must be checked along with fire & safety before issuing clearance for
man-entry inside any equipment. Hydrocarbon (Nil) & oxygen content (not less than 19%) to be
ascertained
8. Always ensure stand-by person while working inside the vessel. Vessel entry register is to be kept
near the vessel for entry
9. Operability of utility hose stations/ plant communication system/ PPEs etc. to be ensured.
10. Ensure that man-hole covers/ gratings/ ladders are in healthy condition.
11. Check the surface drains surrounding the operational area and ensure that drains are free from chokage
and oil accumulation.

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12. Always ensure standby person while other one is working inside the vessel.
13. Temporary lighting inside any vessel should be of 24 volts.
14. Only approved safety torches are permitted inside the Unit.
15. Electrical line clearance must be taken before maintenance job is taken up on any rotary equipment.
16. Regularly check the eyewash and safety showers for its operability.
17. In case of any hydrocarbon leak following actions to be taken:
a) Inform shift in charge, RSM and fire station to review the situation and block the vehicular
movement in the area
b) Stop all hot jobs in unit immediately
c) Identify the leak if possible; isolate the source if possible; shutdown the unit if required
d) Stop draining of hydrocarbon, if any.
18. Always keep all trips, interlocks & securities in-line. For Bypass Refer Section E and for Trip Setting
Change Refer Section F.
19. Maintain good housekeeping in and around Unit area
a) Identify any cleaning required. Record in logbook.
b) Initiate action for cleaning. Issue work request to Civil Maintenance.
c) Check the completion of cleaning job. Advice about safety aspects if any, to the persons involved.
d) Inspect the roads/ open channels around the unit and in case of any abnormality initiate action.
20. Inform any change in process parameter to Unit-in-charge, if it was not advised.
21. Follow the operating guidelines as mentioned in Unit Operating Manual. Any deviation to be
discussed and approved by PNM
22. Report the plant conditions to RSM at the end of the shift.
23. Inform to RSM and connecting upstream and downstream Units/ Offsite facilities, TPS & Laboratory
in case of upset or trip of Unit
24. Co-ordinate with RSM in case of any excess flaring
25. No hydrocarbon draining/ venting is to be done unmanned STRICTLY. Only closed draining/venting
to be done in presence of concerned engineering assistant/shift officer.
26. RSM and Unit-in-charge are to be informed immediately for any disturbance in the plant operation
without fail.
27. Any major changes in utility consumption pattern should be communicated by ‘Shift-In-Charge’ to
‘Unit-In-Charge and UCR/TPS.
28. Ensure that lube-oil/chemical drums and other consumables are available in the Unit and are stored
safely.
29. If any excavation or construction activity is going on, ensure that the area is cordoned off.
30. In case of any oil spillages inform ‘Shift-In-Charge’, RSM and Fire & Safety. Take adequate
precautions to avoid further spreading. Keep firewater/ extinguisher/ steam hose ready. Take
preventive measures depending on site condition and barricade the area. Inform ‘Unit-In-Charge’.

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31. Scales/mucks taken out from equipment’s under lighter HC/hydrogen services (e.g. FG, LPG &
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.
32. Proper stenciling in all process lines/utilities/equipment must be done. Depending on the criticality
of the operational requirements use Tags/display boards marked with ‘DANGER’/ DON’T TOUCH/
NOT IN OPERATION/DISCONNECTED/DO NOT OPERATE etc.
33. Follow the standard operational procedure for starting/stopping of rotary equipment, commissioning
& de-commissioning of exchangers, commissioning and de-commissioning of utilities. In case of any
confusion/operational problem/deficiencies bring to the notice of PNM (Unit-in-charge).
34. All emergencies/abnormalities must be handled as per guidelines given in operating manual.
Corrective/appropriate actions are to be taken in consultation with Unit-in-charge/PNM.
35. As far as possible any leakage in utilities/process streams should be attended at the earliest.
36. While taking round of the unit, check for any oil spillage/general leakage. No oil to be allowed to go
open channel. If oil is noticed, divert it to OWS. Locate and stop the oil leak from the source. Special
care should be taken for leakage from sample points/drains/vents etc.
37. At CRWS/Open channel junction at each B/L always CRWS will be lined up. During heavy rain,
divert the water to open channel after checking oil lenient. Inform RSM/WWTP.
38. Clearance to be issued for all maintenance jobs on the clearance certificate & record the clearances
issued in the Log-Book. Jobs completed by the different maintenance agencies to be recorded in the
‘Shift-In-Charge’ log-book. In case the jobs are not getting liquidated, bring it to the notice of ‘Unit-
In-Charge’
C. WORK PERMIT SYSTEM

1. All maintenance jobs must have permits i.e. either hot job or cold job. No job is to be allowed without
permit from authorized person from Production Department.
2. In cold work permit all the entries must be filled properly and potential Hazards if any should be
clearly mentioned.
a) Use of any special PPE to be clearly mentioned.
b) In case if any electrical equipment requires de-energization, its de-energisation number
should be also mentioned.
c) No Blinding/deblinding operation in toxic gases (H2S), hydrocarbon vapors to be done
without wearing proper PPE.
d) All jobs have to be shown at site by the Issuing Authority.
e) HOT-WORK PERMIT
Normally hot jobs should be avoided in the operating Unit / hazardous areas like area close to
OWS & CRWS lines, etc. In case of exigencies, where such hot jobs become extremely
necessary, the following procedure is to be followed –

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a) A multi-disciplinary team comprising of representatives from operation, execution

and Fire & Safety departments should jointly do a “What-if-Analysis” to assess the
hazards and identify the precautionary measures to be taken.
b) These precautionary measures will be recorded in the work permit after approval by
concerned HOD of user department and implemented without any deviation.
c) Fire permit signatory and the permittee shall be one grade higher than approved
authorities.
The following procedure should be followed for performing the gas test before issuing Hot Work
Permit/Clearances.
a) Check battery level indication every time.

b) Do fresh air calibration and check for Zero Error of the Explosimeter/gas detector.
c) Check whether the filters are clean.
d) Check whether the pump is working or not by feeling the suction (applicable to pump
models only).
e) Check whether the probe (wherever provided) is free from any kind of blockage or foreign
matter.
f) Never put the probe inside the liquid hydrocarbon.
g) Check the instrument functioning with a light hydrocarbon before use.
h) Record the readings of gas test in the Permit Clearance Form
D. ACCIDENTS/INCIDENTS/NEAR MISS
1. All near miss incidents/accidents must be brought to the notice of PNM, who after discussions
with SPNM/CPNM would take the appropriate measures. The record of all such incidents must
be recorded and properly deliberated with all the operating staff about the possible consequences.
2. Whenever any accidents takes place Shift-in-Charge shall act as follows:
a) Report the matter to PNM/CPNM/RSM/F&S.
b) Arrange for ambulance to transfer the injured to first Aid/ Hospital. .
c) Fill-up form A-1 for accident reporting & send one copy each to fire station & medical &
also inform on phone to fire station Shift-in-Charge & PNM. .
d) Shift-in-Charge to make quick investigation regarding cause of the accident and record it
on the office copy of A-1 from and also in the Shift Log Book.
e) Supervisor investigation report to be filled in by the Shift-in-Charge concerned (in whose
shift accident occurred) and submit to PNM for further action. This report should preferably
be submitted within the same shift but not later than 48 hours of occurrence accident.

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3. All incidents of fire/ accidents/incident/near miss should be reported to Fire and Safety using the
prescribed forms. Keep ‘Unit-In-Charge’ informed.
4. Online reporting of Incident/ accident/ Near miss is encouraged. Use ‘i-to-e’ to fill up the same.
E. PROCEDURE & AUTHORITY FOR BYPASSING INTERLOCKS
Safety interlocks are provided to ensure a safe shutdown of equipment/plant in case any critical
process or machine variable has exceeded its safe operating value making it unsafe to continue its
operation and/or result in damage to the equipment or plant.
Endeavour should be made to keep all interlocks in line for the safety of the equipment/plant,
however, at times bypassing of interlocks is called for on account of the following reasons:-
 Defective instrumentation.
 Preventive/breakdown maintenance.
 Change in operating practices like discontinuation of fuel oil/fuel gas firing in
certain heaters.
 Special operations like specific pump changeover, desalter desludging, FD/ID fan
operations etc.
The following system is for bypassing of interlocks and maintaining records for the same:

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Notes:
1. Interlocks may be bypassed from bypass switches provided in DCS HWC, PLC Console
or directly from PLC. The approving authority is applicable for all bypassing, irrespective
of the location.
2. Interlock Bypass Register shall be maintained with Operations.
3. The Interlock Bypass Register shall be readily available at all times at DCS Panel of
Unit/Section.
4. In case interlock bypass is being taken due to process/operational reasons, then approving
authority shall be from operations only.
5. In case bypassing is due to maintenance requirements, then concerned maintenance
authority is required to countersign the bypass record.
6. For process interlocks prior to approval by CGM (T), the proposal has to be countersigned
by CGM (TS) also.
7. When bypassing an interlock, Panel officer should clearly mention time and reason for
bypass in his log book along with alternate safety precautions to be taken/already taken
during interlock bypass period.
8. When interlock bypassing is beyond one day, the same is to be mentioned by Unit/Section
In-charge in the Instruction Book along with alternate safety precautions to be
taken/already taken during interlock bypass period.
9. The updated status of interlock bypass shall be included in the Daily Operating Report
generated by operations.
10. The status of bypassed interlocks shall be displayed in DCS graphics for easy awareness
of the Panel Officer.
11. This procedure applies only to bypassing of interlocks for a fixed period of time. In case
of permanent changes, the Procedure/Authority for Changing of Trip Set Points/
Modification of Interlocks is applicable.
F. PROCEDURE & AUTHORITY FOR CHANGE OF TRIP SETTING

Safety interlocks are provided to ensure a safe shutdown of equipment/plant in case any critical
process or machine variable has exceeded its safe operating value making it unsafe to continue its
operation and/or result in damage to the equipment, plant or catalyst. Safe operating values for
process/equipment are provided by the process licensor, detailed engineering consultant or
equipment vendor based on which trip settings are provided for actuation of interlocks.
However, over a period of time, change of trip settings may be called for on account of the following
reasons:-

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 Operating the plant beyond design capacity.

 Non-reliable instrument/source of actuation resulting in repeated false actuation
of trip or failure of trip actuation calling for modification of interlock.
 Increasing safety of plant/equipment.
The following system is proposed for change of trip setting or modification of interlock:
1. Approving authority for change of trip setting or modification of interlock shall be CGM (T).
2. Approval for the same shall be initiated by the discipline requiring the modification eg.
Mechanical, Electrical or Instrumentation Maintenance for machine trip settings and
Process/Production for process interlocks.
3. Approval from outside agency like OEM or Process Licensor shall be taken by the discipline
initiating the approval.
4. Approval shall be generated by zonal engineer, section or unit in-charge.
5. Approval shall be countersigned by section in-charge, HOD and DGM of all disciplines from
Operations, Maintenance and Technical Services affected by the change of trip setting or
modification of interlock and necessarily by section in-charge, HOD and DGM of
Instrumentation to confirm viability of interlock change.
6. Once approved, the requisite changes shall be implemented by Instrumentation Department
under intimation to all concerned.
7. On receipt of intimation, the modification shall be mentioned in the Instruction Book by
Unit/Section In-charge and updated in the subsequent revision of the operating manual as
tabulated in S.No. 9 below.
8. In case hardware modification is required, scheme for the same shall be prepared by Process and
forwarded to Engineering services for engineering within 15 days of approval.
9. Updated information regarding interlock modification shall be included in the following
documents:-
10. This procedure does not apply to interlock modifications taken up during revamp projects.

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11. This procedure applies only to interlock modification/trip setting change. In case of bypassing
of interlocks for a fixed period of time the Procedure/Authority for Bypassing of Interlocks
shall apply.
G. AVU- OPERATION
1)Throughput of AVU given in the day-to-day instruction is to be adhered to. In case it is changed, it is
to be communicated to Unit In charge at the earliest and reasons for doing the same is to be clearly
mentioned in the Shift Officer Log Book.
Maintenance jobs as given in the Instructions should be strictly followed. In case of deviation from
such instruction prior approval of Unit In charge is a must.
2)Inform RSM/ TPS in case of MP steam flow, pressure fluctuations. During startups, inform RSM, TPS
for MP Steam consumption in advance.
3)Make changes in small increments. Frequent small changes are preferable to a few large changes.
4)Use PPE while draining LPG, Fuel gas KOD, Flare KOD, Vacuum Vent gas KOD and while collecting
caustic sample.
5)Before charging stripping steam and ejector steam to column/ejectors ensure that the steam is fully
condensate free.
6)Change in Stripping Steam flow to columns should be done gradually (Max. 200 kg/hr in every 5 mins.).
7)Before charging stripping steam to column & strippers maintain a healthy level of column /strippers
(55-60%).
8)Before vacuum pulling in VDU, charge stripping steam to avoid sudden expansion of steam.
9)Both process and steam valves are to be kept isolated for standby ejectors.
10)WWTP to be intimated prior to draining or pumping out spent caustic from the unit.
11)During ATF run kerosene color to be reported at the earliest if off color.
12)In case of any upset in Unit, inform RSM, and other units shift in charges.
13)High viscous material like VR, HVGO, and Recycle Oil are not to be drained to OWS.
14)Whenever high viscous material is drained to CBD, it should be immediately followed by draining of
AGO / FLO for adjacent location for dilution of material.
15)When any oil burner shows coking tendency, the concerned operator should close the oil burner & flush
the oil gun for 10-15 minutes intermittently and take the burner again in line. If the burner shows the
repeated coking tendency shut it off and switch over to gas firing. Flush the oil gun and handover to
mechanical for cleaning the burner.
16)During loading and unloading of FD and ID Fans the concerned operator must be present at the site to
observe the condition of the Heaters, if any abnormality is found he will report the same immediately
to the Panel Officer for corrective action.
17)After soot-blowing operation is over ensure that all soot blowers are in park position and main soot-
blowing steam valve at the manifold is closed to reduce the steam consumption in the Unit.
18)Be vigilant during field visits, immediately report and steam, hydrocarbon or water leak sighted.
19)Routine jobs are to be done as per Activity Matrix, strictly as per schedule.

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20)BL Slop valves (both) are to be kept isolated at all times.

21)Chemical loading/solution preparation is to be personally supervised by the concerned area operator.
22)Whenever equipment is handed over after PM Job, its readiness is to be checked by giving kickstart.
23)Hot VR to DCU is to be maximized. However, some flow is to be maintained in the Cold VR line at
all times to avoid its congealing.
24)Positively maintain excess O2 less than 3% in both heaters.
25)Positively maintain ID suction temperature between 145-150 Deg.C.
26)Desalters inlet temperatures to be positively maintained between 125-135Deg.C.
27)Products routings should be altered as per requirement of OM&S and secondary processing units.
Before carrying out any change in routings OM&S and secondary processing should be kept
informed.
28)All abnormalities affecting equipments’ performance should be positively included in DOR.

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JOB SAFETY ANALYSIS

PARADIP REFINERY
PARADIP REFINERY
JOB SAFETY ANALYSIS

JSA No.: Date:
Unit: Area: Location:
Job Title: ANALYSIS

PERFORMED BY:
Name: Desig:
1.
Job to be Executed By :
Department
JSA Reviewed By :
Sl. Recommended action/ Procedures

Activities Hazards
No. Remarks

Page 592 of 592

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CHAPTER-20
PFDs
Chapter-20: Page 1 of 1

Doc. No:
CHAPTER-21
WORK PERMIT SYSTEMS

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PURPOSE:
The purpose of this standard is to describe procedures and guidelines on work permit system to
carry out jobs of inspection, testing, maintenance, alternation, repair, up keepment and
construction in safest possible manner. The implementation of this system will help in bring down
the risks at work sites to acceptable level, thereby reducing possibility of any accident, fire,
explosion, property damage and adverse effect on environment. As per corporate policy all work
permit system is to be done through SAP.
21.2 SCOPE:
This standard shall be applicable to all the Refinery premises of Indian Oil Corporation Limited.
21.3 DEFINITIONS AND ABBREVIATIONS:

a) Hot Work: An activity that can produce a spark or flame or other source of ignition having
sufficient energy to cause ignition, where the potential for flammable vapors, gases, or dust
exists. This includes all works, which produces spark, running of IC engine, breaking of
concrete, use of ordinary torches, use of battery operated devices etc.
b) Cold Work: Cold Work is an activity that does not produce sufficient heat to ignite a
flammable air- hydrocarbon mixture or a flammable substance.
c) Radiation Work: Any activity that is carried with a source of ionizing radiation, which does
not produce sufficient heat to ignite a flammable air- hydrocarbon mixture or a flammable
substance.
d) Working at Height: Any activity that is carried out at 2.0 meters & above on temporary
structure, scaffolds or on a structure not meant to do particular job safely.
e) Excavation: Any job, which requires excavation / digging of earth. An Excavation is any
man-made cut, cavity, trench, or depression in an earth surface that is formed by earth removal.
A Trench is a narrow excavation (in relation to its length) made below the surface of the
ground. In general, the depth of a trench is greater than its width, and the width (measured at
the bottom) is not greater than 15 ft. (4.6 m). If a form or other structure installed or constructed
in an excavation reduces the distance between the form and the side of the excavation to 15
ft (4.6 m) or less (measured at the bottom of the excavation), the excavation is also considered

Doc. No:
to be a trench.
f) Confined Space: It is an enclosure with known potential hazards and restricted means of
entrance and exit. It is not meant for normal occupancy of people and is usually not well
ventilated such as vessels, boilers, storage tanks, large diameter piping etc. The excavation
more than 1.2 M deep, entry into floating roof tanks, when roof is more than 3M down from
the top, space located below ground level such as pits, drain channels etc. shall also be
considered as confined space.
g) Lower Explosive Limit (LEL): LEL is the minimum concentration of a vapor in air (or other
oxidant) below which propagation of flame does not occur on contact with an ignition source.
This is usually expressed as volume percentage of the vapor in air.
h) Upper Explosive Limit (UEL): UEL is the maximum concentration of a vapor in air (or other
oxidant) above which propagation of flame does not occur on contact with and ignition source.
This is usually expressed as a volume percentage of vapors in air.
i) Pyrophoric Substance: Substances that ignites spontaneously in air at ambient temperature.

In hydrocarbon industries iron sulphide is the most commonly observed pyrophoric substance
and is called as pyrophoric iron.
j) Self-Contained Breathing Apparatus (SCBA): It is a lifesaving personal protective

apparatus consisting of a face mask, combined with a hose and source of fresh air generally in
form of a cylinder of compressed air, to be carried by bearer.
k) Gas Safety Inspector (GSI)/Issuer: GSI means a designated officer authorized to perform
all necessary tests before signing a work permit. He must satisfy himself by a personal
inspection that the tank / vessel /line /equipment/ any other confined space involved is safe for
the work intended. He can independently issue Cold work permit and permit for working at
height.
l) Fire Permit Signatory (FPS)/Issuer: FPS means a designated officer authorized to issue work
permit. He is ‘Fire Permit Signatory’/‘Issuer’ in case of hot work/ Vessel entry/ Excavation
permit and for any other permit. He issues the permit for the particular job after addressing the
checklist points of permit for the units/ areas, where he is the in- charge. FPS will sign the
permit after getting satisfied that GSI has carried out all the tests/checks and signed the permit.

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m) Receiver (Permittee): The ‘Receiver’ the designated person authorized to receive work
permit. Receiver generally is the executing department officer, who has to execute the
particular job for which permit has been issued. The executing officer can be Engineer in-
charge / Site in-charge of the job or any other nominated officer for executing dept. (normally
service dept.).
n) Blanket permit: The hot work permit issued to areas after due consideration to safety (the fire
hazard is minimum and hazards due to adjoining facilities taken into consideration) with
approval of local management for a maximum period of 1 month. Such permit shall not need
shift-wise renewal, however the executer has to ensure that permit conditions are compiled
throughout the work period.
21.4 TYPE OF WORK PERMITS, CLEARANCES AND FORMATS:

Depending on the nature of the job, there are 7 types of work permit formats covering various
works as mentioned below:
A) Cold Work Permit

This permit is required for carrying out any activity of maintenance/ cleaning / testing inside
refinery that does not produce sufficient heat to ignite a flammable air- hydrocarbon mixture
or a flammable substance. The format for “Cold Work Permit” is enclosed as Annexure-1.
The list of job includes blinding, de-blinding of equipment/ facilities, tightening/ loosening of
bolts, insulation, painting of lines, cleaning of equipment, repairing on instruments on facilities
etc.
B) Hot work / Entry in to Confined Space Permit and clearances

Hot Work Permit is required for carrying out any activity, which produces sufficient heat to
cause fire in an inflammable air- vapor mixture. Entry to Confined Space Permit is required
for entry into any confined space. The Format for “Hot work / Entry to Confined Space
Permit” is enclosed as Annexure-2.
C) Excavation Permit
Excavation permit is required for carrying out any excavation inside Refinery. The format for
“Excavation Permit” is enclosed as Annexure-3.
D) Electrical Isolation and Energization Permit and Clearances

For all electrical isolation and energization of electrical equipments (HT) “Electrical Isolation
and Energization Permit-HT” Permit is required. The same is enclosed as Annexure-4.For

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all electrical isolation and energization of electrical equipments (LT) “Electrical Isolation
and Energization Permit-LT” Permit is required. The same is enclosed as Annexure-5.
E) Working at Height Permit

For all working at height (of 2M or above) a permit for “Working at Height” is required. The
format for same is enclosed as Annexure-6.
F) Radiation permits
The all jobs, which generate ionizing radiation, “Radiation Permit” is required. The format for
same is enclosed as Annexure-7.
RESPONSIBILITIES OF PERMIT SIGNATORIES:
A) FIRE PERMIT SIGNATORY (FPS):

FPS shall check the permit, submitted by GSI to assess the safety requirement mentioned
in the permit for their adequacy and may check physically some critical checklist
compliance such as gas test, isolation, tagging, LOTO implementation etc. and
recommend corrective measures before signing the permit.
 For all critical activities, he will thoroughly check the work site condition (such as hot
work in running unit / near OSW lines, working at height, entry in confined space,
radiography etc.) and compliance of permit conditions at site before signing.
 With his experience he may visualize additional hazards/ risks in jobs, which needs to be
addressed and will add this in permit for compliance.
 Before signing he shall ensure that conditions mentioned in permit by GSI are fully
complied at site.
 He should withdraw the permit, if the conditions in permit/ clearance are violated or the
job is no safer due to some other reasons. The information about the withdrawal should
be communicated to all concerned.
B) GAS SAFETY INSPECTOR (GSI)/ISSUER:

 To prepare the equipment/ facility/ area properly prepared before handing over for
Maint. / Repair/ construction / inspection as per written down procedure.
 Ensure that equipment/ facility and area is safe for particular work.

Doc. No:
 Permit is properly filled up and precautions are categorically mentioned.

 Gas test has been carried out, if required. (Gas test is mandatory for hot work and entry
into confined space).
 GSI shall ensure before signing any work permit that the atmosphere tested is gas free or
gas levels are within permissible limits for the assigned job and satisfy himself that all
necessary precautions have been taken so that the atmosphere remains under control
during the work.
 Avoid giving general/ vague remarks on permit, which is not specific.
 For working at height, ensure that there is provision of safe access to the work site and
there is provision of ladder/ platform/ scaffold for safe execution of work. Check those
scaffolds provided are with green tags.
 Ensure positive isolation of energy and decide about the extent of isolation required for
the job. Refer chapter on “Energy isolation- electrical and process.
 Permit or clearance shall not be issued until and unless he is satisfied that points
mentioned in work permit has been fully complied and the area as such is safe to
perform the particular work. Positive isolation of all energy sources shall be ensured for
confined spaces.
 Close the permit on completion of work and retain the copy for at least three months.
Copies of “Hot work/ Entry into confined space” shall be returned to Fire station after
close out.
 Keep your copy of permit always with you.
 Don’t sign the permit without authority.
C) Receiver (Permittee) / Executing Authority:

 On issue of permit, Receiver (Permittee) should go through the permit and pass the
instruction down the line as has been mentioned in the permit for compliance. In case of
any doubt, he should clarify from Issuer.
 Do not sign without authority.
 Ensure that precautions mentioned in the permit are compiled at site.
 Ensure that equipment being used is safe to perform the task in particular area.
 Ensure that all power driven equipment including the cables, insulation of cables &
cable joints etc. are as per standard and are maintained in healthy condition.
 Make the permit available at work site all the time during the work.
 Work at specified location only.
 Ensure use of approved type of spark arresters on exhaust of every IC engine.

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 The checking and certifying including providing tag on each scaffold shall be the
responsibility of executing authority.
 All jobs shall be done as per established maintenance practices and relevant safety
norms.
 Check and ensure availability of valid medical fitness certificate for workmen, working
at a height of 2M or above under “Work at Height” permit.
 Clear the site on completion of work.
 Close the permit on completion of work and hand it over to issuing authority.
21.5 ROLES & RESPNSIBILITY

A. REFINERY SHIFT MANAGER:
Carry out random check of work sites under permit, particularly the jobs at critical locations
such as in process units in operation, Tank farm, Gantries, LPG facilities, construction sites
etc. and take immediate corrective measures. He will log the same, report to concerned
HOD and discuss in RSM meetings.
B. HEAD OF DEPARTMENT:
 To assess necessity of job beyond normal working hours.
 To assess the adequacy of safety precautions mentioned in permit and may reinforce,
if required.
 May get an independent check to see the safety compliance at site.
C. FIRE STATION OPERATOR (DURING REGISTARTION)

 Check that authorized signatories have signed the permit at respective column.
 Permit is properly filled up such as period, location; nature of job etc. and all the
columns of the checklist are addressed.
 Gas test has been done and their reading mentioned in case of hot work and Entry into
Confined Space permit.
 Report to Shift in-charge of Fire station, if stand by coverage form Fire station has been
asked.
D. DEPUTY GENERAL MANAGER

 To check the need of blanket permit for the work and dyke cutting for a tank.
 Is the area safe for the job for the purpose of blanket permit?
 To assess the adequacy of safety precautions mentioned in permit and may reinforce,
if required.
 May get an independent check to see the safety compliance at site.

Doc. No:
 For dyke cutting check those resources are mobilized at site to arrest any accidental
release of tank containment.
SAP User Manual for Permit Management System is attached in the

following pages.

Indian Oil Corporation Limited
Corporate Office
Corporate Information Systems Department, Gurgaon
Ref. No: COIS-PMS-MS Date: 13.02.2017
PERMIT MANAGEMENT SYSTEM

PMS Ver 4.0
INDEX
Sl. No. Description Page Number

BACKGROUND 2
WORK FLOW OF PERMIT MANAGEMENT
SYSTEM 03 - 04
FLOW CHART FOR HOT WORK PERMIT SYSTEM 5
WORK INSTRUCTION MANUAL 06 -35

a PMS DASHBOARD 06
b WORK PERMIT REQUEST 07 - 10
c WORK PERMIT ISSUE 11 - 12
d WORK PERMIT RELEASE 13 - 16
e WORK PERMIT CLEARANCE REQUEST 17 - 18
f WORK PERMIT CLEARANCE ISSUE 18 - 20
g WORK PERMIT CLEARANCE CLOSE 20 - 22

h WORK PERMIT CLOSE 22 - 26
i WORK PERMIT PRINT 30
j WORK PERMIT CLEARANCE PRINT 31

k OPERATION REVIEW 32
l MIS & ISSUE 34
m LOCATION REVIEW 35
n PMS REPORT 36
1|Page
Corporate Office
PERMIT MANAGEMENT SYSTEM (Hot Permit)
(1) BACKGROUND:
On-line Permit Management System was developed in SAP with the joint initiative of COIS/
Gujarat refinery/HSE,RHQ. It was developed through in-house resources and started with
the Cold Permit complying with OISD-STD-105. It was first implemented in Gujarat refinery
in May’2012. Based on OISD-STD-105, standard safety practices of the refineries,
feedbacks from users/HSE,RHQ and COIS observations, the system has been evolving
continuously and got matured over a period of time. The latest PMS Ver 2.5 was transported
in Nov’2014 incorporating all these inputs for further improvements of the system. PMS-
Cold Permit had been implemented in phased manner and presently, being used across all
the operating refineries of IOCL. Initiatives for implementation in Pipelines & Marketing
divisions are also in the process.
As a part of the PMS development initiatives, PMS Workshop was organized on 16th
August’2013 at IiPM, where the Hot Work Permit concept note was finalized collectively by
the representatives of the refineries. All efforts were made to replicate the existing manual
Hot Permit system with the requisite checks & balances. The development for Hot Permit
was carried out parallely, while Cold Permit implementation was in progress. It was
imperative to establish the Cold Permit System first, before implementation of the critical
Hot Permit system. The development was prioritized accordingly to suite the familiarised
environment for launching. The development had been completed and ready for User
Acceptance Test(UAT) in May’2014.
A Work Shop cum UAT was organized in PR on 28 th August’2014 on Online Hot Work
Permit system. The objective of the Work shop is to share the concept of the on line
permit management system developed in SAP; to train the representatives through the
class room presentation, online demonstration of the system, interaction and hands on
practice to initiate the implementation across the refineries and involve in generating
feedbacks for further improvement of the system. The issues raised in the Workshop
were implemented suitably after due approval from HSE,RHQ.
On 14th Nov’2014, a multi-disciplinary team from MR tested the system at COIS and
found the system acceptable. The minor issues raised during the UAT were liquidated
and the system was implemented at Mathura Refinery on 16th Dec’2014. Subsequently,
the observations raised at Mathura Refinery was incorporated and transported to PRD
on 14th Jan’2015.
a. New header in the permit print copy as “Vehicle Details”, where details of
the vehicle will be displayed.
b. Provision for vehicle type in the Vehicle Entry permit.
c. Provision for multiple vehicle entry thro’ single vehicle entry permit.
d. Mandatory “yes” against the Gas test points in the check list – In this
column, entry shall be made essential.
e. Different fields for entering gas test, toxic gas and Oxygen results in the
clearance.
f. Reducing checklist answer options to “Yes” or “Not applicable”.
g. Provision for Hot Permit & Vehicle entry permit selection in PMS:MIS
screen for short listing.
h. Additional columns for capturing Hot Permit & Vehicle entry in the PMS
Report (excel format).
2|Page
Corporate Office
(2) WORK FLOW OF PERMIT MANAGEMENT SYSTEM(HOT PERMIT)
The Work Flow and the Instruction Manual of PMS ver 3.0 is given bellow-
Issued by operations or any other depts.,

NOTIFICATION (INDENTER) to the concerned maintenance
depts., i.e. work request or work indent.
T-code:IW21
MAINTENANCE ORDER Issued against the NOTIFICATION by

Maintenance Dept. (EXECUTOR) to their
workgroup. PR can be generated through the
same MAINTENANCE ORDER, which will
capture the cost implication of the particular
maintenance order. T-code:IW31/IW34
Dashboard operation is available from where all

WORK PERMIT DASHBOARD the required transactions as per the work flow
process of PMS can be executed without using
the t-codes. T-code: YPMS
WORK PERMIT REQUEST will be requested by

WORK PERMIT EXECUTOR (RECEIVER) to INDENTER
REQUEST (ISSUER) on the basis of the NOTIFICATION or
MAINTENANCE ORDER. Alternately, if,
notification or maintenance order is not available,
the request can be made through the relevant
work order. Multiple WORK PERMIT REQUESTs
can be posted against one notification or
maintenance order.
WORK PERMIT INDENTER will issue WORK PERMIT to
ISSUE EXECUTOR based on the WORK PERMIT
REQUEST.
WORK PERMIT After issuing the permit, it remains in Hold status

RELEASE till released at different levels. Different release
strategies are applicable as per the Issue Type of
the permit.
WORK PERMIT WORK PERMIT CLEARANCE REQUEST will be

CLEARANCE requested by EXECUTOR to INDENTER for the day
REQUEST to day or shift to shift work on current basis against
the WORK PERMIT REQUEST. The date
& time of Work Permit Clearance Request will be
within the limit of the Work Permit date & time.
Multiple clearances can be requested against a
work permit; however, overlapping of time is not
allowed.
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INDENTER will issue WORK PERMIT

WORK PERMIT CLEARANCE CLEARANCE to EXECUTOR based on the
ISSUE WORK PERMIT CLEARNCE REQUEST. A hard
Copy will be made available at site by the
executing agency while executing the job.
WORK PERMIT CLEARANCE Validity of the WORK PERMIT CLEARANCE

CLOSE remains upto the defined time of the day, after
which it has to be closed by INDENTER. If
required fresh PERMIT CLEARANCE to be
requested and issued from shift to shift or as
practised.
After completion of the job, the WORK PERMIT

WORK PERMIT CLOSE – will be returned to INDENTER by EXECUTOR
RECEIVER / EXECUTOR certifying that the job has been completed and
closing from receiver’s side in the system.
INDENTER will close the WORK PERMIT based

WORK PERMIT CLOSE – on the EXECUTOR’s certification and self-
ISSUER verification.
After completion of the work, the MAINTENANCE

MAINTENANCE ORDER CLOSE ORDER to be technically closed (TECO).
T-code:IW32/IW38
INDENTER will close the NOTIFICATION after

NOTIFICATION CLOSE the WORK PERMIT closure and TECO. T-code:
IW22
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(3) FLOW CHART FOR HOT WORK PERMIT SYSTEM

(ISMS Standard 1004)
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(4) WORK INSTRUCTION MANUAL: PMS- Hot Permit

(A)
WORK PERMIT DASHBOARD
STEP 1: Execute T-CODE: YPMS. All the authorized PMS users can access to the
dashboard. However, individual dashboard operation will be restricted to the
respective roles of authorized users only.
STEP 2: Login UID’s plant code will be defaulted. If required, change the plant code.
STEP 3: Select the required ICON.
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(B) WORK PERMIT REQUEST
STEP 1: Select icon from the dashboard.

PMS Requester screen will appear. The required fields are to be filled as
instructed in the following steps by the requester/permit receiver/executer –
STEP 2: Select PMS “Type” from the dropdown. If request is planned through
Notification/Maintenance order, then select “M”. Otherwise, select “W” for
purchase order.
STEP 3: Select “Issue type” from the dropdown suitably. Depending on the Issue Type,
the release strategy will be applicable. For Shutdown type permit can be
issued up to 15 days and 30 days for Blanket type.
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STEP 4: Fill the required notification no. or maintenance order or purchase order for
“W” type against which permit is requested. The respective maintenance
order( if created) will populate automatically against the entered notification or
vice-versa once executed. If Maintenance Order is selected, then Line no. to
be mandatorily entered in the given field.
STEP 5: For continuation job, expired permit no. can be entered for reference, while
requesting for a new permit.
STEP 6: “Permit” to be selected from the dropdown:
The dropdown of permit is plant code specific i.e. only the relevant permit of a particular
plant will be visible.
For permit type HOT_SEED_A, HOT_SEED_B and WAH_SEED, and additional option for
selecting associated permits gets activated as shown below:
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STEP 7: Start & End date/time to be filled. Duration should be 7 days or less, except
for Shutdown & Blanket Issue type.
STEP 8: “Description/Remarks” will be populated from the Notification or MO, once

Enter Key is executed. Additional space has been provided for entering free
texts upto 256 characters.
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STEP 9: “Long text” & “Exact location of work”, as required to be entered. Long text is
provided both for requester & issuer separately.
STEP 10: For Vehicle Entry permit, the vehicle details has to be mandatorily entered
and upto three vehicles details can be entered in one permit request.
STEP 11: Requested By will be automatically populated by the UID of the requester.
UID of other’s can be entered if requested on other’s behalf. However, UID
has to be valid one. Both the UIDs will be captured for record.
STEP 12: “Gas Tester” field should be kept blank for Issuer’s use. “Maintenance
Technician Name” may be entered as required.
STEP 13: Vendor no. to be entered, if issued to vendor, otherwise by default “D” will be
populated. Normally, Permit is issued to departmental personnel only. Vendor
number will be populated automatically in case of work order route is selected.
Optionally, vendor no. can be entered for reference, which will be printed in
the permit copy.
STEP 14: If permit request is on WO, then the functional location where job will be
executed can be entered, including the work centre.
STEP 15: Execute & Confirm
STEP 16: Work Permit Request has been generated with a unique 12 digit
alphanumerical Work Permit Request No. denoting as given below –
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9010 : Plant code.

H : Hot Permit 14:
Year, 2014
00014: Running serial numbers.
STEP 17: Once ticked the above pop-up of Work Permit Request, and
select any one of the three icons, it will re-direct to the dashboard.
NOTE:- Multiple WORK PERMIT REQUESTS can be generated against single notification
/ maintenance order/ purchase order. WORK PERMIT CLEARANCE REQUEST
can be sought after Work Permit Request is made. But WORK PERMIT
CLEARANCE can be issued only after issuance of
WORK PERMIT.
(C)
WORK PERMIT ISSUE
STEP 2: Enter Permit Request No. Alternately, functional location or Work Centre or
Requested On or other search option may be opted. UID’s plant code will be
auto populated.
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STEP 3: Select - Issue Permit button and Execute.
STEP 4: Click on the Permit Request No.
STEP 5: The status & short description of the Work Permit Request are shown below.
STEP 6: Fill the questionnaires of the permit using either “Yes” or “Not Applicable” from
the dropdowns. Under srl. no.12, answer has to be mandatorily “Yes”. Permit
Observation details to be filled mandatorily in * marked questionnaires. Then
press Enter key & click the Permit Issue button. For vehicle entry permit
check list points will be less.
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STEP 7: Click Permit Issue and the Work Permit Issue page will be available for
entering the concern details and description, if any.

Issuer can change the permit date & time within the requested period
depending on the site condition. However, the starting date cannot be
preponed and end date cannot be postponed.
 Nearest Fire point to be recorded.
Long text for issuer is provided.

Gas tester’s Name and gas test result can be entered in the “Gas Tester” field.
Issuer’s UID can be changed if issued on other valid user’s behalf. Both the UIDs
 will be recorded.
Expected residual hazards appear as ticked; whichever is not required to be un-
 ticked.
Similarly, list of additional PPE to be used will appear as ticked; whichever not
 required to be un-ticked.
Then execute.
STEP 8: Confirmation of permit issue.
STEP 9: Work Permit No. has been generated with a unique 14 characters alphanumerical
denoting as given below. At this stage, the permit is practically kept at hold
status till released.
9060 : Plant code.

HT : Hot Permit
14 : Year, 2014
000001 : Running serial numbers.
(D) WORK PERMIT RELEASE
Although, the permit has been issued, it cannot be used till released as per the
specified release strategy, which is applicable as per the following Issue Types-
1. Execution within normal working office hour, where release
strategy will be –
(i) Gas Safety Inspector,
(ii) Fire Permit Signatory
(iii) Fire & Safety.
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2. Execution beyond office hours / round the clock /Holidays

/Sundays, where release strategy will be –
1. Executing HOD
2. Gas Safety Inspector
3. Fire Permit Signatory
4. Issuer HOD/RSM
5. Fire & Safety
3. Execution with Shutdown permit, where clearance are required and

permit can be issued upto 15 days.
1. Executing HOD
4. Issuer HOD/RSM
5. Fire & Safety
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4. Execution with blanket permit, where clearance are not required to

be renewed. Permit can be issued upto 30 days.
1. Executing HOD
4. Issuer HOD/RSM
5. Super Approver(Functional DGM/GM)
6. Fire & Safety
STEP 1: All releases are done selecting the icon in YPMS Dashboard
and subsequent options to arrive at Permit Monitoring Screen below.
Select icon to release the Hot Permit as required in the
Permit Monitoring screen.
STEP 2: Release process:-

1. GSI will release the permit clicking the flag provided against the “Gas
Safety Inspector” and icon. Similarly, other releaser
will execute as per the respective release strategy.
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2. Releaser can view the Permit before releasing thr’

icon or may reject if found not suitable.
3. In case of rejection, “Remarks” to be entered mandatorily stating the

reason of rejection in the windows as given below.
4. The rejected permit can be reprocessed by GSI and the release sequence
will be followed as required. The previous rejection details (if any) of the
permit can also be viewed before releasing. Only the GSI can change the
details of the permit before releasing, if any.
STEP 3: The final release will be by Fire & Safety and print can be taken only after
their release. The various status of permits are –
STEP 4 : At all the stages of releases users can send e-mail to the next release level.
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Select the respective permit request and click E-mail icon above and enter the
UID of the indented person.
The e-mail will be auto-generated with a copy to the e-mail requester as given
below. Current status of the permit and the next level of action will be
displayed under head of “Pending” alongwith the details of the permit.
(E) WORK PERMIT CLEARANCE REQUEST
STEP 1: Select icon from the dashboard
STEP2: Select Request Work Clearance and fill the Work Permit Request No. The
permit request no. can be selected through search option available in the
dropdown.
STEP 3: Then enter the start/end date/time, which are to be within the limit of the Work
Permit. Also, the time period cannot be more than 8 hrs. Then execute.
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STEP 4: Requested By UID can be changed if requested on other’s behalf.

However, both the record will be available.
STEP 5: Confirm Work Permit Clearance Request.
STEP 6: Work Permit Clearance Request created against the Work Permit Request
maintaining serial numbers, say 001, 002, etc.
STEP 7: Work Permit Clearance Request can be made immediately after the Work
Permit Request is made. However, the clearance can be released only after
issuing of the Work Permit.
STEP 8: After ticking the above pop-up of Work Permit Issue, select icons
repeatedly
NOTE:- Multiple WORK PERMIT CLEARNCE REQUESTS can be generated against

single WORK PERMIT. But, time overlapping is not allowed.
(F)
WORK PERMIT CLEARANCE ISSUE
STEP 1: Select icon from the dashboard
STEP 2: Select Request Work Clearance radio button and fill the Permit Request No.
including the end date & time. Then, execute.
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STEP 3: Selecting the Update Validity button and execute.
STEP4: If required, the defaulted time can be modified as per the requirements; but
limited to 8 hrs., and within the validity period of Work Permit.
Recording of gas test result is mandatory and different fields for HC, Oxygen
& Toxic gas are provided.
Remarks/precaution and gas tester’s name can be recorded, which will be
displayed in the print copy. Then, execute.
STEP5: Accept the Clearance modified message and go back to the releasing screen
pressing icon.
STEP 6: Select the button.
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STEP 7 : Change the UID, if issued on other’s behalf. However, both the UIDs will be
captured and displayed.
STEP 8 : Confirm the Work Permit Clearance Release.
STEP 9: Once the pop-up of Work Permit Clearance Release is confirmed, select
icons repeatedly to re-direct to the dashboard.
(G) WORK PERMIT CLEARANCE CLOSE
STEP2 : Select and enter the Permit Request No. to close

selectively. Then execute.
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STEP 3 : Select the clearance and click the icon.
STEP 4: Confirm Work Permit Clearance closure & check the status by selecting
View/Issue Work Clearance radio button. Status will be changed to “C”. Also,
remarks column will display as Clearance Closed by – UID.
Alternately, at STEP 2, all the clearances against a particular permit request
Can be closed altogether by selecting icon.
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STEP 5: Once confirmed the closure, any of the 3 icons can be clicked
repeatedly to return to the dashboard.
Note: All the Work Permit Clearances issued against the Work Permit gets closed
automatically, if the Work Permit is closed.
(H)
WORK PERMIT CLOSE
Work Permit Closure is done in 2-stages- closure by Requester /Receiver

/Executer and Issuer/Indenter. However, additionally, short closure provision is
made for intermittent closure on various reasons.
(i) CLOSURE BY RECEIVER/EXECUTER:
STEP 2 : Enter plant code and select . Then execute.

Alternately, the search options are available through Permit Request No.,
Permit No., Functional Location, Work Centre, etc.
STEP 3: The issued permit of the plant will be shown as per the search option selected.
Then, select the required permit and click on the icon.
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STEP4: Confirmation?
STEP 5: Tick the button and enter optional remarks in the

given field. Then tick “Certify that the job is completed”. User ID will be
defaulted of the Work Permit Receiver (Executer) and the date & time to be
entered.
STEP 6: Once verified the Work Permit will be closed and status will be changed from
“I” to “M”- Executor Closed.
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Note: All the Work Permit Clearances issued against the Work Permit are closed
automatically, if the Work Permit is closed.
(ii) CLOSURE BY ISSUER/INDENTER:
STEP2 : Enter plant code and select . Then execute. Alternately, the
search options are available through Permit Request No., Permit No.,
Functional Location, Work Centre, etc.
STEP 3: The work permits of the plant will be shown as per the search option selected.
Then, select the required permit with status “M” and click on the
icon.
STEP4: Confirmation ?
STEP 5: Tick the button and enter remarks in the given field if
required. Then tick “Certify that the job is completed”. User ID will be defaulted
of the Work Permit Issuer and the date & time to be entered.
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STEP 6: Verification?
(iii) SHORT CLOSE:
SHORT CLOSE provision is made to close the permit in case of any unsafe
working condition found at site or any other reason to stop the execution
prematurely. Short closure can be exercised by Issuer or Receiver or Fire/Safety
officers.
All the steps are same with the Normal Close by Receiver, except
Button to be ticked and remarks field to be entered mandatorily
stating the reason for the short close.
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User ID of the short closure will be captured and once confirmed the Work Permit
will be closed. The status of the permit will be .
NOTE :- The following radio buttons ( available in the Permit Monitoring System page
as shown in STEP 2 above) can be used to monitor the pending permit closure
on the basis of expired permits or maintenance order already closed. By default
display will be available upto date, which can be changed as per the
requirement.
(I) WORK PERMIT PRINT
A) T-code:YI22
STEP 1: Execute T-Code:YI22
STEP2: Enter Work Permit Request No. & select the Print Permit (Laser/Deskjet)
button. Then execute.
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STEP3: Option will be asked for printing the General Instruction and DOs & DON’Ts
pages alongwith the permit details.
STEP4: Enter “locl” in the OutputDevice field and select .
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STEP5: Permit details will be displayed. Connect a printer to print.
B) Thr’ YPMS:
STEP 1 : Execute T-CODE: YPMS.
STEP2 : Select icon from the Dashboard.
STEP 3 : Select radio button. Filtration option through

Functional location, Work Centre, etc. are available.
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STEP 4: Select the required Permit Request No. and click in the icon.
STEP5: Permit details will be displayed. Follow the steps of Step 3,4 & 5 as
given under A) above.
NOTE: The first print out of the work permit will be printed as “Original Copy” and
subsequent printouts will be marked as “Duplicate Copy”. This will enable the
users to differentiate the original print. Also, the UID of the printing personnel and
printing date & time will be available in each pages of the printout.
C) PRINTING OF CHECKLIST:
The checklist of the permit with details can be printed for physical
checking in the fields by JEA or Fire Service personnel before issuing.
STEP 1: Select the icon in YPMS Dashboard and subsequent

options to arrive at Permit Monitoring Screen below.
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STEP 2: Select the permit request no. & print icon at Permit Monitoring Screen
above and subsequent steps to view the provisional checklist.
(J)
WORK PERMIT CLEARANCE PRINT
STEP 1: Execute T-CODE: YPMS for the dashboard.

STEP2 : Select or icon.
STEP3: Select radio button, enter Permit Request No. & then
execute.
STEP4: Enter “locl” in the OutputDevice field and select .
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STEP5: Work Permit Clearance details will be displayed. Connect a local printer to print.
Alternately,
STEP 1 : Execute T-CODE: YI22
STEP 2 : Enter Work Permit Request No. & select the Print Clearance button. Then
options are given for entering the Clearance no. Then select local printer to
view and print.
(K) OPERATION REVIEW
This functionality is provided to view the LIVE work permits under a particular plant,
superior functional location, functional location, work centre, etc. and also execute
necessary actions if required.
STEP 1 : Select icon in the dashboard.
STEP 2: Execute after entering the plant code and other filtration options like functional
location, work centre, etc.
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Similarly, other radio buttons are selectable for specified functionalities as

given in the bottom of the screen.
STEP 3: List of the live permits will be displayed. By selecting the desired permit, the
following actions can be executed subject to the respective roles of the
functional users–
 Close by requester
 Close by issuer
 Print
 Clearance request
(L) MIS & ISSUE
This functionality is provided to view the work permits & clearances with status under a
particular plant, superior functional location, functional location, work centre, etc., and
also execute necessary action if required.
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STEP 1: Select icon in the dashboard.
STEP 2 : Enter plant code & start date, which are mandatory. Functional location, work
centre, end date & status of the permit are optional, which helps in filtering
the desired results. Then execute.
STEP 3 : The status of the selected permits will be displayed alongwith the attached
clearances. Permit details can be viewed selecting the particular permit.
By selecting the desired permit, the following actions can be executed
subject to the respective roles of the functional users–
 Permit issue
 Clearance Issue
 Print/ Print Preview
 Statistics of permit & clearances numbers
 Excel download of the data
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(M) LOCATION REVIEW
This functionality is provided to view the work permit requests & status against
notifications/maintenance orders. Both maintenance and operation personnel
can take their respective actions viewing the same.
STEP 1 : Select icon in the dashboard.
STEP 2 : By default last 15 days data will be displayed against the plant code.
However, the days can be entered manually to display the desired view.
STEP 3 : Users can adopt various filtration options to view the desired data from the
respective area of interest.
NOTE:- The following radio buttons can be used to monitor the pending permit closure
on the basis of expired permits or maintenance order already closed. By
default display will be available upto date, which can be changed as per the
requirement.
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(N) PMS REPORT
This functionality is provided to view the PMS Report directly in the excel format.
STEP 1 : Select Report icon in the dashboard.
STEP 2 : Enter plant code/ multiple plant codes and document date or date range.
On execution, excel report will be generated directly.
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Doc. No:
Chapter 22
Standard Operating Procedures

Page 1 of 3
Doc. No:
Revised Standard Operating Procedure is available as a separate document. Same to be referred.

Page 2 of 3
Doc. No:
Following documents are provided at the end of the MANUAL as

ANNEXURES
1) APC MODEL IN AVU

2) CDU FURNACE OEM OPERATING MANUAL
3) VDU FURNACE OEM OPERATING MANUAL

Page 3 of 3
Honeywell Process Solutions – Standard Builds
SB-INP13438-APC10006 - AS BUILT DOCUMENT

Doc. No.: SB-INP13438-APC10006 – AS Built Document
Version: 0
Status: For Approval
Date: April 13, 2020
Project: IOCL Paradip AVU,DCU and INDMAX FCCU APC

Subproject: IOCL Paradip AVU APC
Reference: FDS Document
Customer: IOCL Paradip
End user: IOCL Paradip
Signature Name Date

Anirudha Patil April 13, 2020
……………………………………….. Position
Approver Delivery Manager
Signature Name Date
Malave Sachin April 13, 2020
……………………………………….. Position
Reviewer Team Lead
Signature Name Date
Ponraj P April 13, 2020
……………………………………….. Position
Author Project Lead
Honeywell Confidential & Proprietary

This document contains information that is confidential and proprietary to Honeywell and may not be reproduced or given to third parties
without the express written permission of Honeywell Process Solutions.
© Honeywell Process Solutions, 2014
Project: IOCL Paradip AVU, DCU and File Name: SB-INP13438-APC10006 - AS Built
INDMAX FCCU APC DOCUMENT_AVU_Rev 0.0
Version: 0 Doc number: SB-INP13438-APC10006 - AS Built
DOCUMENT_AVU_Rev 0.0
Version date: April 13, 2020 Page: 1 of 159
Honeywell Restricted - Export Controlled

REVISION HISTORY
Ver Date Description of status and changes Issued by
0 13th April 2020 For Review and Approval Ponraj P
REFERENCE DOCUMENTS
Ref ID Title Remark
PN/AVU/OM/U- Operating Manual for Atmospheric & Shared by
1
10 Rev03 Vacuum Distillation Unit Customer
PDRP4210-8110- Process Flow Diagram Atmospheric Shared by
2
20-010-0001 Vacuum Unit Crude Pre-Heat Section Customer

TABLE OF CONTENTS
1 Summary ...........................................................................................6
2 Introduction ......................................................................................7
3 Process and Control Overview .......................................................8
3.1 Feed Preheat Section ......................................................................8
3.2 1st Preheat Train (Pre-Desalter Preheat Train) ................................8
3.3 Desalter, 2nd Preheat Train & Crude Flash Drum ............................9
3.4 3rd Preheat Train ............................................................................11
3.5 CDU Heaters (010-F-101/201).......................................................12
3.6 Atmospheric Distillation Column (010-C-001) ................................13
3.7 Vacuum Distillation Column (010-C-007) .......................................14
3.8 Naphtha Stabilizer Column (010-C-004), De-Ethanizer & De-
Propanizer .............................................................................................16
4 ADVANCED PROCESS CONTROL SOLUTIONS ..........................17
4.1 Overview ........................................................................................17
4.2 Atmospheric Distillation Column Controller (010AVU) ...................18
4.2.1 Control and Optimization Objectives .........................................18
4.2.2 Controlled Variables .................................................................18
4.2.3 Manipulated Variables ..............................................................18
4.2.4 Disturbance Variables ...............................................................19
4.2.5 Strategies..................................................................................19
4.3 Vacuum Distillation Column (010VDU) ..........................................20
4.3.5 Strategies..................................................................................21
4.4 Vacuum Column Cascade Controller (010VDUCAS) ....................21
4.4.1 RMPCCAS Controller ...............................................................21
4.5 Naphtha Stabilizer Column (010NSU) ...........................................22
4.5.5 Strategies..................................................................................22
4.6 De-Propanizer Column & De-Ethanizer Column (010DEDP) ........23
4.6.5 Strategies..................................................................................23

5 Supporting calculations.................................................................24
5.1 Atmospheric Distillation Column Controller (010AVU) ...................24
5.1.1 Naphtha D95% .........................................................................24
5.1.2 Kero Flash Point .......................................................................24
5.1.3 AGO D5% .................................................................................25
5.1.4 AGO D95 ..................................................................................25
5.1.5 Kero Freeze Point .....................................................................26
5.2 Vacuum Distillation Column Controller (010VDU) ..........................27
5.2.1 VD D95% ..................................................................................27
5.2.2 VGO D95% ...............................................................................27
5.2.3 HVGO D95% ............................................................................28
5.2.4 VR 5% recovery ........................................................................28
5.3 Naphtha Stabilizer Controller (010NSU) ........................................29
5.3.1 Naphtha Reid Vapor Pressure ..................................................29
5.3.2 LPG Weathering .......................................................................29
5.4 De-Ethanizer and De-Propanizer Controller (010DEDP) ...............30
5.4.1 C4 slippage at outlet of De-Propanizer .....................................30
5.4.1 C2 in LPG .................................................................................30
6 System Architecture ......................................................................31
6.1 Controller Connection to DCS .......................................................33
6.1.1 Atmospheric Column (010AVU) ................................................33
6.1.2 Vacuum Column (010VDU) ......................................................82
6.1.3 Vacuum Cascade Controller (010VDUCAS) ...........................104
6.1.4 Naphtha Stabilizer Controller (010NSU) .................................117
6.1.5 De-Ethanizer and De-Propanizer (010DEDP).........................135
6.2 BLC Configuration .......................................................................148
6.2.1 HW_EPKS_Ctrl-PAuto_Shed-OAuto_custom.........................148
6.2.2 HW_EPKS_Ctrl-PMan_Shed-OMan_Custom.........................149
6.2.3 HW_EPKS_CV_PV_Custom ..................................................150
6.2.4 HW_EPKS_CV_PV_Calculated..............................................151
6.2.5 HW_EPKS_CV_OP_Custom ..................................................152
6.2.6 HW_EPKS_DV_PV ................................................................152
6.2.7 HW_EPKS_DV_OP ................................................................153
7 SAT Summary ...............................................................................154
7.1 SAT Summary for Profit Controllers.............................................154
7.2 SAT Summary for Inferentials ......................................................154
Appendix: ..............................................................................................155

Table: Abbreviations
ABBREVIATION DESCRIPTION
APC Advanced Process Control
CV Controlled Variable
DV Disturbance Variable
Functional Design Specification (the design document for
FDS
advanced control applications, a blueprint for the design)
MV Manipulated Variable
AVU Atmospheric Vacuum Unit
Profit Controller Honeywell’s multivariable predictive control package
Profit Sensor Pro Honeywell’s inferential modelling package
Profit Web Honeywell’s operator and engineer interface for their
Viewer products
Robust Multivariable Process Control Technology – now
RMPCT
called Profit Controller
RVP Reid Vapor Pressure
HAGO Heavy Atmospheric Gas Oil
CCR Conradson Carbon Residue
LAGO Light Atmospheric Gas oil
HAGO Heavy Atmospheric Gas Oil
IR Internal Reflux
PA Pump Around
DE De-Ethanizer
NS Naphtha Stabilizer
PCT Pressure Compensated Temperature

1 Summary
M/s. IOCL, Paradip refinery engaged with M/s. Honeywell to implement the Advanced
Process Control for AVU unit.
This document presents the Detail Design Specification based on the valuable inputs
from the operations & engineering personnel of IOCL, Paradip. PID tuning and pre-
step test, which was carried out from 3rd June 2019 to 22nd June 2019. Step Test was
carried out from 23rd September to 23rd October. The Model Acceptance Test was
carried out from 09th December 2019 to 11th December 2019. Commissioning was
carried out from 13th January to 8th February. The main objective of this document is
to specify the control objectives, strategy and the Implemented APC specifications.
The operating variables in AVU unit are interactive with each other, hence Honeywell
Advance Solutions’ Robust Multivariable Control Technology (RMPCT®) has been
used. RMPCT has been used extensively in previous similar projects and has proven
its stability and superiority in the field.
With the implemented RMPCT control configuration, IOCL Paradip refinery can be
able to operate the process closer to the specification and the constraints. This
results in a significant benefit from stable feed, better quality control, reducing the
energy consumption and the workload of operators.

2 Introduction
Multivariable controllers are defined for the following equipment areas:
1. Atmospheric Distillation Column (010-C-001) with side strippers (010-C-002 & 010-
C-003, 010-C-008) Section
2. Naphtha Stabilizer Column (010-C-004)
3. De-Ethanizer Column (010-C-005) and De-Propanizer Column (010-C-006)
4. Vacuum Column (010-C-007)
The remainder of this document is divided into the following parts:
Section 3 contains process and control overview;

Section 4 provides design for the multivariable controllers;
Section 5 contains supporting calculations;
Section 6 details the basic control modification required;
Section 7 details the equipment and control issues;
Section 8 details the system architecture.

3 Process and Control Overview

Designing advanced control and optimization strategies requires an understanding of the
design and potential of the unit, the current and future operating objectives and constraints
together with the advanced control and optimization technology. This section presents
Honeywell Process Solution’s understanding of the process and operation of the Process
unit at IOCL Paradip. The items in the following section are numbered for easy reference.
The Process complex consists of:

a. Feed Preheat Section
b. 1st Preheat Train (Pre-Desalter Preheat Train)
c. Desalter, 2nd Preheat Train & Crude Flash Drum
d. 3rd Preheat Train
e. CDU Heaters (010-F-101/201)
f. Atmospheric Distillation Column (010-C-001)
g. Vacuum Distillation Column (010-C-007)
h. Naphtha Stabilizer Column (010-C-004), De-Ethanizer & De-Propanizer
The DCS is a Honeywell Experion DCS.
Loop Scout is running on the system for collecting data on the basic controllers prior to the
Pre-step test.
3.1 Feed Preheat Section

Atmosphere and Vacuum unit (AVU) of Paradip Refinery is designed to process 15.0
MMTPA of feed stocks Light Crude (50 wt% Basrah Light 50 wt% Oman Export) and
Heavy Crude (60 wt% Kuwait Export 40 wt% Maya).
3.2 1st Preheat Train (Pre-Desalter Preheat Train)

Imported crude oil unloaded from VLCC at South jetty sent to refinery crude oil storage
tanks 201-TK-001 to 011. Cold crude from the Crude tank (free of water) is pumped by
offsite crude charge pumps (201-P-001 A/B/C/D/E) to AVU at a pressure of 30 kg/cm 2and
temperature 350C.
After entering unit, the crude split into two identical pre heat trains, Train-1& Train-2 for
optimum heat recovery from various product streams. PI-1118, TI-1102 and FI-1001
provided on the main crude line at the battery limit of the unit, to measures pressure,
temperature and total crude flow into the unit. FI-1002 and FI-1003 measures the crude
passing through Train-1 and Train-2 respectively.
Crude routed to Train-1/Train-2, passes through the shell side of 1st pre heat train heat
exchanger 010-E-102/E-202 (Vacuum Diesel Pump Around vs. Wet Crude) and heated up
to 44/450C. Crude outlet temperature ex 010-E-102/E-202 is controlled by TIC-1002/TIC-
1502, which controls the temperature by controlling vacuum diesel pump around flow

through the bypass of the heat exchangers 010-E-102/E-202. Crude from the outlet of
010-E-102/E-202 passes through the tube side of 010-E-103/E-103 (Wet Crude vs. AGO
Product) and gain temperature up to 49/520C and then passes through the tube side of
010-E-104 A-D/ E-204 AD (Wet Crude vs. Top Pump Around) and heated up to
107/1020C.
Crude outlet ex 010-E-104 A-D / 204 A-D split into two streams under split range flow
controllers HV-1017A & HV-1017B / HV-1517A & HV-1517B (for Train-II) and passes
through the tube sides of 010-10-E-107/E-207 (Wet crude vs. AGO product) and 010-E-
106 / E-206 (Wet crude vs. Kerosene Pump Around) in parallel trains, where crude
temperature is raised up to 119/1210C at the combined outlet of both the exchangers. The
crude from the outlet of 010-E-106 & 010-E-107 / E-206 & E-207 passes through the tube
side of 010-E-108/E-208 (Wet Crude vs. VGO product) and picks up heat from VGO
product stream and enters the 1st stage Desalters (010-V-102A/010- V-202B) at a
temperature of 1300C.
3.3 Desalter, 2nd Preheat Train & Crude Flash Drum

A two stage Desalter 10-V-102A and 10-V-102B has been present and used for removal of
salt and water from the crude to desired level. Preheated Crude from 010-E-108/E-208
enters 1st Desalter (010-V-102A/V-202A) after mixing with wash water from 2nd Desalter
across static mixer and mixing valve (010-PDV-1003/PDV-1503).

Desalted and dewatered crude from the 2nd stage desalter 010-V-102B/V-202-B passes
through the tube side of 010-E-128/E-228 (Desalted crude / AGO product) and gains
temperature up to 139 / 1350C by exchanging heat with hot AGO product. Crude from the
O/L of 010-E-128/E-228 splits into two streams by HIC-1018A-B/HIC-1518A-B. The part of
the crude entering HV-1018A/HV-1518A passes through 010-E-131/E-231(Desalted crude
/ Kerosene PA) picks up heat from hot Kerosene PA, hot crude from the outlet of 010-E-
131/E-231 with a temperature of 170 / 1530C passes through the tube side of 010-E-
117/E-217 (Desalted crude / Vacuum Residue Product) where it exchanges heat with hot
Vacuum Residue Product and gains a temperature 175 / 1670C.
The other part of the crude passes through the tube side of 010-E-119/E-219 (desalted
crude/LAGO PA) where the crude is heated to 151 0C and then passes through the tube
side of 010-E-118 A-D / E-218A-D (Desalted crude / VGO PA) and heated to 181 /183 0C.
Crude from the outlets of 010-E-117/E-217 and 010-E-118A-D/E-218A-D combines and
enters the crude Flash vessel (010-V-003) at a temperature of 1800C through PIC-
1019/PIC-1022. Provision is given to process wild naphtha along with train-2 pre heated
crude to Flash vessel.

Pre heated crude entering crude flash vessel gets flashed, lighter ends (vapors) from the
top of flash vessel is routed to the flash zone of the main crude distillation column, 010-C-
001 under pressure control PIC-1021. The normal operating pressure of crude flash vessel
top is 3.5kg/cm2g. Pre-flashed crude from the bottom of flash vessel is pumped out by
010-P-003A/B/C to third pre heat train for further pre-heating before entering furnace. LIC-
1010, a split range controller which controls flash vessel bottom level by manipulating
Crude flow to CDU furnaces pass balancer and charge crude blender control valves.
3.4 3rd Preheat Train
Flashed crude is pumped by 010-P-003A/B/C and routed to train-1 and train-2 in 3rd
section preheat exchangers. HV-1019 A/B & HV-1519 A/B splits pump discharge into two
streams for each train.
One part of the flashed crude sent via HV-1019A/HV-1519A passes through the tube side
of 010-E-122A-D/E-222A-D (Flashed crude/VGO), picks up heat from hot VGO product
and heated up to 222 / 2210C. Crude O/L from 010-E-122/E-222 passes through the tube
side of 010-E-123A-B/E-223A-B (Flashed crude/HAGO PA) heated up to 251/ 246 0C by
hot HAGO PA at the exchanger outlet further passes through the tube side of 010-E-124A-
C/E-224A-C (Flashed crude/HVGO) picks up heat from hot HVGO and leaves from the
outlet of 010-E-124/224 at a temperature of 2920C.
The other part of flashed crude sent via HV-1019B/HV-1519B passes through the tube
side of 010-E-129/E-229 (flashed crude/AGO) gets heated up to 205 / 195 0C. Flashed
crude from the outlet of 010-E-129/E-229 passes through the tube side of 010-E-132/E-
232 (flashed crude/HAGO PA) picks up heat from hot HAGO PA enters the tube side of
010-E-126/E-226 (flashed crude/VR) and comes out of the exchanger at a temperature of

232 / 2300C. Pre heated flashed crude from the outlet of 010-126 passes through the tube
side of 010-E-127A-K/E-227A-K (flashed crude/VR) comes out of the exchanger at a
temperature of 3300C.
The pre heated flashed crude from the outlets of 010-E-124A-C/E-224A-C and 010-E-
127A-K /E-227A-K combines and enters 010-F-101/F-201 passes (8 no of Passes) at a
pre heat temperature of 3010C.The pre heated crude passing through 010-F-101/F-201
heated up to 3660C, enters the flash zone of 010-C-001(main distillation column).
3.5 CDU Heaters (010-F-101/201)

To achieve design flash temperature of the crude, preheated flashed crude at a
temperature of 299/3010C from the outlet of 3rd pre heat trains of Train-1/Train-2, further
heated to 355/367 0C in the respective furnaces (Train-1 010-F-101, Train-2 F-201). The
crude charge heaters 010-F-101 and 010-F-201 are identical vertical box type furnaces.
010-F-101/010-F-201 is an eight pass, balanced draft, dual fired heater of absorbed heat
capacity 66.42 MMKcal/hr. The duty includes Super heating coils of LP steam used for
steam stripping in main distillation column and side draw strippers of CDU and super
heating coils of saturated MP steam coils.
Total feed flow to 010-F-101/010-F-201 is controlled by pass balancer under pre-flash

drum level control (LIC-1010) is distributed in eight passes through flow control valves FIC-
1018A-H/FIC-1518A-H.Combined passes coil O/L temperatures(COT) of 010-F-101/F-201
is maintained around 355/3660C by TIC-1069/TIC-1569 through the pass balance control
system.

3.6 Atmospheric Distillation Column (010-C-001)

Desalted crude from the desalters (free of salts, water & sludge) passes through 2 nd Pre
heat Train (2 number of parallel train) exchangers, where it heats up to 180 0C and enters
the Flash drum. Flash drum overhead vapors routed to 010-C-001 in the Flash zone. 010-
PIC-1021 maintains the flash drum top pressure (3.5 kg/cm 2g). Flashed crude from flash
drum bottom passes through 3rd Pre-heat train exchangers (2 nos. of parallel heat
exchanger trains) where it gains the temperature up to ~299 0C/3010C and enters two nos.
parallel crude charge heaters 010-F-101/010-F-201, each having 8 passes of crude. The
crude is heated up to ~3550C/3660C depending upon light and heavy crude in crude
charge heater. The partially vaporized crude then fed into the flash zone of crude column
(010-C-001).
OVHD VAPOUR TO AC-007

SIDE CUT NAPTHA
TO P-014 A/B/C
116oC 98oC
1.2 Kg/Cm2g
2100 T/hr
TPA WET CRUDE
E-104 A-D
o
132 C P-004 A/B/C
315 T/hr
DESALTED WET CRUDE
CRUDE
C-002 KERO PA E-131 E-106
SH LP
STRIPPING STEAM 010-C-001 193 C P-005 A/B
o
730 T/hr DESALTED CRUDE

KEROSENE
NAPTHA
PRODCUT
STAB. BTM. E-119
DEETH.
P-008 A/B DEPROP.
LAGO PA BTM.
E-038 BTM.
SH LP C-003
STRIPPING STEAM P-006 A/B
WET CRUDE E-116 WET CRUDE E-128 FLASHED CRUDE FLASHED CRUDE E-043 E-047
o
249 C
AGO LAGO 650 T/hr
E-132 A/B
HAGO PA FLASHED CRUDE
E-103 DESALTING E-107 A-D DESALTED E-129 C-008
WATER CRUDE P-009 A/B
P-030 A/B E-123 A/B
SH LP STRIPPING
STEAM
349/366oC HEATED CRUDE FROM F-201
1.65Kg/Cm2g
HAGO 325oC
SH LP STRIPPING STEAM
FLASHED VAPOUR P-029 A/B
FROM V-003
HEATED CRUDE
FROM F-101
356oC ATM. RESIDUETO F-002
P-007 A/B/C
The CDU column consists of 6 stripping trays, 40 fractionation trays and 5 nos. of Draw
trays. The column operates at a pressure 1.2 kg/cm2g and temperature of 116 0C at the
top. The crude is fractionated four side stream yields viz. Side cut Naphtha, Kerosene,
Light Atmospheric Gas Oil (LAGO), Heavy Atmospheric Gas Oil (HAGO). An off-gas
compressor is provided at the downstream of overhead receiver for achieving maximum
LPG recovery.
To maintain the heat balance in the column there are four (Top Naphtha, Kerosene, LAGO
& HAGO) pump around refluxes are provided. The Atmospheric Distillation column (010-C-

001) was not been provided with top reflux from the overhead condenser accumulator to
maximize heat recovery in the unit, achieved by preheating wet crude. Further each draw
off tray is designed as total draw off tray, part of the PA pump discharge is recycled back
to the column as internal reflux (IR).
TPA is drawn as first side draw (D1) at 1360C. A slip stream taken from the TPA as side
cut naphtha and routed along with stabilizer feed to Naphtha stabilizer. Kerosene product
and pump around is drawn as the second side draw (D2) at 2000C. Kerosene product is
routed to the stripper (010-C-002) and the stripped Kerosene routed to KTU. LAGO
Product and Pump Around are drawn as the third side draw (D3) at 254 0C. LAGO Product
is routed to the stripper (010-C-003) and the stripped LAGO along with HAGO products
passes through heat exchangers /air coolers and routed to DHDT.
The bottom most CR HAGO along with product is drawn as fourth side draw (D4) at
3100C. HAGO product is sent to the stripper (010-C-008) and the stripped HAGO along
with LAGO products passes through heat exchangers /air coolers and routed to DHDT and
storage tanks.
3.7 Vacuum Distillation Column (010-C-007)

RCO (AR) from 010-C-001 bottom at temp of 3570C passes through vacuum furnace 010-
F-002 (12 pass furnace) where it is heated up to ~ 400 0C and fed into the flash zone of
vacuum column, 010-C-007. The vacuum column consists of 6 stripping trays, 5 nos.
structural packed beds & 5 nos. of Draw trays. The column operates at a pressure of 17
mm Hg. with the help of three stage ejector system (EJ-001/002/003). Overhead vapors
from the top of the column is drawn through the ejectors 010-EJ-001/002/003 separately
and cooled. The condensed liquid collected in the hot well 010-V-013, via barometric legs
under gravity.
In the hot well, water and oil is separated by maintaining required interface level. Hot well
oil is pumped to DHDT unit and uncondensed vapor from 2 nd stage Ejector condenser
routed to vacuum furnace LP burners via LP amine scrubber 010-C-009.
Flashed AR is fractionated into four side stream yields (Vac. Diesel oil, VGO, HVGO,
Recycle oil). Vacuum diesel is drawn as first side draw from tray D1 at 115 0C. Part of the
draw is routed from pump discharge to the column as IR above the bed-2 and the other
part is cooled to 440C in preheat exchangers /Air Cooler and sent back above bed-1 as
vacuum diesel PA. Vacuum diesel as product from the downstream of 010-E-102 & 010-E-
202 is routed to DHDT.

OVERHEADS
CORROSION WCS WCR TO 010-EJ-001 A/B/C
AQUEOUS
AMMONIA INHIBITOR
010-AC--016
44/42oC
E-039 A/B WET CRUDE 010-AC--014
540/510T/hr VACCUM DIESEL
VACUUM DIESEL
o PDT. TO DHDT
115/114 C
E-102
010-P-021 A/B
TRAIN 2 VACCUM DIESEL
PDT. TO DIESEL HDT
186/184oC
1015/960T/hr
010-AC-015 VGO & HVGO
TO STORAGE
LVGO
VGO & HVGO
250/252oC E-122 E-118 A-F E-108 TO VGO HDT
P-022 A-C FLASHED DESALTED TRAIN 2
CRUDE CRUDE WET CRUDE
281/280oC
700/680T/hr
MP STEAM LP STEAM
010-C-007
HVGO
345/349oC E-124 A/B E-149 E-150
P-023 A-C
WASH OIL BFW BFW
FLASHED TRAIN 2
CRUDE
HEATED AR
EX F-002
RECYCLE Oil TO 010-F-002
010-P-024 A/B VR
SH STRIPPING 265oC QUENCH TO DCU
STEAM LP STEAM
365oC FLASHED FLASHED DESALTED
CRUDE CRUDE CRUDE
o
354 C VR TO STORAGE
E-127 A-K E-126 E-117 E-151 A-C
TRAIN 2 TRAIN 2
010-P-025 A/B/C BFW
VGO is drawn as second side draw from draw tray D3 at a temperature of 2500C and gets
cooled to 1840C in preheat exchangers/Air coolers and a part of VGO sent back to the
column above bed-3 as VGO PA. The remaining VGO further cooled and routed to VGO
HDT at 1530C.
HVGO is drawn as the third side draw from draw tray D4 at temperature of 3490C. One
part of the pump discharge sent back to the column as wash oil above bed D-5 the other
part passes through preheat exchangers gets cooled up to 2810C and split into two
streams. One stream sent back above bed-4 as HVGO PA and the other stream further
gets cooled in E-149 & E-150 up to 1890C and routed along with VGO to VGO-HDT.
Recycle oil is drawn as the 4th side draw from draw tray D-5 at a temperature of 3800C
and sent to feed inlet line of Vacuum furnace.010-C-007 bottom product (Vacuum residue)
pumped out by 010-P-025A/B/C passes through train-3 pre heat exchangers and then split
into two streams. One stream is sent back to the column below the stripping section at a
temperature of 2650C as quench to minimize cracking and the rest is further cooled and
routed to DCU at 1900C.

3.8 Naphtha Stabilizer Column (010-C-004), De-Ethanizer & De-Propanizer

The vapor from crude column overhead receiver (010-V-005) routed to off-gas compressor
via a KOD. The compressor discharges to re-contactor drum 010-V-007 via air cooler 010-
AC-008 and condensed Naphtha from re contactor drum along with the Naphtha side cut
stream from CDU enters the stabilizer 010-C-004, Stabilized Naphtha is drawn from the
bottom. The liquid hydrocarbon (C2-C4) stream from stabilizer overhead receiver is fed to
the De-Ethanizer and LPG components are removed in the bottom.
The De-Ethanizer overhead vapors are partially condensed and fully refluxed, the Off
gases from the De-Ethanizer overhead receiver and re-contact or drum are sent to Amine
Treatment Unit for removal of H2S to get clean fuel gas.
De-Ethanizer bottom is sent to SR LPG treater for Sulphur compounds removal.
Product from SR LPG treater is termed as sweet LPG is routed to De-Propanizer for
separation of C3 and C4 LPG. De-Propanizer bottom product C4 is sent to the Alkylation
unit as feed or to storage. The overhead vapors as C3 stream are totally condensed and
routed to LPG storage.
To accommodate the extra load of overhead vapors, a new scheme for diverting V-08 off
gas directly to V-16 available for minimizing flaring of overhead vapor gases. The off-
gases routed via. this new line will be amine treated and directly routed to fuel gas header.
V-08 over head pressure will be controlled in split range with 0-33% opening of PV-2018
will open valve A (towards AC-08), 0-66% opening will open valve C (new line) and 66-
100% will open valve B (towards flare).
FG to
Amine Flare
Treatment
E-042
V-009
Overhead
Receiver Naptha Stabilizer
Deethaniser
Overhead Reciever
C-005
CWS
E-046 P-018A-B
Sour Water
E-043
FV-2038A FV-2010
Fuel Gas to LAGO PA
FG Header
Depropaniser
C3/C4
V-010 P-002 A-C
C-006
Overhead FV-2012
Receiver SR LPG
FV-2016 Treatment
C3 LPG to Storage FV-2013
E-047
C4 LPG to Alkylation
LAGO PA
P-019A/B/C
C4 LPG TO storage
P-020A-C FV-2014

4 ADVANCED PROCESS CONTROL SOLUTIONS

4.1 Overview
In this section, the Profit Controller applications are specified. Profit Controller stabilizes
the process operations, provides tighter control of the operating targets and reduces the
variations of the process variables. This reduction in variation permits operating the unit
closer to constraints. As a result, unit profitability is improved.
The Profit Controller manipulates a set of independent variables (manipulated variables) to
maintain a set of dependent variables (controlled variables) at targets or within constraints.
The controller can also use disturbance variables as feed-forward control to reject the
disturbances.
The predictive control algorithm uses dynamic models relating the controlled variables to
the manipulated variables and disturbance variables. The models will be generated during
step test of the unit.
A linear or quadratic program optimizer and a predictive dynamic control algorithm
coordinate the movement of the manipulated variables. The optimizer cost function is
configurable to meet the plant operating objectives. The cost function can be adjusted to
reflect the changing of the unit objectives and economics.
The following table lists the implemented Profit controller applications. The controller
objectives, strategies and the design are explained in detail in the later sections.
S. No. Section Controller ID

1. Atmospheric distillation column 010AVU
2. Naphtha Stabilizer 010NSU
3. Vacuum Column 010VDU
4. Vacuum Column Cascade Controller 010VDUCAS
5. De-Ethanizer & De-Propanizer 010DEDP

4.2 Atmospheric Distillation Column Controller (010AVU)

A single Profit Controller application has been implemented for Atmospheric Distillation
Column (010-C-001). The main objectives and the controlled variables (CVs), manipulated
variables (MVs) and disturbance variables (DVs) are listed below.
4.2.1 Control and Optimization Objectives
• Provide stable operation within operating limits
• Side cut Naphtha Maximization subjected to Kero Freeze point
• AGO maximization subjected to AGO D95%
• Pump around flow maximization by honoring quality constraints
• Minimization of Over-flash flow
4.2.2 Controlled Variables

No Tag Number Descriptions Remarks
1. 010PIC1072.PV CDU Top pressure Minimization
2. 010TIC1074 C-001 Ovhd Vap O/L Temp
3. 010SN_D95 SR Naphtha D95% Maximization
4. 010Kero_Flash Kero Flash point
5. 010TI1112.PV Kero Draw Temperature
6. 010KERO_Freez Kero Freeze point Maximization
7. 010TI1114.PV LAGO Draw Temperature
8. 010LIC1046ERR.PV LAGO Tray Level SP-PV
9. 010AGO_D5 AGO D5%
10. 010LIC1050ERR.PV HAGO Tray Level SP-PV
11. 010TI1018.PV HAGO Draw Temperature
12. 010AGO_D95 AGO D95% Maximization
13. 010ARSS AR to Stripping steam ratio
14. OFFDRATIO Over-flash flow to Feed Ratio
4.2.3 Manipulated Variables

1 010TIC1087.OP AC-007 OVHDS Temp OP
2 010FIC1092.SP Side Cut Naphtha SP Maximization
3 010FIC1036.SP TPA FLOW Maximization
4 010QIC1001.SP TPA HEAT DUTY
5 010FIC1038.SP KERO PA FLOW Maximization
6 010QIC1003.SP KERO PA HEAT DUTY
7 010FIC1020.SP KERO STRIPPING STEAM Minimization
8 010FIC1041.SP LAGO PA FLOW
9 010QIC1006.SP LAGO PA HEAT DUTY
10 010FIC1014.SP LAGO PRODUCT FLOW Maximization
11 010FIC1115.SP HAGO PA FLOW Maximization
12 010QIC1007.SP HAGO PA HEAT DUTY
13 010FIC1023.SP LAGO STRIPPING STEAM Minimization
14 010FIC1015.OP HAGO PDT FLOW Maximization


15 010TIC1069.SP F-101 COT
16 010TIC1569.SP F-201 COT
17 010FIC1034A.SP BOTTOM STRIPPING STEAM
18 010FIC1042.SP HAGO IR Flow
4.2.4 Disturbance Variables

1. 010TI3038.PV Ambient Temperature
4.2.5 Strategies
Naphtha Maximization:
CDU Column Top temperature is maximized to maximize the Naphtha yield subjected to
Kero freeze point quality.
AGO Maximization:
HAGO draw temperature is maximized to maximize the AGO yield from Atmospheric
Residue subjected to corresponding AGO D95%.
Over-flash minimization:
This is achieved by manipulating the LAGO & HAGO rundown product flows and
minimizing HAGO IR flow.

4.3 Vacuum Distillation Column (010VDU)

A single Profit Controller application has been implemented in Vacuum Distillation
Column. The main objectives and the controlled variables (CVs), manipulated variables
(MVs) and disturbance variables (DVs) are listed below.
• To provide stable operation within operating limits
• Maximize the VD flow from VGO subjected to VD D95%
• Maximize VGO flow from VR rundown flow subjected to HVGO 95%.

1. 010TI3049.PV VD draw temperature
2. 010VD_D95 VD D95% Maximization
3. 010TI3050.PV VGO Draw Temperature Maximization
4. 010LVGO_D95 VGO D95%
5. 010TI3051.PV HVGO Draw Temperature
6. 010HVGO_D95 HVGO D95% Maximization
7. 010TI3004.PV Flash zone temperature
8. 010VR_5 VR D5%

1. 010FI1046_1045.PV VD Cold Circuit PA flow Note 1
2. 010FIC3029A.SP VD IR Flow Minimization
3. 010FIC3030.SP VGO PA Flow Maximization
4. 010QIC3004.SP VGO Heat Duty
5. 010FIC3014.SP HVGO PA Flow Maximization
6. 010QIC3002.SP HVGO Heat Duty
7. 010FIC3016.SP HVGO IR Flow Minimization
8. 010TIC3003.SP F-002 COT Maximization
9. 010FIC3013.OP Recycle flow to F-002
Notes:
1. 010FI1046_1045.PV is an internal APC Manipulated Variables. The output of the

variable will not go to DCS but will go to Control Variables in 010VDUCAS
Controller.

4.3.5 Strategies
VD Maximization
VD is maximized by maximizing VD draw temperature subjected to VD D95% constraint.
HVGO Maximization
HVGO is maximized by maximizing VGO & HVGO Draw temperature subjected to HVGO
D95%.
4.4 Vacuum Column Cascade Controller (010VDUCAS)

This controller has been deployed for heat duty control of Vacuum Column Pump around
flows.
4.4.1 RMPCCAS Controller
RMPC cascade controller involves two APC profit controllers and it works in the same way
as PID Auto-Cascade configuration. One is a higher-level controller (Master) and other is
the lower level controller (Slave). The master controller MV is writing set point to the slave
controller CV Set point. Slave controller will maintain this set point by manipulating the
corresponding MV.

1. 010FI1046_1045.PV VD Cold Circuit PA flow
2. 010VDPAFD.PV VD Cold flow FD
3. 010LI3039.PV Vacuum Column bottom Level
4. 010LIC3006.PV VGO Tray Level

1. 010HY1012A.AUTOMANA.OP VD cold PA train-1 flow
2. 010HY1012B.AUTOMANA.OP VD cold PA train-2 flow
3. 010FIC1597.OP VR rundown Flow
4. 010FIC1097.OP VR rundown Flow
5. 010FY3032B.AUTOMANA.OP VGO Cold R/D OP
6. 010FI3033.SP VGO Hot R/D flow Maximization

4.5 Naphtha Stabilizer Column (010NSU)

A single Profit Controller application has been implemented for Naphtha Stabilizer Column
(010-C-004). The main objectives and the controlled variables (CVs), manipulated
variables (MVs) and disturbance variables (DVs) are listed below.
• Maximize the LPG yield

1. 010PIC2018SP_PV Reflux drum PIC.SP-PV
2. 010PCT2015.PV NS top PCT
3. 010NSRF.PV NSU Reflux to feed ratio
4. 010LPGW.PV LPG Weathering
5. 010TI2011.PV Bottom Liquid Temperature Maximization
6. 010RVP.PV Naphtha RVP
7. 010LIC2011.PV Reflux drum level

1. 010TIC2016A.OP AC-009 TIC OP - A Maximization
2. 010TIC2016C.OP AC-009 TIC OP – C Maximization
3. 010TIC2016E.OP AC-009 TIC OP - E Maximization
4. 010TIC2015.SP Top Temperature Maximization
5. 010TIC2013.OP Bottom Control Tray Temp
6. 010FIC2008.SP LPG Flow to DE

1. 010FIC2001.SP Feed Flow
2. 010LAGOPAFlow.PV LAGO Cold PA Flow
3. 010TI1116.PV LAGO Draw Temperature
4.5.5 Strategies
LPG Yield Maximization

LPG Yield will be maximized by minimizing the RVP. Bottom temperature constrained to
High Limit.
Reflux to Feed Ratio Minimization

Reflux to feed ratio is minimized to minimize the reboiler energy consumption.

4.6 De-Propanizer Column & De-Ethanizer Column (010DEDP)

A single Profit Controller application has been implemented for De-Ethanizer Column
(010-C-005) and De-Propanizer Column (010-C-006). The main objectives and the
controlled variables (CVs), manipulated variables (MVs) and disturbance variables (DVs)
are listed below.
• Minimize the slippage of C3 in C4 stream

De-Ethanizer
1. 010DERF.PV DE Reflux to Feed Ratio
2. 010PIC2065.OP DE Reflux drum Pr OP
3. 010LIC2016.OP DE Reflux drum Level OP
4. 010TIC2025.PV DE Tray 21 temperature
5. 010C2inLPG.PV C2 slippage in LPG
De-Propanizer
6. 010DPRF.PV DP reflux to feed ratio
7. 010PIC2038.PV DP Ovhd pressure
8. 010TIC2040.PV DP Top tray temp
9. 010TI2036.PV DP reboiler OL temp
10. C3inC4.PV C3 slippage in C4

De-Ethanizer
1. 010TIC2025.OP DE Tray 21 temperature
De-Propanizer
2. 010TIC2040.OP Bottom Tray Temperature
3. 010TIC2035.OP DP Bottom Temp Minimization

1. 010FIC2008.SP LPG Flow to DE
2. 011FI0009.PV DP Feed flow
4.6.5 Strategies
Maximization:
Maximize the De-Ethanizer reboiler outlet temperature constraint to Pressure OP & Level
OP to minimize C2 slippage in LPG.
C4 Slippage in C3:
Control of C4 slippage into C3 in De-Propanizer Column.

5 Supporting calculations
The supporting calculations are designed to provide calculated controlled variables
The supporting calculations are designed to provide calculated controlled variables for the
Profit Controllers. The calculations will be implemented using Profit Excel or Profit Sensor
Pro Toolkits on the APC servers.
5.1 Atmospheric Distillation Column Controller (010AVU)
5.1.1 Naphtha D95%

The objective of this calculation is to predict the Naphtha D95% for the Naphtha Product.
Incentive
The Naphtha D95% will be used as for online monitoring and control of the Naphtha D95%
property.
Calculation Description
The Naphtha D95% is calculated based on a regressed model against laboratory results in
Profit SensorPro toolkit.
Calculation Inputs
The following table lists the probable process inputs to the calculation
Tag Name Description Unit

PCT1074 Crude Column Top PCT 0C
TPAHEATDUTY Crude Column Overhead pressure Kg/cm2

PCT1114 Kero PCT 0C
Calculation Outputs
The following table lists the calculation outputs

010NaphthaD95 Naphtha D95% 0C
5.1.2 Kero Flash Point

The objective of this calculation is to predict the Kero flash point for the Kero Product.
Incentive
The Kero Flash point will be used as for online monitoring and control of the Kero Flash
point quality.
The Kero Flash point is calculated based on a regressed model against laboratory results
in Profit SensorPro toolkit.
Calculation Inputs


0C
PCT1114.PV Kero draw PCT
010KEROPCTDT.PV Kero Stripper bottom temperature 0C
Calculation Outputs
010KeroFlash Kero Flash Point 0C
5.1.3 AGO D5%

The objective of this calculation is to predict the AGO D5% for the AGO Product.
Incentive
The AGO D5% will be used as for online monitoring and control of the AGO product
quality.
The AGO D5% is calculated based on a regressed model against laboratory results in
Calculation Inputs

0C
PCT1116.PV LAGO Draw PCT
010AGOSSPDT LAGO Draw Tray Pressure Kg/cm2
0C
010LAGOSTDT LAGO Stripper bottom temperature
Calculation Outputs
010AGOD5% AG0 D5% 0C
5.1.4 AGO D95

The objective of this calculation is to predict the AGO D95% for the AGO Product.
Incentive
The AGO D95 will be used as for online monitoring and control of the AGO product quality.
The AGO D95 is calculated based on a regressed model against laboratory results in
Calculation Inputs


0C
PCT1018 HAGO draw PCT
010OVERFLASH_FEED Over-flash flow to Feed ratio Kg/cm2
010CDUSSAR Stripping steam to AR flow ratio Ton/Hr
Calculation Outputs
010AGOD95% AGO Distillation 95% quality 0C
5.1.5 Kero Freeze Point

The objective of this calculation is to predict the Kero freeze point for the Kero Product.
Incentive
The Kero Freeze Point will be used as for online monitoring and control of the Kero
product quality.
The Kero Freeze Point is calculated based on a regressed model against laboratory
results in Profit SensorPro toolkit.
Calculation Inputs

PCT1116 LAGO draw PCT 0C
PCT1114 Kero draw PCT 0C
010KERODSTD Kero draw temp – Kero stripper bottom temperature 0C
Calculation Outputs
010Kero Freeze Point Kero Freeze Point 0C

5.2 Vacuum Distillation Column Controller (010VDU)
5.2.1 VD D95%
The objective of this calculation is to predict the VD D95% for the Vacuum Diesel (VD)
Product.
Incentive
The VD D95% will be used as for online monitoring and control of the VD D95% property.
The VD D95% is calculated based on a regressed model against laboratory results in
Calculation Inputs

010TI1039.PV VD Draw temperature 0C
0C
010TI3050.PV VGO draw temperature
010PI3037.PV Vacuum column top pressure Kg/cm2
0C
010TI1089.PV Atmospheric column bottom flash zone temp
Calculation Outputs

010VD D95% VD D95% 0C
5.2.2 VGO D95%

The objective of this calculation is to predict the VGO D95% for the VGO Product.
Incentive
The VGO D95% will be used as for online monitoring and control of the VGO product
quality.
The VGO D95% is calculated based on a regressed model against laboratory results in
Calculation Inputs

0C
010TI3050.PV VGO Draw temperature
0C
010TI3051.PV HVGO draw temperature
010PIC3019.PV Vacuum column top pressure Kg/cm2

Calculation Outputs
010VGO D95% VGO D95% product quality 0C
5.2.3 HVGO D95%

The objective of this calculation is to predict the HVGO D95% for the HVGO Product.
Incentive
The HVGO D95% will be used as for online monitoring and control of the HVGO product
quality.
The HVGO D95% is calculated based on a regressed model against laboratory results in
Calculation Inputs
0C
010TI3051.PV HVGO Draw temperature
0C
010TI3052.PV Vacuum Recycle draw temperature
Calculation Outputs
010HVGOD95% HVGO D95% 0C
5.2.4 VR 5% recovery
The objective of this calculation is to predict the VR_5% for the VR Product.
Incentive
The VR_5% will be used as for online monitoring and control of the VR product quality.
The VR_5% is calculated based on a regressed model against laboratory results in Profit
SensorPro toolkit.
Calculation Inputs
010TIC3003.PV VDU Furnace COT 0C
010VRSS VDU Bottom Stripping steam Ton/Hr

010TI3004.PV Flash zone temperature 0C
010RECYLETOVR Recycle flow to over flash flow ratio
Calculation Outputs


010VR5% VR 5% mass recovery Mass %
5.3 Naphtha Stabilizer Controller (010NSU)
5.3.1 Naphtha Reid Vapor Pressure
Incentive
The Naphtha RVP is used for online monitoring and control of the RVP of the Naphtha
Splitter Bottom.
The Naphtha RVP is calculated based on a regressed model against laboratory results in
Calculation Inputs

010NSBOTPCT Naphtha bottom Liquid outlet PCT Kg/cm2
010NSDT2 Naphtha stripping & rectifying section temp diff 0C
Calculation Outputs
010NaphthaRVP Naphtha RVP kPa
5.3.2 LPG Weathering
Incentive
The LPG Weathering is used for online monitoring and control of the LPG Weathering of
the Debutanizer top section.
The Naphtha RVP is calculated based on a regressed model against laboratory results in
Calculation Inputs
010NSDT2.PV Naphtha stripping & rectifying section temp diff 0C
010NSPCT2015.PV Top PCT 0C
010NSRP.PV Reflux to products ratio

010NSDP.PV Column Pressure difference Kg/cm2
Calculation Outputs
010LPGW LPG Weathering 0C

5.4 De-Ethanizer and De-Propanizer Controller (010DEDP)
5.4.1 C4 slippage at outlet of De-Propanizer
Incentive
The C4 slippage in De-Propanizer propane product is used for online monitoring and
control of the C4 slippage at the top product outlet of De-Propanizer in 010EPCON
controller.
The C4 slippage is calculated based on a regressed model against laboratory results in
Calculation Inputs
010TI2036.PV Reboiler outlet temperature 0C
010PI2066.PV DP Column pressure Kg/cm2

DPRF Reflux to feed ratio
DPPF Products to feed ratio
Calculation Outputs
010C4slippage C4 Slippage into C3 in De-Propanizer Mol %
5.4.1 C2 in LPG
Incentive
The C2 slippage in LPG is used for online monitoring and control of the C2 in LPG.
The C2 slippage is calculated based on a regressed model against laboratory results in
Calculation Inputs
010TIC2025.PV DE tray 21 temperature 0C
010PI2063.PV DE Column bottom pressure Kg/cm2
Calculation Outputs
010C4slippage C4 Slippage into C3 in De-Propanizer Mass %

6 System Architecture
System configuration for AVU APC is shown below
AVUAPCSERVER
EASR501+PSR502
10.25.0.18
LIU CONVERTER APC NETWORK

SWITCH
OPTICAL FIBER CABLE

APC FIREWALL
DUAL ETHERNET NETWORK
LIU
CONVERTER
APC CLIENT AVU OPERATOR

MACHINE STATIONS + PROFIT AVU EPKS SERVER
10.25.0.149 WEB VIEWER

Profit Suite R502 server side has been installed on AVU APC server machine. All the
online APC applications (controller + toolkit) are communicating with Honeywell EPKS
Server through DSA (Distributed Server Architecture).
A PSOS client Machine has been provided in AVU DCS Panel. The client machine is
connected to the AVU APC server machine and it is being used by the Panel Officers to
View and control the APC applications.
Apart from the client Machine Profit Suite Web Viewer has been installed in all the AVU
DCS operator stations for accessing the AVU APC applications.
DETAILS DCU APC SERVER DCU APC CLIENT
Machine Name AVUAPCSERVER AVUAPCCLIENT
Dell Precision 3630
Hardware Details Dell PowerEdge T640
Tower CTO Base
Operating System Windows Server 2016 Standard Windows 10 Pro
IP Address 10.25.0.18 10.25.0.149
Subnet Mask 255.255.248.0 255.255.248.0
Default Gateway 10.26.0.101 NA
Login Username Experionadmin Experionadmin
Login Password pdrp.123 pdrp.123
Service Account Mngr Mngr
Username
Service Account pdrp.123 pdrp.123
Password
EAS Version R501.1 NA
Profit Suite Version R502 NA
EAS License File M15300-AA04_EXP-EAS- NA
500_112675_1.xml
Profit Suite Order SW-19-04816 NA
Reference
Profit Suite License f4c4-7b75-c7f9-4f41-8dc0-e2d3-528d- NA
7e80
ProfitSensorPro 5149-d836-2be2-48e0-9e2a-2440-14af- NA
License 63b4
ULM Key 17b9-234f-ff5b-cbad-UPS NA
PWV Operator Login APC APC
username
PWV Operator Login apc apc
Password

6.1 Controller Connection to DCS
6.1.1 Atmospheric Column (010AVU)

Control Parameter DCS Tag Read/Write
/$010AVU/010AVU/PreGroup/PCT1074/ 010TIC1074.PIDA.PV Read
Combinations/Combination0/Variables
/$010AVU/010AVU/PreGroup/PCT1074/ 010PI1041.DACA.PV Read
/$010AVU/010AVU/PreGroup/PCT1114/ 010TI1114.DACA.PV Read
/$010AVU/010AVU/PreGroup/TPA_Heat 010FIC1036.PIDA.PV Read
Duty_PV/Combinations/Combination0/Va
riables
/$010AVU/010AVU/PreGroup/TPA_Heat 010TI1112.DACA.PV Read
riables
/$010AVU/010AVU/PreGroup/TPA_Heat 010TI1202.DACA.PV Read
riables
/$010AVU/010AVU/PreGroup/010KeroSt 010TI1077.DACA.PV Read
PCT_PV/Combinations/Combination0/Va
riables
/$010AVU/010AVU/PreGroup/010KeroSt 010PI1049.DACA.PV Read
PCT_PV/Combinations/Combination0/Va
riables
/$010AVU/010AVU/PreGroup/010KeroD 010TI1114.DACA.PV Read
STD_PV/Combinations/Combination0/Va
riables
/$010AVU/010AVU/PreGroup/010KeroD 010TI1077.DACA.PV Read
STD_PV/Combinations/Combination0/Va
riables
/$010AVU/010AVU/PreGroup/010QIC10 010FIC1041.PIDA.PV Read
06_SP/Combinations/Combination0/Vari
ables
/$010AVU/010AVU/PreGroup/010QIC10 010TI1116.DACA.PV Read

ables
ables
/$010AVU/010AVU/PreGroup/010QIC10 010FIC1115.PIDA.SP Read
ables
ables
ables
/$010AVU/010AVU/PreGroup/010LIC10 010LIC1046.PIDA.SP Read
46ERR_PV/Combinations/Combination0/
Variables
/$010AVU/010AVU/PreGroup/010LIC10 010LIC1046.DACA.PV Read
Variables
/$010AVU/010AVU/PreGroup/010LIC10 010AVU.CV08.PV[5] Write Always
Variables
/$010AVU/010AVU/PreGroup/010AGOS 010FIC1023.DACA.PV Read
SPDT_PV/Combinations/Combination0/
Variables
/$010AVU/010AVU/PreGroup/010AGOS 010FIC1014.DACA.PV Read
SPDT_PV/Combinations/Combination0/
Variables
/$010AVU/010AVU/PreGroup/010LAGO 010TI1116.DACA.PV Read
STDT_PV/Combinations/Combination0/V
ariables
/$010AVU/010AVU/PreGroup/010LAGO 010TI1078.DACA.PV Read
STDT_PV/Combinations/Combination0/V
ariables
/$010AVU/010AVU/PreGroup/010LIC10 010LIC1050.PIDA.SP Read
Variables
/$010AVU/010AVU/PreGroup/010LIC10 010LIC1050.DACA.PV Read
Variables

/$010AVU/010AVU/PreGroup/010LIC10 010AVU.CV10.PV[5] Write Always

Variables
/$010AVU/010AVU/PreGroup/010Overfl 010FI1035.DACA.PV Read
ash_Feed_PV/Combinations/Combinatio
n0/Variables
/$010AVU/010AVU/PreGroup/010Overfl 010FI1001.DACA.PV Read
ash_Feed_PV/Combinations/Combinatio
n0/Variables
/$010AVU/010AVU/PreGroup/010CDUS 010FIC1034A.PIDA.PV Read
SAR_PV/Combinations/Combination0/Va
riables
/$010AVU/010AVU/PreGroup/010CDUS 010FIC3003A.PIDA.PV Read
SAR_PV/Combinations/Combination0/Va
riables
/$010AVU/010AVU/PreGroup/010ARSS 010FIC3003A.DACA.PV Read
_PV/Combinations/Combination0/Variabl
es
/$010AVU/010AVU/PreGroup/010ARSS 010FIC1034A.PIDA.SP Read
es
/$010AVU/010AVU/PreGroup/OFFDRAT 010FI1035.DACA.PV Read
IO_PV/Combinations/Combination0/Vari
ables
/$010AVU/010AVU/PreGroup/OFFDRAT 010FI1001.DACA.PV Read
ables
/$010AVU/010AVU/PreGroup/OFFDRAT 010AVU.CV14.PV[5] Write Always
ables
010AVU.010AVU.PV[2] Write Always
ProfCon/Controller Mode
010AVU.CVSW01.PV Read
ProfCon/CV/010PIC1072_PV/Control
This CV
010AVU.CVSW01.PV Write If
ProfCon/CV/010PIC1072_PV/Control Changed

This CV
010PIC1072.DACA.PVEUHI Read
ProfCon/CV/010PIC1072_PV/CV
Process High Limit
010PIC1072.DACA.PVEULO Read
Process Low Limit
010AVU.CV01.PV[2] Read
ProfCon/CV/010PIC1072_PV/High Limit
010AVU.CV01.PV[2] Write If
ProfCon/CV/010PIC1072_PV/High Limit Changed
ProfCon/CV/010PIC1072_PV/Low Limit
ProfCon/CV/010PIC1072_PV/Low Limit Changed
010PIC1072.DACA.PV Read
ProfCon/CV/010PIC1072_PV/Read
Value DCS
010AVU.CV01.PV[3] Write Always
ProfCon/CV/010PIC1072_PV/SS Value
ProfCon/CV/010PIC1072_PV/Status
ProfCon/CV/010TIC1074_PV/Control
This CV
ProfCon/CV/010TIC1074_PV/Control Changed
This CV
010TIC1074.DACA.PVEUHI Read
ProfCon/CV/010TIC1074_PV/CV
Process High Limit
010TIC1074.DACA.PVEULO Read
Process Low Limit
ProfCon/CV/010TIC1074_PV/High Limit
ProfCon/CV/010TIC1074_PV/High Limit Changed
ProfCon/CV/010TIC1074_PV/Low Limit

ProfCon/CV/010TIC1074_PV/Low Limit Changed
010TIC1074.DACA.PV Read
ProfCon/CV/010TIC1074_PV/Read
Value DCS
ProfCon/CV/010TIC1074_PV/SS Value
ProfCon/CV/010TIC1074_PV/Status
ProfCon/CV/010SN_D95_PV/Control
This CV
ProfCon/CV/010SN_D95_PV/Control Changed
This CV
ProfCon/CV/010SN_D95_PV/High Limit
ProfCon/CV/010SN_D95_PV/High Limit Changed
ProfCon/CV/010SN_D95_PV/Low Limit
ProfCon/CV/010SN_D95_PV/Low Limit Changed
ProfCon/CV/010SN_D95_PV/Read
Value DCS
ProfCon/CV/010SN_D95_PV/SS Value
ProfCon/CV/010SN_D95_PV/Status
ProfCon/CV/010Kero_Flash_PV/Control
This CV
ProfCon/CV/010Kero_Flash_PV/Control Changed
This CV
ProfCon/CV/010Kero_Flash_PV/High
Limit

ProfCon/CV/010Kero_Flash_PV/High Changed
Limit
ProfCon/CV/010Kero_Flash_PV/Low
Limit
ProfCon/CV/010Kero_Flash_PV/Low Changed
Limit
ProfCon/CV/010Kero_Flash_PV/Read
Value DCS
ProfCon/CV/010Kero_Flash_PV/SS
Value
ProfCon/CV/010Kero_Flash_PV/Status
ProfCon/CV/010TI1114_PV/Control This
CV
ProfCon/CV/010TI1114_PV/Control This Changed
CV
010TI1114.DACA.PVEUHI Read
ProfCon/CV/010TI1114_PV/CV Process
High Limit
010TI1114.DACA.PVEULO Read
Low Limit
ProfCon/CV/010TI1114_PV/High Limit
ProfCon/CV/010TI1114_PV/High Limit Changed
ProfCon/CV/010TI1114_PV/Low Limit
ProfCon/CV/010TI1114_PV/Low Limit Changed
010TI1114.DACA.PV Read
ProfCon/CV/010TI1114_PV/Read Value
DCS
ProfCon/CV/010TI1114_PV/SS Value


ProfCon/CV/010TI1114_PV/Status
ProfCon/CV/010KERO_Freez_PV/Contr
ol This CV
ProfCon/CV/010KERO_Freez_PV/Contr Changed
ol This CV
ProfCon/CV/010KERO_Freez_PV/High
Limit
ProfCon/CV/010KERO_Freez_PV/High Changed
Limit
ProfCon/CV/010KERO_Freez_PV/Low
Limit
ProfCon/CV/010KERO_Freez_PV/Low Changed
Limit
ProfCon/CV/010KERO_Freez_PV/Read
Value DCS
ProfCon/CV/010KERO_Freez_PV/SS
Value
ProfCon/CV/010KERO_Freez_PV/Status
CV
CV
High Limit
Low Limit

DCS
ProfCon/CV/010LIC1046ERR_PV/Contr
ol This CV
ProfCon/CV/010LIC1046ERR_PV/Contr Changed
ol This CV
ProfCon/CV/010LIC1046ERR_PV/High
Limit
ProfCon/CV/010LIC1046ERR_PV/High Changed
Limit
ProfCon/CV/010LIC1046ERR_PV/Low
Limit
ProfCon/CV/010LIC1046ERR_PV/Low Changed
Limit
ProfCon/CV/010LIC1046ERR_PV/Read
Value DCS
ProfCon/CV/010LIC1046ERR_PV/SS
Value
ProfCon/CV/010LIC1046ERR_PV/Status

ProfCon/CV/010AGO_D5_PV/Control
This CV
ProfCon/CV/010AGO_D5_PV/Control Changed
This CV
ProfCon/CV/010AGO_D5_PV/High Limit
ProfCon/CV/010AGO_D5_PV/High Limit Changed
ProfCon/CV/010AGO_D5_PV/Low Limit
ProfCon/CV/010AGO_D5_PV/Low Limit Changed
ProfCon/CV/010AGO_D5_PV/Read
Value DCS
ProfCon/CV/010AGO_D5_PV/SS Value
ProfCon/CV/010AGO_D5_PV/Status
ProfCon/CV/010LIC1050ERR_PV/Contr
ol This CV
ProfCon/CV/010LIC1050ERR_PV/Contr Changed
ol This CV
ProfCon/CV/010LIC1050ERR_PV/High
Limit
ProfCon/CV/010LIC1050ERR_PV/High Changed
Limit
ProfCon/CV/010LIC1050ERR_PV/Low
Limit
ProfCon/CV/010LIC1050ERR_PV/Low Changed
Limit
ProfCon/CV/010LIC1050ERR_PV/Read

Value DCS
ProfCon/CV/010LIC1050ERR_PV/SS
Value
ProfCon/CV/010LIC1050ERR_PV/Status
CV
CV
High Limit
Low Limit
DCS
ProfCon/CV/010AGO_D95_PV/Control
This CV
ProfCon/CV/010AGO_D95_PV/Control Changed
This CV
ProfCon/CV/010AGO_D95_PV/High

Limit
ProfCon/CV/010AGO_D95_PV/High Changed
Limit
ProfCon/CV/010AGO_D95_PV/Low Limit
ProfCon/CV/010AGO_D95_PV/Low Limit Changed
ProfCon/CV/010AGO_D95_PV/Read
Value DCS
ProfCon/CV/010AGO_D95_PV/SS Value
ProfCon/CV/010AGO_D95_PV/Status
ProfCon/CV/010ARSS_PV/Control This
CV
ProfCon/CV/010ARSS_PV/Control This Changed
CV
ProfCon/CV/010ARSS_PV/High Limit
ProfCon/CV/010ARSS_PV/High Limit Changed
ProfCon/CV/010ARSS_PV/Low Limit
ProfCon/CV/010ARSS_PV/Low Limit Changed
ProfCon/CV/010ARSS_PV/Read Value
DCS
ProfCon/CV/010ARSS_PV/SS Value
ProfCon/CV/010ARSS_PV/Status
ProfCon/CV/OFFDRATIO_PV/Control
This CV

ProfCon/CV/OFFDRATIO_PV/Control Changed
This CV
ProfCon/CV/OFFDRATIO_PV/High Limit
ProfCon/CV/OFFDRATIO_PV/High Limit Changed
ProfCon/CV/OFFDRATIO_PV/Low Limit
ProfCon/CV/OFFDRATIO_PV/Low Limit Changed
ProfCon/CV/OFFDRATIO_PV/Read
Value DCS
ProfCon/CV/OFFDRATIO_PV/SS Value
ProfCon/CV/OFFDRATIO_PV/Status
ProfCon/DV/010TI3038_PV/Read Value
010AVU.MV01.PV[3] Write Always
ProfCon/MV/010TIC1087_OP/Current
Move
010AVU.MV01.PV[2] Read
ProfCon/MV/010TIC1087_OP/High Limit
010AVU.MV01.PV[2] Write If
ProfCon/MV/010TIC1087_OP/High Limit Changed
ProfCon/MV/010TIC1087_OP/Low Limit
ProfCon/MV/010TIC1087_OP/Low Limit Changed
010TIC1087.PIDA.OPHILM Read
ProfCon/MV/010TIC1087_OP/Process
High Limit
010TIC1087.PIDA.OPLOLM Read
Low Limit
ProfCon/MV/010TIC1087_OP/Read OP
Process High Limit

Process Low Limit
010TIC1087.PIDA.OP Read
Value
ProfCon/MV/010TIC1087_OP/Read
Process Value
Value
ProfCon/MV/010TIC1087_OP/SS Value
ProfCon/MV/010TIC1087_OP/Status
010AVU.MVSW01.PV Read
ProfCon/MV/010TIC1087_OP/Use This
MV
010AVU.MVSW01.PV Write If
ProfCon/MV/010TIC1087_OP/Use This Changed
MV
ProfCon/MV/010FIC1092_SP/Current
Move
ProfCon/MV/010FIC1092_SP/High Limit
ProfCon/MV/010FIC1092_SP/High Limit Changed
ProfCon/MV/010FIC1092_SP/Low Limit
ProfCon/MV/010FIC1092_SP/Low Limit Changed
010FIC1092.PIDA.SPHILM Read
ProfCon/MV/010FIC1092_SP/Process
High Limit
010FIC1092.PIDA.SPLOLM Read
Low Limit
010FIC1092.PIDA.OPHILM Read
ProfCon/MV/010FIC1092_SP/Read OP
Process High Limit

010FIC1092.PIDA.OPLOLM Read
Process Low Limit
010FIC1092.PIDA.OP Read
Value
010FIC1092.PIDA.PV Read
ProfCon/MV/010FIC1092_SP/Read
Process Value
010FIC1092.PIDA.SP Read
Value
ProfCon/MV/010FIC1092_SP/SS Value
ProfCon/MV/010FIC1092_SP/Status
ProfCon/MV/010FIC1092_SP/Use This
MV
ProfCon/MV/010FIC1092_SP/Use This Changed
MV
Move
High Limit
Low Limit

Process High Limit

Process Low Limit
Value
Process Value
Value
MV
MV
ProfCon/MV/010QIC1001_SP/Current
Move
ProfCon/MV/010QIC1001_SP/High Limit
ProfCon/MV/010QIC1001_SP/High Limit Changed
ProfCon/MV/010QIC1001_SP/Low Limit
ProfCon/MV/010QIC1001_SP/Low Limit Changed
010QIC1001.PIDA.SPHILM Read
ProfCon/MV/010QIC1001_SP/Process
High Limit
010QIC1001.PIDA.SPLOLM Read
Low Limit

010QIC1001.PIDA.OPHILM Read
ProfCon/MV/010QIC1001_SP/Read OP
Process High Limit
010QIC1001.PIDA.OPLOLM Read
Process Low Limit
010QIC1001.PIDA.OP Read
Value
010QIC1001.PIDA.PV Read
ProfCon/MV/010QIC1001_SP/Read
Process Value
010QIC1001.PIDA.SP Read
Value
ProfCon/MV/010QIC1001_SP/SS Value
ProfCon/MV/010QIC1001_SP/Status
ProfCon/MV/010QIC1001_SP/Use This
MV
ProfCon/MV/010QIC1001_SP/Use This Changed
MV
Move
High Limit

Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
MV
Move
High Limit

Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
MV
Move

High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
MV
Move

High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
MV
Move


High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
MV
Move

High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
MV
Move

High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
MV
Move

High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
MV
Move


High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
MV
ProfCon/MV/010FIC1015_OP/Current
Move
ProfCon/MV/010FIC1015_OP/High Limit

ProfCon/MV/010FIC1015_OP/High Limit Changed
ProfCon/MV/010FIC1015_OP/Low Limit
ProfCon/MV/010FIC1015_OP/Low Limit Changed
ProfCon/MV/010FIC1015_OP/Process
High Limit
Low Limit
ProfCon/MV/010FIC1015_OP/Read OP
Process High Limit
Process Low Limit
Value
ProfCon/MV/010FIC1015_OP/Read
Process Value
Value
ProfCon/MV/010FIC1015_OP/SS Value
ProfCon/MV/010FIC1015_OP/Status
ProfCon/MV/010FIC1015_OP/Use This
MV
ProfCon/MV/010FIC1015_OP/Use This Changed
MV
ProfCon/MV/010TIC1069_SP/Current
Move

ProfCon/MV/010TIC1069_SP/High Limit
ProfCon/MV/010TIC1069_SP/High Limit Changed
ProfCon/MV/010TIC1069_SP/Low Limit
ProfCon/MV/010TIC1069_SP/Low Limit Changed
010TIC1069.PIDA.SPHILM Read
ProfCon/MV/010TIC1069_SP/Process
High Limit
010TIC1069.PIDA.SPLOLM Read
Low Limit
ProfCon/MV/010TIC1069_SP/Read OP
Process High Limit
Process Low Limit
Value
010TIC1069.PIDA.PV Read
ProfCon/MV/010TIC1069_SP/Read
Process Value
010TIC1069.PIDA.SP Read
Value
ProfCon/MV/010TIC1069_SP/SS Value
ProfCon/MV/010TIC1069_SP/Status
ProfCon/MV/010TIC1069_SP/Use This
MV
ProfCon/MV/010TIC1069_SP/Use This Changed
MV
Move

ProfCon/MV/010TIC1569_SP/High Limit
ProfCon/MV/010TIC1569_SP/Low Limit
High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
ProfCon/MV/010TIC1569_SP/Use This
MV
MV
ProfCon/MV/010FIC1034A_SP/Current

Move
ProfCon/MV/010FIC1034A_SP/High
Limit
ProfCon/MV/010FIC1034A_SP/High Changed
Limit
ProfCon/MV/010FIC1034A_SP/Low Limit
ProfCon/MV/010FIC1034A_SP/Low Limit Changed
010FIC1034A.PIDA.SPHILM Read
ProfCon/MV/010FIC1034A_SP/Process
High Limit
010FIC1034A.PIDA.SPLOL Read
ProfCon/MV/010FIC1034A_SP/Process M
Low Limit
010FIC1034A.PIDA.OPHILM Read
ProfCon/MV/010FIC1034A_SP/Read OP
Process High Limit
010FIC1034A.PIDA.OPLOL Read
ProfCon/MV/010FIC1034A_SP/Read OP M
Process Low Limit
010FIC1034A.PIDA.OP Read
ProfCon/MV/010FIC1034A_SP/Read OP
Value
010FIC1034A.PIDA.PV Read
ProfCon/MV/010FIC1034A_SP/Read
Process Value
010FIC1034A.PIDA.SP Read
ProfCon/MV/010FIC1034A_SP/Read
Value
ProfCon/MV/010FIC1034A_SP/SS Value
ProfCon/MV/010FIC1034A_SP/Status
ProfCon/MV/010FIC1034A_SP/Use This
MV
ProfCon/MV/010FIC1034A_SP/Use This Changed

MV
High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
010AVU.010AVU.PV[3] Read
ProfCon/Turn ON OFF
010AVU.010AVU.PV[3] Write If
ProfCon/Turn ON OFF Changed
010AVU_WD1.WATCHDOG Write Always
ProfCon/Watchdog_WDInfo/WD/010AVU A.IN
_WD1/Pulse
010AVU_WD1.EXECSTATE Read
ProfCon/Watchdog_WDInfo/WD/010AVU /ENUM
_WD1/ExecState
/$010AVU/010AVU/PreGroup/010ARSS 010AVU.CV13.PV[5] Write Always
es
010AVU_WD1.ORA.IN[1] Write If
ProfCon/Watchdog_WDInfo/WD/010AVU Changed
_WD1/EnableFlag
010AVU_WD1.WATCHDOG Write If
ProfCon/Watchdog_WDInfo/WD/010AVU A.DELAYTIME Changed
_WD1/DelayTime

010TIC1087.PIDA.MODEAT Read
ProfCon/SchedBLC/MV/010TIC1087_OP TR/ENUM
/DSC/010TIC1087_OP/Get/ModeConnec
t/ModeConnect1
010TIC1087.PIDA.MODE/E Read
ProfCon/SchedBLC/MV/010TIC1087_OP NUM
/DSC/010TIC1087_OP/Get/ModeConnec
t/ModeConnect2
010TIC1087.EXECSTATE/E Read
/DSC/010TIC1087_OP/Get/ExecStateCo
nnect/ExecState1
010TIC1087.CEESTATE/EN Read
ProfCon/SchedBLC/MV/010TIC1087_OP UM
nnect/ExecState2
010TIC1087.PIDA.ARWOP/ Read
ProfCon/SchedBLC/MV/010TIC1087_OP ENUM
/DSC/010TIC1087_OP/Get/WindupConn
ect/WindupStatus1
010TIC1087.PIDA.MODEAT Write Always
/DSC/010TIC1087_OP/Set/ModeConnec
t/ModeConnect1
010TIC1087.PIDA.MODE/E Write Always
t/ModeConnect2
010TIC1087.PIDA.OP Write Always
ProfCon/SchedBLC/MV/010TIC1087_OP
/DSC/010TIC1087_OP/Set/SentValue
/DSC/010TIC1087_OP/Set/SentValueEU
High
Low
010FIC1092.PIDA.MODEAT Read
ProfCon/SchedBLC/MV/010FIC1092_SP TR/ENUM
/DSC/010FIC1092_SP/Get/ModeConnec
t/ModeConnect1

010FIC1092.PIDA.MODE/E Read
ProfCon/SchedBLC/MV/010FIC1092_SP NUM
t/ModeConnect2
010FIC1092.EXECSTATE/E Read
/DSC/010FIC1092_SP/Get/ExecStateCo
nnect/ExecState1
010FIC1092.CEESTATE/EN Read
ProfCon/SchedBLC/MV/010FIC1092_SP UM
nnect/ExecState2
010FIC1092.PIDA.ARWNET Read
ProfCon/SchedBLC/MV/010FIC1092_SP [1]/ENUM
/DSC/010FIC1092_SP/Get/WindupConn
ect/WindupStatus1
010FIC1092.PIDA.MODEAT Write Always
/DSC/010FIC1092_SP/Set/ModeConnec
t/ModeConnect1
010FIC1092.PIDA.MODE/E Write Always
t/ModeConnect2
010FIC1092.PIDA.SP Write Always
ProfCon/SchedBLC/MV/010FIC1092_SP
/DSC/010FIC1092_SP/Set/SentValue
/DSC/010FIC1092_SP/Set/SentValueEU
High
Low
t/ModeConnect1
t/ModeConnect2

nnect/ExecState1
nnect/ExecState2
ect/WindupStatus1
t/ModeConnect1
t/ModeConnect2
High
Low
010QIC1001.PIDA.MODEAT Read
ProfCon/SchedBLC/MV/010QIC1001_S TR/ENUM
P/DSC/010QIC1001_SP/Get/ModeConn
ect/ModeConnect1
010QIC1001.PIDA.MODE/E Read
ProfCon/SchedBLC/MV/010QIC1001_S NUM
ect/ModeConnect2
010QIC1001.EXECSTATE/E Read
P/DSC/010QIC1001_SP/Get/ExecState
Connect/ExecState1

010QIC1001.CEESTATE/EN Read
ProfCon/SchedBLC/MV/010QIC1001_S UM
Connect/ExecState2
010QIC1001.PIDA.ARWNET Read
ProfCon/SchedBLC/MV/010QIC1001_S [1]/ENUM
P/DSC/010QIC1001_SP/Get/WindupCon
nect/WindupStatus1
010QIC1001.PIDA.MODEAT Write Always
P/DSC/010QIC1001_SP/Set/ModeConn
ect/ModeConnect1
010QIC1001.PIDA.MODE/E Write Always
ect/ModeConnect2
010QIC1001.PIDA.SP Write Always
ProfCon/SchedBLC/MV/010QIC1001_S
P/DSC/010QIC1001_SP/Set/SentValue
P/DSC/010QIC1001_SP/Set/SentValueE
UHigh
ULow
t/ModeConnect1
t/ModeConnect2
nnect/ExecState1
nnect/ExecState2

ect/WindupStatus1
t/ModeConnect1
t/ModeConnect2
High
Low
ect/ModeConnect1
ect/ModeConnect2
Connect/ExecState1
Connect/ExecState2
nect/WindupStatus1


ect/ModeConnect1
ect/ModeConnect2
UHigh
ULow
t/ModeConnect1
t/ModeConnect2
nnect/ExecState1
nnect/ExecState2
ect/WindupStatus1
t/ModeConnect1


t/ModeConnect2
High
Low
t/ModeConnect1
t/ModeConnect2
nnect/ExecState1
nnect/ExecState2
ect/WindupStatus1
t/ModeConnect1
t/ModeConnect2


High
Low
ect/ModeConnect1
ect/ModeConnect2
Connect/ExecState1
Connect/ExecState2
nect/WindupStatus1
ect/ModeConnect1
ect/ModeConnect2

UHigh
ULow
t/ModeConnect1
t/ModeConnect2
nnect/ExecState1
nnect/ExecState2
ect/WindupStatus1
t/ModeConnect1
t/ModeConnect2
High

Low
t/ModeConnect1
t/ModeConnect2
nnect/ExecState1
nnect/ExecState2
ect/WindupStatus1
t/ModeConnect1
t/ModeConnect2
High
Low

ect/ModeConnect1
ect/ModeConnect2
Connect/ExecState1
Connect/ExecState2
nect/WindupStatus1
ect/ModeConnect1
ect/ModeConnect2
UHigh
ULow
t/ModeConnect1

t/ModeConnect2
nnect/ExecState1
nnect/ExecState2
ect/WindupStatus1
t/ModeConnect1
t/ModeConnect2
High
Low
ProfCon/SchedBLC/MV/010FIC1015_OP TR/ENUM
/DSC/010FIC1015_OP/Get/ModeConnec
t/ModeConnect1
ProfCon/SchedBLC/MV/010FIC1015_OP NUM
/DSC/010FIC1015_OP/Get/ModeConnec
t/ModeConnect2

/DSC/010FIC1015_OP/Get/ExecStateCo
nnect/ExecState1
ProfCon/SchedBLC/MV/010FIC1015_OP UM
/DSC/010FIC1015_OP/Get/ExecStateCo
nnect/ExecState2
010FIC1015.PIDA.ARWOP/ Read
ProfCon/SchedBLC/MV/010FIC1015_OP ENUM
/DSC/010FIC1015_OP/Get/WindupConn
ect/WindupStatus1
ProfCon/SchedBLC/MV/010FIC1015_OP TR/ENUM
/DSC/010FIC1015_OP/Set/ModeConnec
t/ModeConnect1
/DSC/010FIC1015_OP/Set/ModeConnec
t/ModeConnect2
010FIC1015.PIDA.OP Write Always
ProfCon/SchedBLC/MV/010FIC1015_OP
/DSC/010FIC1015_OP/Set/SentValue
/DSC/010FIC1015_OP/Set/SentValueEU
High
/DSC/010FIC1015_OP/Set/SentValueEU
Low
ProfCon/SchedBLC/MV/010TIC1069_SP TR/ENUM
/DSC/010TIC1069_SP/Get/ModeConnec
t/ModeConnect1
ProfCon/SchedBLC/MV/010TIC1069_SP NUM
t/ModeConnect2
/DSC/010TIC1069_SP/Get/ExecStateCo
nnect/ExecState1

ProfCon/SchedBLC/MV/010TIC1069_SP UM
nnect/ExecState2
010TIC1069.PIDA.ARWNET Read
ProfCon/SchedBLC/MV/010TIC1069_SP [1]/ENUM
/DSC/010TIC1069_SP/Get/WindupConn
ect/WindupStatus1
/DSC/010TIC1069_SP/Set/ModeConnec
t/ModeConnect1
t/ModeConnect2
010TIC1069.PIDA.SP Write Always
ProfCon/SchedBLC/MV/010TIC1069_SP
/DSC/010TIC1069_SP/Set/SentValue
/DSC/010TIC1069_SP/Set/SentValueEU
High
Low
t/ModeConnect1
t/ModeConnect2
nnect/ExecState1
nnect/ExecState2

ect/WindupStatus1
t/ModeConnect1
t/ModeConnect2
High
Low
010FIC1034A.PIDA.MODEA Read
ProfCon/SchedBLC/MV/010FIC1034A_S TTR/ENUM
P/DSC/010FIC1034A_SP/Get/ModeCon
nect/ModeConnect1
010FIC1034A.PIDA.MODE/ Read
ProfCon/SchedBLC/MV/010FIC1034A_S ENUM
P/DSC/010FIC1034A_SP/Get/ModeCon
nect/ModeConnect2
010FIC1034A.EXECSTATE/ Read
P/DSC/010FIC1034A_SP/Get/ExecState
Connect/ExecState1
010FIC1034A.CEESTATE/E Read
ProfCon/SchedBLC/MV/010FIC1034A_S NUM
P/DSC/010FIC1034A_SP/Get/ExecState
Connect/ExecState2
010FIC1034A.PIDA.ARWNE Read
ProfCon/SchedBLC/MV/010FIC1034A_S T[1]/ENUM
P/DSC/010FIC1034A_SP/Get/WindupCo
nnect/WindupStatus1
010FIC1034A.PIDA.MODEA Write Always

ProfCon/SchedBLC/MV/010FIC1034A_S TTR/ENUM
P/DSC/010FIC1034A_SP/Set/ModeCon
nect/ModeConnect1
010FIC1034A.PIDA.MODE/ Write Always
P/DSC/010FIC1034A_SP/Set/ModeCon
nect/ModeConnect2
010FIC1034A.PIDA.SP Write Always
ProfCon/SchedBLC/MV/010FIC1034A_S
P/DSC/010FIC1034A_SP/Set/SentValue
ProfCon/SchedBLC/MV/010FIC1034A_S
EUHigh
ProfCon/SchedBLC/MV/010FIC1034A_S M
EULow
t/ModeConnect1
t/ModeConnect2
nnect/ExecState1
nnect/ExecState2
ect/WindupStatus1
t/ModeConnect1

t/ModeConnect2
High
Low
010TI3038.EXECSTATE/EN Read
ProfCon/SchedBLC/DV/010TI3038_PV/0 UM
10TI3038_PV/Get/ExecStateConnect/Ex
ecState1
010TI3038.CEESTATE/ENU Read
ProfCon/SchedBLC/DV/010TI3038_PV/0 M
ecState2
010PIC1072.EXECSTATE/E Read
ProfCon/SchedBLC/CV/010PIC1072_PV NUM
/010PIC1072_PV/Get/ExecStateConnect
/ExecState1
010PIC1072.CEESTATE/EN Read
ProfCon/SchedBLC/CV/010PIC1072_PV UM
/ExecState2
ProfCon/SchedBLC/CV/010TIC1074_PV NUM
/010TIC1074_PV/Get/ExecStateConnect
/ExecState1
ProfCon/SchedBLC/CV/010TIC1074_PV UM
/ExecState2
010AVU.EXECSTATE/ENU Read
ProfCon/SchedBLC/CV/010SN_D95_PV/ M
010SN_D95_PV/Get/ExecStateConnect/
ExecState1
010AVU.CEESTATE/ENUM Read

ProfCon/SchedBLC/CV/010SN_D95_PV/
010SN_D95_PV/Get/ExecStateConnect/
ExecState2
ProfCon/SchedBLC/CV/010Kero_Flash_ M
PV/010Kero_Flash_PV/Get/ExecStateCo
nnect/ExecState1
ProfCon/SchedBLC/CV/010Kero_Flash_
PV/010Kero_Flash_PV/Get/ExecStateCo
nnect/ExecState2
ProfCon/SchedBLC/CV/010TI1114_PV/0 UM
ecState1
ProfCon/SchedBLC/CV/010TI1114_PV/0 M
ecState2
ProfCon/SchedBLC/CV/010KERO_Freez M
_PV/010KERO_Freez_PV/Get/ExecStat
eConnect/ExecState1
ProfCon/SchedBLC/CV/010KERO_Freez
_PV/010KERO_Freez_PV/Get/ExecStat
eConnect/ExecState2
ecState1
ecState2
ProfCon/SchedBLC/CV/010LIC1046ERR M
_PV/010LIC1046ERR_PV/Get/ExecStat
eConnect/ExecState1
ProfCon/SchedBLC/CV/010LIC1046ERR
eConnect/ExecState2

ProfCon/SchedBLC/CV/010AGO_D5_PV M
/010AGO_D5_PV/Get/ExecStateConnec
t/ExecState1
ProfCon/SchedBLC/CV/010AGO_D5_PV
/010AGO_D5_PV/Get/ExecStateConnec
t/ExecState2
ProfCon/SchedBLC/CV/010LIC1050ERR M
eConnect/ExecState1
ProfCon/SchedBLC/CV/010LIC1050ERR
eConnect/ExecState2
ecState1
ecState2
ProfCon/SchedBLC/CV/010AGO_D95_P M
V/010AGO_D95_PV/Get/ExecStateConn
ect/ExecState1
ProfCon/SchedBLC/CV/010AGO_D95_P
V/010AGO_D95_PV/Get/ExecStateConn
ect/ExecState2
ProfCon/SchedBLC/CV/010ARSS_PV/0 M
10ARSS_PV/Get/ExecStateConnect/Exe
cState1
ProfCon/SchedBLC/CV/010ARSS_PV/0
10ARSS_PV/Get/ExecStateConnect/Exe
cState2
ProfCon/SchedBLC/CV/OFFDRATIO_P 010AVU.EXECSTATE/ENU Read
V/OFFDRATIO_PV/Get/ExecStateConne M
ct/ExecState1

ProfCon/SchedBLC/CV/OFFDRATIO_P 010AVU.CEESTATE/ENUM Read

V/OFFDRATIO_PV/Get/ExecStateConne
ct/ExecState2
6.1.2 Vacuum Column (010VDU)

/$010VDU/010VDU/PreGroup/010FI104 010FI1046.DACA.PV Read
6_1045_SUM_PV/Combinations/Combin
ation0/Variables
/$010VDU/010VDU/PreGroup/010FI104 010FI1045.DACA.PV Read
6_1045_SUM_PV/Combinations/Combin
ation0/Variables
ProfCon/Controller Mode 010VDU.010VDU.PV[2] Write Always
010VDU.CVSW01.PV Write If
ProfCon/CV/010TI3049_DACA_PV/Cont Changed
rol This CV
ProfCon/CV/010TI3049_DACA_PV/CV
Process High Limit
Process Low Limit
010VDU.CV01.PV[2] Write If
ProfCon/CV/010TI3049_DACA_PV/High Changed
Limit
ProfCon/CV/010TI3049_DACA_PV/Low Changed
Limit
ProfCon/CV/010TI3049_DACA_PV/Rea
d Value DCS
010VDU.CV01.PV[3] Write Always
ProfCon/CV/010TI3049_DACA_PV/SS
Value
ProfCon/CV/010TI3049_DACA_PV/Statu
s
ProfCon/CV/010VD95_PV/Control This Changed
CV

ProfCon/CV/010VD95_PV/High Limit Changed
ProfCon/CV/010VD95_PV/Low Limit Changed
ProfCon/CV/010VD95_PV/SS Value
ProfCon/CV/010VD95_PV/Status
rol This CV
Process High Limit
Process Low Limit
Limit
Limit
d Value DCS
Value
s
ProfCon/CV/010VGO95_PV/Control This Changed
CV
ProfCon/CV/010VGO95_PV/High Limit Changed
ProfCon/CV/010VGO95_PV/Low Limit Changed
ProfCon/CV/010VGO95_PV/SS Value


ProfCon/CV/010VGO95_PV/Status
rol This CV
Process High Limit
Process Low Limit
Limit
Limit
d Value DCS
Value
s
ProfCon/CV/010HVGOD95_PV/Control Changed
This CV
ProfCon/CV/010HVGOD95_PV/High Changed
Limit
ProfCon/CV/010HVGOD95_PV/Low Changed
Limit
010VDU.CV06.PV[5] Read
ProfCon/CV/010HVGOD95_PV/Read
Value DCS
ProfCon/CV/010HVGOD95_PV/SS
Value


ProfCon/CV/010HVGOD95_PV/Status
rol This CV
Process High Limit
Process Low Limit
Limit
Limit
d Value DCS
Value
s
ProfCon/CV/010VR_5_PV/Control This Changed
CV
ProfCon/CV/010VR_5_PV/High Limit Changed
ProfCon/CV/010VR_5_PV/Low Limit Changed
ProfCon/CV/010VR_5_PV/SS Value
ProfCon/CV/010VR_5_PV/Status
010VDU.MV02.PV[3] Write Always
ProfCon/MV/010FIC3029A_PIDA_SP/Cu
rrent Move

010VDU.MV02.PV[2] Write If
ProfCon/MV/010FIC3029A_PIDA_SP/Hi Changed
gh Limit
ProfCon/MV/010FIC3029A_PIDA_SP/Lo Changed
w Limit
ProfCon/MV/010FIC3029A_PIDA_SP/Pr
ocess High Limit
ProfCon/MV/010FIC3029A_PIDA_SP/Pr M
ocess Low Limit
010FIC3029A.PIDA.OPHILM Read
ProfCon/MV/010FIC3029A_PIDA_SP/Re
ad OP Process High Limit
010FIC3029A.PIDA.OPLOL Read
ProfCon/MV/010FIC3029A_PIDA_SP/Re M
ad OP Process Low Limit
010FIC3029A.PIDA.OP Read
ad OP Value
010FIC3029A.PIDA.PV Read
ad Process Value
010FIC3029A.PIDA.SP Read
ad Value
ProfCon/MV/010FIC3029A_PIDA_SP/S
S Value
ProfCon/MV/010FIC3029A_PIDA_SP/St
atus
010VDU.MVSW02.PV Write If
ProfCon/MV/010FIC3029A_PIDA_SP/Us Changed
e This MV
ProfCon/MV/010FIC3030_PIDA_SP/Curr
ent Move
ProfCon/MV/010FIC3030_PIDA_SP/Hig Changed
h Limit

ProfCon/MV/010FIC3030_PIDA_SP/Low Changed
Limit
ProfCon/MV/010FIC3030_PIDA_SP/Pro
cess High Limit
cess Low Limit
ProfCon/MV/010FIC3030_PIDA_SP/Rea
d OP Process High Limit
d OP Process Low Limit
d OP Value
d Process Value
d Value
ProfCon/MV/010FIC3030_PIDA_SP/SS
Value
ProfCon/MV/010FIC3030_PIDA_SP/Stat
us
ProfCon/MV/010FIC3030_PIDA_SP/Use Changed
This MV
ProfCon/MV/010QIC3004_PIDA_SP/Cur
rent Move
ProfCon/MV/010QIC3004_PIDA_SP/Hig Changed
h Limit
ProfCon/MV/010QIC3004_PIDA_SP/Lo Changed
w Limit

ProfCon/MV/010QIC3004_PIDA_SP/Pro
cess High Limit
cess Low Limit
ProfCon/MV/010QIC3004_PIDA_SP/Re
ad OP Value
ad Process Value
ad Value
ProfCon/MV/010QIC3004_PIDA_SP/SS
Value
ProfCon/MV/010QIC3004_PIDA_SP/Stat
us
ProfCon/MV/010QIC3004_PIDA_SP/Use Changed
This MV
ProfCon/MV/010FIC3014_PIDA_SP/Curr
ent Move
ProfCon/MV/010FIC3014_PIDA_SP/Hig Changed
h Limit
ProfCon/MV/010FIC3014_PIDA_SP/Low Changed
Limit
cess High Limit

cess Low Limit
d OP Value
d Process Value
d Value
ProfCon/MV/010FIC3014_PIDA_SP/SS
Value
ProfCon/MV/010FIC3014_PIDA_SP/Stat
us
ProfCon/MV/010FIC3014_PIDA_SP/Use Changed
This MV
ProfCon/MV/010QIC3002_PIDA_SP/Cur
rent Move
ProfCon/MV/010QIC3002_PIDA_SP/Hig Changed
h Limit
ProfCon/MV/010QIC3002_PIDA_SP/Lo Changed
w Limit
cess High Limit
cess Low Limit

ad OP Value
ad Process Value
ad Value
ProfCon/MV/010QIC3002_PIDA_SP/SS
Value
ProfCon/MV/010QIC3002_PIDA_SP/Stat
us
ProfCon/MV/010QIC3002_PIDA_SP/Use Changed
This MV
ProfCon/MV/010FIC3016_PIDA_OP/Cur
rent Move
ProfCon/MV/010FIC3016_PIDA_OP/Hig Changed
h Limit
ProfCon/MV/010FIC3016_PIDA_OP/Low Changed
Limit
ProfCon/MV/010FIC3016_PIDA_OP/Pro
cess High Limit
cess Low Limit
ProfCon/MV/010FIC3016_PIDA_OP/Rea

d OP Value
d Process Value
d Value
ProfCon/MV/010FIC3016_PIDA_OP/SS
Value
ProfCon/MV/010FIC3016_PIDA_OP/Stat
us
ProfCon/MV/010FIC3016_PIDA_OP/Use Changed
This MV
ProfCon/MV/010TIC3003_PIDA_SP/Curr
ent Move
ProfCon/MV/010TIC3003_PIDA_SP/Hig Changed
h Limit
ProfCon/MV/010TIC3003_PIDA_SP/Low Changed
Limit
ProfCon/MV/010TIC3003_PIDA_SP/Pro
cess High Limit
ProfCon/MV/010TIC3003_PIDA_SP/Pro
cess Low Limit
ProfCon/MV/010TIC3003_PIDA_SP/Rea

d OP Value
d Process Value
d Value
ProfCon/MV/010TIC3003_PIDA_SP/SS
Value
ProfCon/MV/010TIC3003_PIDA_SP/Stat
us
ProfCon/MV/010TIC3003_PIDA_SP/Use Changed
This MV
ProfCon/MV/010FIC3013_PIDA_OP/Cur
rent Move
ProfCon/MV/010FIC3013_PIDA_OP/Hig Changed
h Limit
ProfCon/MV/010FIC3013_PIDA_OP/Low Changed
Limit
cess High Limit
cess Low Limit
d OP Value

d Process Value
d Value
ProfCon/MV/010FIC3013_PIDA_OP/SS
Value
ProfCon/MV/010FIC3013_PIDA_OP/Stat
us
ProfCon/MV/010FIC3013_PIDA_OP/Use Changed
This MV
010VDU.010VDU.PV[3] Read
ProfCon/Turn ON OFF
010VDU.010VDU.PV[3] Write If
010VDU_WD1.WATCHDOG Write Always
ProfCon/Watchdog_WDInfo/WD/010VD A.IN
U_WD1/Pulse
010VDU_WD1.WATCHDOG Write If
ProfCon/Watchdog_WDInfo/WD/010VD A.DELAYTIME Changed
U_WD1/DelayTime
010VDU_WD1.ORA.IN[1] Write If
ProfCon/Watchdog_WDInfo/WD/010VD Changed
U_WD1/EnableFlag
010VDU_WD1.EXECSTATE Read
ProfCon/Watchdog_WDInfo/WD/010VD /ENUM
U_WD1/ExecState
ProfCon/CV/010VD95_PV/Read Value
DCS
ProfCon/CV/010VGO95_PV/Read Value
DCS
ProfCon/CV/010VR_5_PV/Read Value
DCS

(010VDUCAS)/$010VDUCA Read
ProfCon/MV/010FI1046_1045_PV/Read S/010VDUCAS/ProfCon/CV/
Process Value 010FI1046_1045_PV/Read
Value DCS
ProfCon/MV/010FI1046_1045_PV/Read S/010VDUCAS/ProfCon/CV/
Value 010FI1046_1045_PV/SetPoi
ntVal
ProfCon/SchedBLC/MV/010FI1046_104 S/010VDUCAS/ProfCon/Tur
5_PV/DSC/010FI1046_1045_PV/Get/Mo n ON OFF
deConnect/ModeConnect1
ProfCon/SchedBLC/MV/010FI1046_104 S/010VDUCAS/ProfCon/MV/
5_PV/DSC/010FI1046_1045_PV/Get/Mo 010HY1012A_AUTOMANA_
deConnect/ModeConnect2 OP/Use This MV
5_PV/DSC/010FI1046_1045_PV/Get/Mo 010HY1012B_AUTOMANA_
ProfCon/SchedBLC/MV/010FI1046_104 S/010VDUCAS/ProfCon/CV/
5_PV/DSC/010FI1046_1045_PV/Get/Ex 010FI1046_1045_PV/Status
ecStateConnect/ExecState1 Display
(010VDU)/$010VDU/010VD Read
ProfCon/SchedBLC/MV/010FI1046_104 U/PreGroup/MV1_WNDUP/
5_PV/DSC/010FI1046_1045_PV/Get/Wi Combinations/Combination0/
ndupConnect/WindupStatus1 Result
(010VDUCAS)/$010VDUCA Write Always
5_PV/DSC/010FI1046_1045_PV/Set/Mo 010FI1046_1045_PV/Contro
deConnect/ModeConnect1 l This CV
5_PV/DSC/010FI1046_1045_PV/Set/Mo 010HY1012A_AUTOMANA_
5_PV/DSC/010FI1046_1045_PV/Set/Mo 010HY1012B_AUTOMANA_


5_PV/DSC/010FI1046_1045_PV/Set/Se 010FI1046_1045_PV/SetPoi
ntValue ntVal
010FIC3029A.PIDA.MODEA Read
ProfCon/SchedBLC/MV/010FIC3029A_P TTR/ENUM
IDA_SP/DSC/010FIC3029A_PIDA_SP/G
et/ModeConnect/ModeConnect1
010FIC3029A.PIDA.MODE/ Read
ProfCon/SchedBLC/MV/010FIC3029A_P ENUM
010FIC3029A.EXECSTATE/ Read
et/ExecStateConnect/ExecState1
010FIC3029A.CEESTATE/E Read
ProfCon/SchedBLC/MV/010FIC3029A_P NUM
et/ExecStateConnect/ExecState2
010FIC3029A.PIDA.ARWNE Read
ProfCon/SchedBLC/MV/010FIC3029A_P T[1]/ENUM
et/WindupConnect/WindupStatus1
010FIC3029A.PIDA.MODEA Write Always
ProfCon/SchedBLC/MV/010FIC3029A_P TTR/ENUM
IDA_SP/DSC/010FIC3029A_PIDA_SP/S
010FIC3029A.PIDA.MODE/ Write Always
010FIC3029A.PIDA.SP Write Always
ProfCon/SchedBLC/MV/010FIC3029A_P
et/SentValue
ProfCon/SchedBLC/MV/010FIC3029A_P
et/SentValueEUHigh

ProfCon/SchedBLC/MV/010FIC3029A_P M
et/SentValueEULow
ProfCon/SchedBLC/MV/010FIC3030_PI TR/ENUM
DA_SP/DSC/010FIC3030_PIDA_SP/Get
/ModeConnect/ModeConnect1
ProfCon/SchedBLC/MV/010FIC3030_PI NUM
/ExecStateConnect/ExecState1
ProfCon/SchedBLC/MV/010FIC3030_PI UM
ProfCon/SchedBLC/MV/010FIC3030_PI [1]/ENUM
/WindupConnect/WindupStatus1
DA_SP/DSC/010FIC3030_PIDA_SP/Set
ProfCon/SchedBLC/MV/010FIC3030_PI
/SentValue
/SentValueEUHigh

/SentValueEULow
ProfCon/SchedBLC/MV/010QIC3004_PI TR/ENUM
DA_SP/DSC/010QIC3004_PIDA_SP/Ge
t/ModeConnect/ModeConnect1
ProfCon/SchedBLC/MV/010QIC3004_PI NUM
t/ExecStateConnect/ExecState1
ProfCon/SchedBLC/MV/010QIC3004_PI UM
ProfCon/SchedBLC/MV/010QIC3004_PI [1]/ENUM
t/WindupConnect/WindupStatus1
DA_SP/DSC/010QIC3004_PIDA_SP/Set
ProfCon/SchedBLC/MV/010QIC3004_PI
/SentValue
/SentValueEUHigh

/SentValueEULow
ProfCon/SchedBLC/MV/010FIC3014_PI [1]/ENUM
/SentValue
/SentValueEUHigh

/SentValueEULow
ProfCon/SchedBLC/MV/010QIC3002_PI UM
ProfCon/SchedBLC/MV/010QIC3002_PI [1]/ENUM
/SentValue
/SentValueEUHigh

/SentValueEULow
DA_OP/DSC/010FIC3016_PIDA_OP/Ge
ProfCon/SchedBLC/MV/010FIC3016_PI ENUM
DA_OP/DSC/010FIC3016_PIDA_OP/Set
/SentValue
/SentValueEUHigh

/SentValueEULow
ProfCon/SchedBLC/MV/010TIC3003_PI TR/ENUM
DA_SP/DSC/010TIC3003_PIDA_SP/Get
ProfCon/SchedBLC/MV/010TIC3003_PI NUM
ProfCon/SchedBLC/MV/010TIC3003_PI UM
ProfCon/SchedBLC/MV/010TIC3003_PI [1]/ENUM
ProfCon/SchedBLC/MV/010TIC3003_PI TR/ENUM
DA_SP/DSC/010TIC3003_PIDA_SP/Set
ProfCon/SchedBLC/MV/010TIC3003_PI
/SentValue
/SentValueEUHigh

/SentValueEULow
ProfCon/SchedBLC/MV/010FIC3013_PI ENUM
/SentValue
/SentValueEUHigh

/SentValueEULow
ProfCon/SchedBLC/CV/010TI3049_DAC UM
A_PV/010TI3049_DACA_PV/Get/ExecSt
ateConnect/ExecState1
ProfCon/SchedBLC/CV/010TI3049_DAC M
010VDU.EXECSTATE/ENU Read
ProfCon/SchedBLC/CV/010VD95_PV/01 M
0VD95_PV/Get/ExecStateConnect/Exec
State1
010VDU.CEESTATE/ENUM Read
ProfCon/SchedBLC/CV/010VD95_PV/01
0VD95_PV/Get/ExecStateConnect/Exec
State2
ProfCon/SchedBLC/CV/010TI3050_DAC M
010VDU.EXECSTATE/ENU Read
ProfCon/SchedBLC/CV/010VGO95_PV/ M
010VGO95_PV/Get/ExecStateConnect/
ExecState1
010VDU.CEESTATE/ENUM Read
ProfCon/SchedBLC/CV/010VGO95_PV/
010VGO95_PV/Get/ExecStateConnect/
ExecState2
ProfCon/SchedBLC/CV/010TI3051_DAC 010TI3051.CEESTATE/ENU Read
A_PV/010TI3051_DACA_PV/Get/ExecSt M

ProfCon/SchedBLC/CV/010HVGOD95_ 010VDU.EXECSTATE/ENU Read

PV/010HVGOD95_PV/Get/ExecStateCo M
nnect/ExecState1
ProfCon/SchedBLC/CV/010HVGOD95_ 010VDU.CEESTATE/ENUM Read
PV/010HVGOD95_PV/Get/ExecStateCo
nnect/ExecState2
ProfCon/SchedBLC/CV/010TI3004_DAC 010TI3004.EXECSTATE/EN Read
A_PV/010TI3004_DACA_PV/Get/ExecSt UM
ProfCon/SchedBLC/CV/010TI3004_DAC 010TI3004.CEESTATE/ENU Read
A_PV/010TI3004_DACA_PV/Get/ExecSt M
ProfCon/SchedBLC/CV/010VR_5_PV/01 010VDU.EXECSTATE/ENU Read
0VR_5_PV/Get/ExecStateConnect/Exec M
State1
ProfCon/SchedBLC/CV/010VR_5_PV/01 010VDU.CEESTATE/ENUM Read
0VR_5_PV/Get/ExecStateConnect/Exec
State2
6.1.3 Vacuum Cascade Controller (010VDUCAS)

/$010VDUCAS/010VDUCAS/PreGroup/0 010FI1046.DACA.PV Read
10FI1046_1045_PV/Combinations/Comb
ination0/Variables
10FI1046_1045_PV/Combinations/Comb
ination0/Variables
10VDPAFD_PV/Combinations/Combinati
on0/Variables
10VDPAFD_PV/Combinations/Combinati
on0/Variables
010VDUCAS.010VDUCAS.P Write Always
ProfCon/Controller Mode V[2]
010LI3039.DACA.PVEUHI Read
ProfCon/CV/010LI3039_PV/CV Process
High Limit
010LI3039.DACA.PVEULO Read
ProfCon/CV/010LI3039_PV/CV Process
Low Limit

010LI3039.DACA.PV Read
ProfCon/CV/010LI3039_PV/Read Value
DCS
010LIC3006.PIDA.PVEUHI Read
ProfCon/CV/010LIC3006_PIDA_PV/CV
Process High Limit
010LIC3006.PIDA.PVEULO Read
ProfCon/CV/010LIC3006_PIDA_PV/CV
Process Low Limit
010LIC3006.PIDA.PV Read
ProfCon/CV/010LIC3006_PIDA_PV/Rea
d Value DCS
010HY1012A.AUTOMANA. Read
ProfCon/MV/010HY1012A_AUTOMANA OPHILM
_OP/Process High Limit
ProfCon/MV/010HY1012A_AUTOMANA OPLOLM
_OP/Process Low Limit
ProfCon/MV/010HY1012A_AUTOMANA OPHILM
_OP/Read OP Process High Limit
ProfCon/MV/010HY1012A_AUTOMANA OPLOLM
_OP/Read OP Process Low Limit
ProfCon/MV/010HY1012A_AUTOMANA OP
_OP/Read OP Value
_OP/Read Process Value
_OP/Read Value
010HY1012B.AUTOMANA. Read
ProfCon/MV/010HY1012B_AUTOMANA OPHILM
ProfCon/MV/010HY1012B_AUTOMANA OPLOLM
ProfCon/MV/010HY1012B_AUTOMANA OPHILM

ProfCon/MV/010HY1012B_AUTOMANA OPLOLM
ProfCon/MV/010HY1012B_AUTOMANA OP
_OP/Read OP Value
_OP/Read Value
High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
High Limit
Low Limit
Process High Limit

Process Low Limit
Value
Process Value
Value
010FY3032B.AUTOMANA.O Read
ProfCon/MV/010FY3032B_AUTOMANA PHILM
ProfCon/MV/010FY3032B_AUTOMANA PLOLM
ProfCon/MV/010FY3032B_AUTOMANA PHILM
ProfCon/MV/010FY3032B_AUTOMANA PLOLM
ProfCon/MV/010FY3032B_AUTOMANA P
_OP/Read OP Value
_OP/Read Value
010FI3033.PIDA.SPHILM Read
ProfCon/MV/010FI3033_SP/Process
High Limit
010FI3033.PIDA.SPLOLM Read
ProfCon/MV/010FI3033_SP/Process
Low Limit
010FI3033.PIDA.OPHILM Read
ProfCon/MV/010FI3033_SP/Read OP
Process High Limit

010FI3033.PIDA.OPLOLM Read
Process Low Limit
010FI3033.PIDA.OP Read
Value
010FI3033.PIDA.PV Read
ProfCon/MV/010FI3033_SP/Read
Process Value
010FI3033.PIDA.SP Read
ProfCon/MV/010FI3033_SP/Read Value
010VDUCAS.010VDUCAS.P Read
ProfCon/Turn ON OFF V[3]
010VDUCAS.010VDUCAS.P Write If
ProfCon/Turn ON OFF V[3] Changed
010VDUCAS_WD1.WATCH Write Always
ProfCon/Watchdog_WDInfo/WD/010VD DOGA.IN
UCAS_WD1/Pulse
010VDUCAS_WD1.WATCH Write If
ProfCon/Watchdog_WDInfo/WD/010VD DOGA.DELAYTIME Changed
UCAS_WD1/DelayTime
010VDUCAS_WD1.ORA.IN[ Write If
ProfCon/Watchdog_WDInfo/WD/010VD 1] Changed
UCAS_WD1/EnableFlag
010VDUCAS_WD1.EXECST Read
ProfCon/Watchdog_WDInfo/WD/010VD ATE/ENUM
UCAS_WD1/ExecState
010VDUCAS.CV02.PV[1] Write Always
ProfCon/CV/010VDPAFD_PV/Low Limit
ProfCon/CV/010VDPAFD_PV/High Limit
ProfCon/CV/010VDPAFD_PV/SS Value
ProfCon/CV/010VDPAFD_PV/Status
ProfCon/CV/010VDPAFD_PV/Read
Value
ProfCon/CV/010LI3039_PV/Read Value


ProfCon/CV/010LI3039_PV/Low Limit
ProfCon/CV/010LI3039_PV/High Limit
ProfCon/CV/010LI3039_PV/SS Value
ProfCon/CV/010LI3039_PV/Status
ProfCon/CV/010LIC3006_PIDA_PV/Low
Limit
ProfCon/CV/010LIC3006_PIDA_PV/High
Limit
ProfCon/CV/010LIC3006_PIDA_PV/SS
Value
ProfCon/CV/010LIC3006_PIDA_PV/Stat
us
ProfCon/CV/010LIC3006_PIDA_PV/Rea
d Value
010VDUCAS.CVSW01.PV Write Always
ProfCon/CV/010FI1046_1045_PV/Contr
ol This CV
ProfCon/CV/010VDPAFD_PV/Control
This CV
ProfCon/CV/010LI3039_PV/Control This
CV
ProfCon/CV/010LIC3006_PIDA_PV/Cont
rol This CV
010VDUCAS.MV01.PV[1] Write Always
ProfCon/MV/010HY1012A_AUTOMANA
_OP/Low Limit
_OP/High Limit


_OP/Current Move
_OP/Status
_OP/SS Value
ProfCon/MV/010HY1012B_AUTOMANA
_OP/Low Limit
_OP/High Limit
_OP/Current Move
_OP/Status
_OP/SS Value
Move

Move
ProfCon/MV/010FY3032B_AUTOMANA
_OP/Low Limit
_OP/High Limit
_OP/Current Move
_OP/Status
_OP/SS Value
010VDUCAS.MVSW01.PV Write Always
_OP/Use This MV
_OP/Use This MV
MV
MV
_OP/Use This MV
ProfCon/SchedBLC/MV/010HY1012A_A MODEATTR/ENUM
UTOMANA_OP/DSC/010HY1012A_AUT
OMANA_OP/Get/ModeConnect/ModeCo
nnect1
ProfCon/SchedBLC/MV/010HY1012A_A

UTOMANA_OP/DSC/010HY1012A_AUT MODE/ENUM
nnect2
010HY1012A.EXECSTATE/ Read
ProfCon/SchedBLC/MV/010HY1012A_A ENUM
OMANA_OP/Get/ExecStateConnect/Exe
cState1
010HY1012A.CEESTATE/E Read
ProfCon/SchedBLC/MV/010HY1012A_A NUM
cState2
010HY1012A.AUTOMANA. Write Always
ProfCon/SchedBLC/MV/010HY1012A_A MODEATTR/ENUM
OMANA_OP/Set/ModeConnect/ModeCo
nnect1
ProfCon/SchedBLC/MV/010HY1012A_A MODE/ENUM
nnect2
ProfCon/SchedBLC/MV/010HY1012A_A OP
OMANA_OP/Set/SentValue
ProfCon/SchedBLC/MV/010HY1012A_A OPHILM
OMANA_OP/Set/SentValueEUHigh
ProfCon/SchedBLC/MV/010HY1012A_A OPLOLM
OMANA_OP/Set/SentValueEULow
ProfCon/SchedBLC/MV/010HY1012B_A MODEATTR/ENUM
UTOMANA_OP/DSC/010HY1012B_AUT
nnect1
ProfCon/SchedBLC/MV/010HY1012B_A MODE/ENUM

nnect2
010HY1012B.EXECSTATE/ Read
ProfCon/SchedBLC/MV/010HY1012B_A ENUM
cState1
010HY1012B.CEESTATE/E Read
ProfCon/SchedBLC/MV/010HY1012B_A NUM
cState2
010HY1012B.AUTOMANA. Write Always
ProfCon/SchedBLC/MV/010HY1012B_A MODEATTR/ENUM
nnect1
ProfCon/SchedBLC/MV/010HY1012B_A MODE/ENUM
nnect2
ProfCon/SchedBLC/MV/010HY1012B_A OP
ProfCon/SchedBLC/MV/010HY1012B_A OPHILM
ProfCon/SchedBLC/MV/010HY1012B_A OPLOLM
ProfCon/SchedBLC/MV/010FIC1597_O TR/ENUM
P/DSC/010FIC1597_OP/Get/ModeConn
ect/ModeConnect1
ProfCon/SchedBLC/MV/010FIC1597_O NUM
ect/ModeConnect2

P/DSC/010FIC1597_OP/Get/ExecState
Connect/ExecState1
ProfCon/SchedBLC/MV/010FIC1597_O UM
Connect/ExecState2
ProfCon/SchedBLC/MV/010FIC1597_O ENUM
P/DSC/010FIC1597_OP/Get/WindupCon
nect/WindupStatus1
P/DSC/010FIC1597_OP/Set/ModeConn
ect/ModeConnect1
ect/ModeConnect2
ProfCon/SchedBLC/MV/010FIC1597_O
P/DSC/010FIC1597_OP/Set/SentValue
P/DSC/010FIC1597_OP/Set/SentValueE
UHigh
ULow
ect/ModeConnect1
ect/ModeConnect2
Connect/ExecState1
ProfCon/SchedBLC/MV/010FIC1097_O UM

Connect/ExecState2
ProfCon/SchedBLC/MV/010FIC1097_O ENUM
P/DSC/010FIC1097_OP/Get/WindupCon
nect/WindupStatus1
ect/ModeConnect1
ect/ModeConnect2
P/DSC/010FIC1097_OP/Set/SentValue
UHigh
ULow
010FY3032B.AUTOMANA.M Read
ProfCon/SchedBLC/MV/010FY3032B_A ODEATTR/ENUM
UTOMANA_OP/DSC/010FY3032B_AUT
nnect1
010FY3032B.AUTOMANA.M Read
ProfCon/SchedBLC/MV/010FY3032B_A ODE/ENUM
nnect2
010FY3032B.EXECSTATE/ Read
ProfCon/SchedBLC/MV/010FY3032B_A ENUM
cState1
010FY3032B.CEESTATE/E Read
ProfCon/SchedBLC/MV/010FY3032B_A NUM

cState2
010FY3032B.AUTOMANA.M Write Always
ProfCon/SchedBLC/MV/010FY3032B_A ODEATTR/ENUM
nnect1
010FY3032B.AUTOMANA.M Write Always
ProfCon/SchedBLC/MV/010FY3032B_A ODE/ENUM
nnect2
010FY3032B.AUTOMANA.O Write Always
ProfCon/SchedBLC/MV/010FY3032B_A P
ProfCon/SchedBLC/MV/010FY3032B_A PHILM
ProfCon/SchedBLC/MV/010FY3032B_A PLOLM
010FI3033.PIDA.MODEATT Read
ProfCon/SchedBLC/MV/010FI3033_SP/ R/ENUM
DSC/010FI3033_SP/Get/ModeConnect/
ModeConnect1
010FI3033.PIDA.MODE/EN Read
ProfCon/SchedBLC/MV/010FI3033_SP/ UM
DSC/010FI3033_SP/Get/ModeConnect/
ModeConnect2
010FI3033.EXECSTATE/EN Read
ProfCon/SchedBLC/MV/010FI3033_SP/ UM
DSC/010FI3033_SP/Get/ExecStateConn
ect/ExecState1
010FI3033.CEESTATE/ENU Read
ProfCon/SchedBLC/MV/010FI3033_SP/ M
DSC/010FI3033_SP/Get/ExecStateConn
ect/ExecState2
ProfCon/SchedBLC/MV/010FI3033_SP/ 010FI3033.PIDA.ARWNET[1 Read
DSC/010FI3033_SP/Get/WindupConnec ]/ENUM
t/WindupStatus1

ProfCon/SchedBLC/MV/010FI3033_SP/ 010FI3033.PIDA.MODEATT Write Always

DSC/010FI3033_SP/Set/ModeConnect/ R/ENUM
ModeConnect1
ProfCon/SchedBLC/MV/010FI3033_SP/ 010FI3033.PIDA.MODE/EN Write Always
DSC/010FI3033_SP/Set/ModeConnect/ UM
ModeConnect2
ProfCon/SchedBLC/MV/010FI3033_SP/ 010FI3033.PIDA.SP Write Always
DSC/010FI3033_SP/Set/SentValue
ProfCon/SchedBLC/MV/010FI3033_SP/ 010FI3033.PIDA.SPHILM Read
DSC/010FI3033_SP/Set/SentValueEUHi
gh
ProfCon/SchedBLC/MV/010FI3033_SP/ 010FI3033.PIDA.SPLOLM Read
DSC/010FI3033_SP/Set/SentValueEULo
w
ProfCon/SchedBLC/CV/010LI3039_PV/0 010LI3039.EXECSTATE/EN Read
10LI3039_PV/Get/ExecStateConnect/Ex UM
ecState1
ProfCon/SchedBLC/CV/010LI3039_PV/0 010LI3039.CEESTATE/ENU Read
10LI3039_PV/Get/ExecStateConnect/Ex M
ecState2
ProfCon/SchedBLC/CV/010LIC3006_PI 010LIC3006.EXECSTATE/E Read
DA_PV/010LIC3006_PIDA_PV/Get/Exec NUM
StateConnect/ExecState1
ProfCon/SchedBLC/CV/010LIC3006_PI 010LIC3006.CEESTATE/EN Read
DA_PV/010LIC3006_PIDA_PV/Get/Exec UM
StateConnect/ExecState2
6.1.4 Naphtha Stabilizer Controller (010NSU)

/$010NSU/010NSU/PreGroup/010PIC20 010PIC2018.PIDA.SP Read
18SP_PV/Combinations/Combination0/V
ariables
/$010NSU/010NSU/PreGroup/010PIC20 010PIC2018.DACA.PV Read
ariables
/$010NSU/010NSU/PreGroup/010PIC20 010NSU.CV01.PV[5] Write Always
ariables
/$010NSU/010NSU/PreGroup/010PCT2 010TIC2015.DACA.PV Read
015_PV/Combinations/Combination0/Var
iables

/$010NSU/010NSU/PreGroup/010PCT2 010PI2014.DACA.PV Read

iables
/$010NSU/010NSU/PreGroup/010PCT2 010NSU.CV02.PV[5] Write Always
iables
/$010NSU/010NSU/PreGroup/010NSRF 010FIC2002.DACA.PV Read
es
/$010NSU/010NSU/PreGroup/010NSRF 010FIC2001.DACA.PV Read
es
/$010NSU/010NSU/PreGroup/010NSRF 010NSU.CV03.PV[5] Write Always
es
/$010NSU/010NSU/PreGroup/010NSDT 010TI2011.DACA.PV Read
2_PV/Combinations/Combination0/Varia
bles
/$010NSU/010NSU/PreGroup/010NSDT 010TIC2013.DACA.PV Read
bles
/$010NSU/010NSU/PreGroup/010NSDT 010TIC2015.DACA.PV Read
bles
/$010NSU/010NSU/PreGroup/010NSPC 010TIC2015.DACA.PV Read
T2015_PV/Combinations/Combination0/
Variables
/$010NSU/010NSU/PreGroup/010NSPC 010PI2014.DACA.PV Read
T2015_PV/Combinations/Combination0/
Variables
/$010NSU/010NSU/PreGroup/010Napht 010FIC2005.DACA.PV Read
haFlow_PV/Combinations/Combination0/
Variables
/$010NSU/010NSU/PreGroup/010Napht 010FIC2004.DACA.PV Read
haFlow_PV/Combinations/Combination0/
Variables
/$010NSU/010NSU/PreGroup/010NSRP 010FIC2002.DACA.PV Read
es
/$010NSU/010NSU/PreGroup/010NSRP 010FIC2008.DACA.PV Read
es

/$010NSU/010NSU/PreGroup/010NSDP 010PI2059.DACA.PV Read

es
/$010NSU/010NSU/PreGroup/010NSDP 010PI2014.DACA.PV Read
es
/$010NSU/010NSU/PreGroup/010LAGO 010FI2020.DACA.PV Read
PAFlow_PV/Combinations/Combination0
/Variables
/$010NSU/010NSU/PreGroup/010LAGO 010FI2021.DACA.PV Read
PAFlow_PV/Combinations/Combination0
/Variables
010NSU.010NSU.PV[2] Write Always
ProfCon/Controller Mode
010NSU.CVSW01.PV Write If
ProfCon/CV/010PIC2018SP_PV_PV/Co Changed
ntrol This CV
010NSU.CV01.PV[2] Write If
ProfCon/CV/010PIC2018SP_PV_PV/Hig Changed
h Limit
ProfCon/CV/010PIC2018SP_PV_PV/Lo Changed
w Limit
010NSU.CV01.PV[5] Read
ProfCon/CV/010PIC2018SP_PV_PV/Re
ad Value DCS
010NSU.CV01.PV[3] Write Always
ProfCon/CV/010PIC2018SP_PV_PV/SS
Value
ProfCon/CV/010PIC2018SP_PV_PV/Sta
tus
ProfCon/CV/010PCT2015_PV/Control Changed
This CV
ProfCon/CV/010PCT2015_PV/High Limit Changed
ProfCon/CV/010PCT2015_PV/Low Limit Changed
ProfCon/CV/010PCT2015_PV/Read

Value DCS
ProfCon/CV/010PCT2015_PV/SS Value
ProfCon/CV/010PCT2015_PV/Status
ProfCon/CV/010NSRF_PV/Control This Changed
CV
ProfCon/CV/010NSRF_PV/High Limit Changed
ProfCon/CV/010NSRF_PV/Low Limit Changed
ProfCon/CV/010NSRF_PV/Read Value
DCS
ProfCon/CV/010NSRF_PV/SS Value
ProfCon/CV/010NSRF_PV/Status
ProfCon/CV/010LPGW_PV/Control This Changed
CV
ProfCon/CV/010LPGW_PV/High Limit Changed
ProfCon/CV/010LPGW_PV/Low Limit Changed
ProfCon/CV/010LPGW_PV/Read Value
DCS
ProfCon/CV/010LPGW_PV/SS Value
ProfCon/CV/010LPGW_PV/Status
CV
High Limit

Low Limit
DCS
ProfCon/CV/010RVP_PV/Control This Changed
CV
ProfCon/CV/010RVP_PV/High Limit Changed
ProfCon/CV/010RVP_PV/Low Limit Changed
ProfCon/CV/010RVP_PV/Read Value
DCS
ProfCon/CV/010RVP_PV/SS Value
ProfCon/CV/010RVP_PV/Status
ProfCon/CV/010LIC2011_PV/Control Changed
This CV
010LIC2011.DACA.PVEUHI Read
ProfCon/CV/010LIC2011_PV/CV
Process High Limit
010LIC2011.DACA.PVEULO Read
ProfCon/CV/010LIC2011_PV/CV
Process Low Limit
ProfCon/CV/010LIC2011_PV/High Limit Changed
ProfCon/CV/010LIC2011_PV/Low Limit Changed

010LIC2011.DACA.PV Read
ProfCon/CV/010LIC2011_PV/Read
Value DCS
ProfCon/CV/010LIC2011_PV/SS Value
ProfCon/CV/010LIC2011_PV/Status
ProfCon/DV/010FIC2001_SP/Read
Value
ProfCon/DV/010TI1116_PV/Read Value
010NSU.MV01.PV[3] Write Always
ProfCon/MV/010TIC2016A_OP/Current
Move
010NSU.MV01.PV[2] Write If
ProfCon/MV/010TIC2016A_OP/High Changed
Limit
ProfCon/MV/010TIC2016A_OP/Low Changed
Limit
010TIC2016A.PIDA.OPHIL Read
ProfCon/MV/010TIC2016A_OP/Process M
High Limit
010TIC2016A.PIDA.OPLOL Read
ProfCon/MV/010TIC2016A_OP/Process M
Low Limit
ProfCon/MV/010TIC2016A_OP/Read OP M
Process High Limit
ProfCon/MV/010TIC2016A_OP/Read OP M
Process Low Limit
010TIC2016A.PIDA.OP Read
ProfCon/MV/010TIC2016A_OP/Read OP
Value
ProfCon/MV/010TIC2016A_OP/Read
Process Value
ProfCon/MV/010TIC2016A_OP/Read

Value
ProfCon/MV/010TIC2016A_OP/SS
Value
ProfCon/MV/010TIC2016A_OP/Status
010NSU.MVSW01.PV Write If
ProfCon/MV/010TIC2016A_OP/Use This Changed
MV
ProfCon/MV/010TIC2016C_OP/Current
Move
010NSU.MV02.PV[2] Read
ProfCon/MV/010TIC2016C_OP/High
Limit
ProfCon/MV/010TIC2016C_OP/High Changed
Limit
010NSU.MV02.PV[1] Read
ProfCon/MV/010TIC2016C_OP/Low
Limit
ProfCon/MV/010TIC2016C_OP/Low Changed
Limit
010TIC2016C.PIDA.OPHIL Read
ProfCon/MV/010TIC2016C_OP/Process M
High Limit
010TIC2016C.PIDA.OPLOL Read
ProfCon/MV/010TIC2016C_OP/Process M
Low Limit
ProfCon/MV/010TIC2016C_OP/Read M
OP Process High Limit
ProfCon/MV/010TIC2016C_OP/Read M
OP Process Low Limit
010TIC2016C.PIDA.OP Read
ProfCon/MV/010TIC2016C_OP/Read
OP Value

Process Value
Value
ProfCon/MV/010TIC2016C_OP/SS
Value
ProfCon/MV/010TIC2016C_OP/Status
ProfCon/MV/010TIC2016C_OP/Use This Changed
MV
ProfCon/MV/010TIC2016E_OP/Current
Move
ProfCon/MV/010TIC2016E_OP/High Changed
Limit
ProfCon/MV/010TIC2016E_OP/Low Changed
Limit
010TIC2016E.PIDA.OPHIL Read
ProfCon/MV/010TIC2016E_OP/Process M
High Limit
010TIC2016E.PIDA.OPLOL Read
ProfCon/MV/010TIC2016E_OP/Process M
Low Limit
ProfCon/MV/010TIC2016E_OP/Read OP M
Process High Limit
010TIC2016E.PIDA.OPLOL Read
ProfCon/MV/010TIC2016E_OP/Read OP M
Process Low Limit
010TIC2016E.PIDA.OP Read
ProfCon/MV/010TIC2016E_OP/Read OP
Value
ProfCon/MV/010TIC2016E_OP/Read
Process Value
ProfCon/MV/010TIC2016E_OP/Read

Value
ProfCon/MV/010TIC2016E_OP/SS
Value
ProfCon/MV/010TIC2016E_OP/Status
ProfCon/MV/010TIC2016E_OP/Use This Changed
MV
Move
High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value

MV
Move
High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
Move

High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
010NSU.010NSU.PV[3] Read
ProfCon/Turn ON OFF
010NSU.010NSU.PV[3] Write If
010NSU_WD1.WATCHDOG Write Always
ProfCon/Watchdog_WDInfo/WD/010NS A.IN
U_WD1/Pulse
010NSU_WD1.WATCHDOG Write If
ProfCon/Watchdog_WDInfo/WD/010NS A.DELAYTIME Changed

U_WD1/DelayTime
010NSU_WD1.ORA.IN[1] Write If
ProfCon/Watchdog_WDInfo/WD/010NS Changed
U_WD1/EnableFlag
010NSU_WD1.EXECSTATE Read
ProfCon/Watchdog_WDInfo/WD/010NS /ENUM
U_WD1/ExecState
(010NSU)/$010NSU/010NS Read
ProfCon/DV/010LAGOPAFlow_PV/Read U/PreGroup/010LAGOPAFlo
Value w_PV/Combinations/Combin
ation0/Result.Value
010TIC2016A.PIDA.MODEA Read
ProfCon/SchedBLC/MV/010TIC2016A_O TTR/ENUM
P/DSC/010TIC2016A_OP/Get/ModeCon
nect/ModeConnect1
010TIC2016A.PIDA.MODE/ Read
ProfCon/SchedBLC/MV/010TIC2016A_O ENUM
P/DSC/010TIC2016A_OP/Get/ModeCon
nect/ModeConnect2
010TIC2016A.EXECSTATE/ Read
P/DSC/010TIC2016A_OP/Get/ExecState
Connect/ExecState1
010TIC2016A.CEESTATE/E Read
ProfCon/SchedBLC/MV/010TIC2016A_O NUM
P/DSC/010TIC2016A_OP/Get/ExecState
Connect/ExecState2
010TIC2016A.PIDA.ARWOP Read
ProfCon/SchedBLC/MV/010TIC2016A_O /ENUM
P/DSC/010TIC2016A_OP/Get/WindupC
onnect/WindupStatus1
010TIC2016A.PIDA.MODEA Write Always
ProfCon/SchedBLC/MV/010TIC2016A_O TTR/ENUM
P/DSC/010TIC2016A_OP/Set/ModeCon
nect/ModeConnect1
010TIC2016A.PIDA.MODE/ Write Always
P/DSC/010TIC2016A_OP/Set/ModeCon
nect/ModeConnect2
010TIC2016A.PIDA.OP Write Always
ProfCon/SchedBLC/MV/010TIC2016A_O
P/DSC/010TIC2016A_OP/Set/SentValue

ProfCon/SchedBLC/MV/010TIC2016A_O M
EUHigh
ProfCon/SchedBLC/MV/010TIC2016A_O M
EULow
010TIC2016C.PIDA.MODEA Read
ProfCon/SchedBLC/MV/010TIC2016C_ TTR/ENUM
OP/DSC/010TIC2016C_OP/Get/ModeCo
nnect/ModeConnect1
010TIC2016C.PIDA.MODE/ Read
ProfCon/SchedBLC/MV/010TIC2016C_ ENUM
OP/DSC/010TIC2016C_OP/Get/ModeCo
nnect/ModeConnect2
010TIC2016C.EXECSTATE/ Read
OP/DSC/010TIC2016C_OP/Get/ExecSta
teConnect/ExecState1
010TIC2016C.CEESTATE/E Read
ProfCon/SchedBLC/MV/010TIC2016C_ NUM
OP/DSC/010TIC2016C_OP/Get/ExecSta
teConnect/ExecState2
010TIC2016C.PIDA.ARWO Read
ProfCon/SchedBLC/MV/010TIC2016C_ P/ENUM
OP/DSC/010TIC2016C_OP/Get/Windup
Connect/WindupStatus1
010TIC2016C.PIDA.MODEA Write Always
ProfCon/SchedBLC/MV/010TIC2016C_ TTR/ENUM
OP/DSC/010TIC2016C_OP/Set/ModeCo
nnect/ModeConnect1
010TIC2016C.PIDA.MODE/ Write Always
OP/DSC/010TIC2016C_OP/Set/ModeCo
nnect/ModeConnect2
010TIC2016C.PIDA.OP Write Always
ProfCon/SchedBLC/MV/010TIC2016C_
OP/DSC/010TIC2016C_OP/Set/SentVal
ue
ProfCon/SchedBLC/MV/010TIC2016C_ M

ueEUHigh
ProfCon/SchedBLC/MV/010TIC2016C_ M
ueEULow
010TIC2016E.PIDA.MODEA Read
ProfCon/SchedBLC/MV/010TIC2016E_O TTR/ENUM
P/DSC/010TIC2016E_OP/Get/ModeCon
nect/ModeConnect1
010TIC2016E.PIDA.MODE/ Read
ProfCon/SchedBLC/MV/010TIC2016E_O ENUM
P/DSC/010TIC2016E_OP/Get/ModeCon
nect/ModeConnect2
010TIC2016E.EXECSTATE/ Read
P/DSC/010TIC2016E_OP/Get/ExecState
Connect/ExecState1
010TIC2016E.CEESTATE/E Read
ProfCon/SchedBLC/MV/010TIC2016E_O NUM
P/DSC/010TIC2016E_OP/Get/ExecState
Connect/ExecState2
010TIC2016E.PIDA.ARWOP Read
ProfCon/SchedBLC/MV/010TIC2016E_O /ENUM
P/DSC/010TIC2016E_OP/Get/WindupC
onnect/WindupStatus1
010TIC2016E.PIDA.MODEA Write Always
ProfCon/SchedBLC/MV/010TIC2016E_O TTR/ENUM
P/DSC/010TIC2016E_OP/Set/ModeCon
nect/ModeConnect1
010TIC2016E.PIDA.MODE/ Write Always
P/DSC/010TIC2016E_OP/Set/ModeCon
nect/ModeConnect2
010TIC2016E.PIDA.OP Write Always
ProfCon/SchedBLC/MV/010TIC2016E_O
P/DSC/010TIC2016E_OP/Set/SentValue
ProfCon/SchedBLC/MV/010TIC2016E_O M
P/DSC/010TIC2016E_OP/Set/SentValue
EUHigh
ProfCon/SchedBLC/MV/010TIC2016E_O 010TIC2016E.PIDA.OPLOL Read
P/DSC/010TIC2016E_OP/Set/SentValue M
EULow

ProfCon/SchedBLC/MV/010TIC2015_SP 010TIC2015.PIDA.MODEAT Read

/DSC/010TIC2015_SP/Get/ModeConnec TR/ENUM
t/ModeConnect1
t/ModeConnect2
nnect/ExecState1
nnect/ExecState2
ect/WindupStatus1
t/ModeConnect1
t/ModeConnect2
High
ProfCon/SchedBLC/MV/010TIC2015_SP 010TIC2015.PIDA.SPLOLM Read
Low
ProfCon/SchedBLC/MV/010TIC2013_OP 010TIC2013.PIDA.MODEAT Read
/DSC/010TIC2013_OP/Get/ModeConnec TR/ENUM
t/ModeConnect1
ProfCon/SchedBLC/MV/010TIC2013_OP 010TIC2013.PIDA.MODE/E Read
/DSC/010TIC2013_OP/Get/ModeConnec NUM
t/ModeConnect2

ProfCon/SchedBLC/MV/010TIC2013_OP 010TIC2013.EXECSTATE/E Read

/DSC/010TIC2013_OP/Get/ExecStateCo NUM
nnect/ExecState1
ProfCon/SchedBLC/MV/010TIC2013_OP UM
nnect/ExecState2
ProfCon/SchedBLC/MV/010TIC2013_OP ENUM
/DSC/010TIC2013_OP/Get/WindupConn
ect/WindupStatus1
t/ModeConnect1
t/ModeConnect2
/DSC/010TIC2013_OP/Set/SentValue
High
Low
ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.PIDA.MODEAT Read
/DSC/010FIC2008_SP/Get/ModeConnec TR/ENUM
t/ModeConnect1
ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.PIDA.MODE/E Read
/DSC/010FIC2008_SP/Get/ModeConnec NUM
t/ModeConnect2
ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.EXECSTATE/E Read
/DSC/010FIC2008_SP/Get/ExecStateCo NUM
nnect/ExecState1
ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.CEESTATE/EN Read
/DSC/010FIC2008_SP/Get/ExecStateCo UM
nnect/ExecState2

ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.PIDA.ARWNET Read

/DSC/010FIC2008_SP/Get/WindupConn [1]/ENUM
ect/WindupStatus1
ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.PIDA.MODEAT Write Always
/DSC/010FIC2008_SP/Set/ModeConnec TR/ENUM
t/ModeConnect1
ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.PIDA.MODE/E Write Always
/DSC/010FIC2008_SP/Set/ModeConnec NUM
t/ModeConnect2
ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.PIDA.SP Write Always
ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.PIDA.SPHILM Read
High
ProfCon/SchedBLC/MV/010FIC2008_SP 010FIC2008.PIDA.SPLOLM Read
Low
ProfCon/SchedBLC/DV/010FIC2001_SP 010FIC2001.EXECSTATE/E Read
/010FIC2001_SP/Get/ExecStateConnect NUM
/ExecState1
ProfCon/SchedBLC/DV/010FIC2001_SP 010FIC2001.CEESTATE/EN Read
/010FIC2001_SP/Get/ExecStateConnect UM
/ExecState2
ProfCon/SchedBLC/DV/010TI1116_PV/0 010TI1116.EXECSTATE/EN Read
10TI1116_PV/Get/ExecStateConnect/Ex UM
ecState1
ProfCon/SchedBLC/DV/010TI1116_PV/0 010TI1116.CEESTATE/ENU Read
10TI1116_PV/Get/ExecStateConnect/Ex M
ecState2
ProfCon/SchedBLC/CV/010PIC2018SP_ 010NSU.EXECSTATE/ENU Read
PV_PV/010PIC2018SP_PV_PV/Get/Exe M
cStateConnect/ExecState1
ProfCon/SchedBLC/CV/010PIC2018SP_ 010NSU.CEESTATE/ENUM Read
PV_PV/010PIC2018SP_PV_PV/Get/Exe
cStateConnect/ExecState2
ProfCon/SchedBLC/CV/010PCT2015_P 010NSU.EXECSTATE/ENU Read
V/010PCT2015_PV/Get/ExecStateConn M
ect/ExecState1
ProfCon/SchedBLC/CV/010PCT2015_P 010NSU.CEESTATE/ENUM Read
V/010PCT2015_PV/Get/ExecStateConn
ect/ExecState2

ProfCon/SchedBLC/CV/010NSRF_PV/0 010NSU.EXECSTATE/ENU Read

10NSRF_PV/Get/ExecStateConnect/Exe M
cState1
ProfCon/SchedBLC/CV/010NSRF_PV/0 010NSU.CEESTATE/ENUM Read
10NSRF_PV/Get/ExecStateConnect/Exe
cState2
ProfCon/SchedBLC/CV/010LPGW_PV/0 010NSU.EXECSTATE/ENU Read
10LPGW_PV/Get/ExecStateConnect/Ex M
ecState1
ProfCon/SchedBLC/CV/010LPGW_PV/0 010NSU.CEESTATE/ENUM Read
10LPGW_PV/Get/ExecStateConnect/Ex
ecState2
ProfCon/SchedBLC/CV/010TI2011_PV/0 010TI2011.EXECSTATE/EN Read
ecState1
ProfCon/SchedBLC/CV/010TI2011_PV/0 010TI2011.CEESTATE/ENU Read
ecState2
ProfCon/SchedBLC/CV/010RVP_PV/010 010NSU.EXECSTATE/ENU Read
RVP_PV/Get/ExecStateConnect/ExecSt M
ate1
ProfCon/SchedBLC/CV/010RVP_PV/010 010NSU.CEESTATE/ENUM Read
RVP_PV/Get/ExecStateConnect/ExecSt
ate2
ProfCon/SchedBLC/CV/010LIC2011_PV/ 010LIC2011.EXECSTATE/E Read
010LIC2011_PV/Get/ExecStateConnect/ NUM
ExecState1
ProfCon/SchedBLC/CV/010LIC2011_PV/ 010LIC2011.CEESTATE/EN Read
010LIC2011_PV/Get/ExecStateConnect/ UM
ExecState2
ProfCon/SchedBLC/DV/010LAGOPAFlo (010NSU)/$010NSU/010NS Read
w_PV/010LAGOPAFlow_PV/Get/ExecSt U/PreGroup/010LAGOPAFlo
ateConnect/ExecState1 w_PV/Combinations/Combin
ation0/Result.Quality

6.1.5 De-Ethanizer and De-Propanizer (010DEDP)

/$010DEDP/010DEDP/PreGroup/010DE 010FIC2011.DACA.PV Read
RF_PV/Combinations/Combination0/Vari
ables
/$010DEDP/010DEDP/PreGroup/010DE 010FIC2008.DACA.PV Read
ables
/$010DEDP/010DEDP/PreGroup/010DE 010DEDP.CV01.PV[5] Write Always
ables
/$010DEDP/010DEDP/PreGroup/010C2i 010PI2063.DACA.PV Read
nLPG_PV/Combinations/Combination0/V
ariables
/$010DEDP/010DEDP/PreGroup/010C2i 010TIC2025.DACA.PV Read
nLPG_PV/Combinations/Combination0/V
ariables
/$010DEDP/010DEDP/PreGroup/010DP 010FI2037.DACA.PV Read
ables
/$010DEDP/010DEDP/PreGroup/010DP 011FI0009.DACA.PV Read
ables
/$010DEDP/010DEDP/PreGroup/010DP 010DEDP.CV06.PV[5] Write Always
ables
/$010DEDP/010DEDP/PreGroup/DPPF_ 010FIC2013.DACA.PV Read
PV/Combinations/Combination0/Variable
s
/$010DEDP/010DEDP/PreGroup/DPPF_ 010FIC2014.DACA.PV Read
s
/$010DEDP/010DEDP/PreGroup/DPPF_ 011FI0009.DACA.PV Read
s
/$010DEDP/010DEDP/PreGroup/C3inC4 010PI2066.DACA.PV Read
/Combinations/Combination0/Variables
/$010DEDP/010DEDP/PreGroup/C3inC4 010TI2036.DACA.PV Read
/Combinations/Combination0/Variables
ProfCon/Controller Mode 010DEDP.010DEDP.PV[2] Write Always

ProfCon/CV/010DERF_PV/Control This 010DEDP.CVSW01.PV Write If

CV Changed
ProfCon/CV/010DERF_PV/High Limit 010DEDP.CV01.PV[2] Write If
Changed
010DEDP.CV01.PV[1] Write If
ProfCon/CV/010DERF_PV/Low Limit Changed
010DEDP.CV01.PV[3] Write Always
ProfCon/CV/010DERF_PV/SS Value
ProfCon/CV/010DERF_PV/Status
010DEDP.CVSW02.PV Write If
ProfCon/CV/010PIC2065_OP/Control Changed
This CV
010PIC2065.PIDA.OPHILM Read
ProfCon/CV/010PIC2065_OP/CV
Process High Limit
ProfCon/CV/010PIC2065_OP/CV 010PIC2065.PIDA.OPLOLM Read
Process Low Limit
ProfCon/CV/010PIC2065_OP/High Limit Changed
ProfCon/CV/010PIC2065_OP/Low Limit Changed
010PIC2065.PIDA.OP Read
ProfCon/CV/010PIC2065_OP/Read
Value DCS
ProfCon/CV/010PIC2065_OP/SS Value 010DEDP.CV02.PV[3] Write Always
ProfCon/CV/010PIC2065_OP/Status 010DEDP.CV02.PV[4] Write Always
ProfCon/CV/010LIC2016_OP/Control 010DEDP.CVSW03.PV Write If
This CV Changed
ProfCon/CV/010LIC2016_OP/CV 010LIC2016.PIDA.OPHILM Read
Process High Limit
ProfCon/CV/010LIC2016_OP/CV 010LIC2016.PIDA.OPLOLM Read
Process Low Limit
ProfCon/CV/010LIC2016_OP/High Limit 010DEDP.CV03.PV[2] Write If
Changed
ProfCon/CV/010LIC2016_OP/Low Limit 010DEDP.CV03.PV[1] Write If
Changed
ProfCon/CV/010LIC2016_OP/Read 010LIC2016.PIDA.OP Read
Value DCS


ProfCon/CV/010LIC2016_OP/SS Value
ProfCon/CV/010LIC2016_OP/Status
This CV
Process High Limit
Process Low Limit
Value DCS
ProfCon/CV/010C2inLPG_PV/Control Changed
This CV
ProfCon/CV/010C2inLPG_PV/High Limit Changed
ProfCon/CV/010C2inLPG_PV/Low Limit Changed
ProfCon/CV/010C2inLPG_PV/SS Value
ProfCon/CV/010C2inLPG_PV/Status
ProfCon/CV/010DPRF_PV/Control This Changed
CV
ProfCon/CV/010DPRF_PV/High Limit Changed

ProfCon/CV/010DPRF_PV/Low Limit Changed
ProfCon/CV/010DPRF_PV/SS Value
ProfCon/CV/010DPRF_PV/Status
ProfCon/CV/010PIC2038_PV/Control Changed
This CV
010PIC2038.DACA.PVEUHI Read
Process High Limit
010PIC2038.DACA.PVEUL Read
ProfCon/CV/010PIC2038_PV/CV O
Process Low Limit
ProfCon/CV/010PIC2038_PV/High Limit Changed
ProfCon/CV/010PIC2038_PV/Low Limit Changed
010PIC2038.DACA.PV Read
ProfCon/CV/010PIC2038_PV/Read
Value DCS
ProfCon/CV/010PIC2038_PV/SS Value
ProfCon/CV/010PIC2038_PV/Status
This CV
Process High Limit
Process Low Limit

Value DCS
CV
High Limit
Low Limit
DCS
ProfCon/CV/C3inC4_PV/Control This CV Changed
ProfCon/CV/C3inC4_PV/High Limit Changed
ProfCon/CV/C3inC4_PV/Low Limit Changed
ProfCon/CV/C3inC4_PV/SS Value
ProfCon/CV/C3inC4_PV/Status
ProfCon/DV/010FIC2008_SP/Read
Value
011FI0009.DACA.PV Read

ProfCon/DV/011FI0009_PV/Read Value
010DEDP.MV01.PV[3] Write Always
Move
010DEDP.MV01.PV[2] Write If
High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
010DEDP.MVSW01.PV Write If
MV
Move

High Limit
Low Limit
Process High Limit
Process Low Limit
Value
Process Value
Value
MV
Move
ProfCon/MV/010TIC2035_OP/High Limit 010DEDP.MV03.PV[2] Write If
Changed
ProfCon/MV/010TIC2035_OP/Low Limit 010DEDP.MV03.PV[1] Write If
Changed
ProfCon/MV/010TIC2035_OP/Process 010TIC2035.PIDA.OPHILM Read
High Limit
ProfCon/MV/010TIC2035_OP/Process 010TIC2035.PIDA.OPLOLM Read
Low Limit

Process High Limit
Process Low Limit
Value
Process Value
Value
MV
010DEDP.010DEDP.PV[3] Read
ProfCon/Turn ON OFF
010DEDP.010DEDP.PV[3] Write If
010DEDP_WD1.WATCHDO Write Always
ProfCon/Watchdog_WDInfo/WD/010DE GA.IN
DP_WD1/Pulse
010DEDP_WD1.WATCHDO Write If
ProfCon/Watchdog_WDInfo/WD/010DE GA.DELAYTIME Changed
DP_WD1/DelayTime
010DEDP_WD1.ORA.IN[1] Write If
ProfCon/Watchdog_WDInfo/WD/010DE Changed
DP_WD1/EnableFlag
010DEDP_WD1.EXECSTAT Read
ProfCon/Watchdog_WDInfo/WD/010DE E/ENUM
DP_WD1/ExecState
010DEDP.CV01.PV[5] Read
ProfCon/CV/010DERF_PV/Read Value
DCS

ProfCon/CV/010C2inLPG_PV/Read
Value DCS
ProfCon/CV/010DPRF_PV/Read Value
DCS
ProfCon/CV/C3inC4_PV/Read Value
DCS
ProfCon/SchedBLC/MV/010TIC2025_O TR/ENUM
P/DSC/010TIC2025_OP/Get/ModeConn
ect/ModeConnect1
ProfCon/SchedBLC/MV/010TIC2025_O NUM
ect/ModeConnect2
P/DSC/010TIC2025_OP/Get/ExecState
Connect/ExecState1
ProfCon/SchedBLC/MV/010TIC2025_O UM
Connect/ExecState2
ProfCon/SchedBLC/MV/010TIC2025_O ENUM
P/DSC/010TIC2025_OP/Get/WindupCon
nect/WindupStatus1
P/DSC/010TIC2025_OP/Set/ModeConn
ect/ModeConnect1
ect/ModeConnect2
ProfCon/SchedBLC/MV/010TIC2025_O
P/DSC/010TIC2025_OP/Set/SentValue
P/DSC/010TIC2025_OP/Set/SentValueE

UHigh
ULow
ect/ModeConnect1
ect/ModeConnect2
Connect/ExecState1
Connect/ExecState2
nect/WindupStatus1
ect/ModeConnect1
ect/ModeConnect2
UHigh
ProfCon/SchedBLC/MV/010TIC2040_O 010TIC2040.PIDA.OPLOLM Read
ULow

ect/ModeConnect1
ect/ModeConnect2
Connect/ExecState1
Connect/ExecState2
nect/WindupStatus1
ect/ModeConnect1
ect/ModeConnect2
UHigh
ULow
ProfCon/SchedBLC/DV/010FIC2008_SP NUM
/010FIC2008_SP/Get/ExecStateConnect
/ExecState1

ProfCon/SchedBLC/DV/010FIC2008_SP UM
/010FIC2008_SP/Get/ExecStateConnect
/ExecState2
011FI0009.EXECSTATE/EN Read
ProfCon/SchedBLC/DV/011FI0009_PV/0 UM
11FI0009_PV/Get/ExecStateConnect/Ex
ecState1
011FI0009.CEESTATE/ENU Read
ProfCon/SchedBLC/DV/011FI0009_PV/0 M
11FI0009_PV/Get/ExecStateConnect/Ex
ecState2
010DEDP.EXECSTATE/EN Read
ProfCon/SchedBLC/CV/010DERF_PV/0 UM
10DERF_PV/Get/ExecStateConnect/Exe
cState1
010DEDP.CEESTATE/ENU Read
ProfCon/SchedBLC/CV/010DERF_PV/0 M
10DERF_PV/Get/ExecStateConnect/Exe
cState2
ProfCon/SchedBLC/CV/010PIC2065_OP NUM
/010PIC2065_OP/Get/ExecStateConnec
t/ExecState1
ProfCon/SchedBLC/CV/010PIC2065_OP UM
/010PIC2065_OP/Get/ExecStateConnec
t/ExecState2
010LIC2016.EXECSTATE/E Read
ProfCon/SchedBLC/CV/010LIC2016_OP NUM
/010LIC2016_OP/Get/ExecStateConnect
/ExecState1
010LIC2016.CEESTATE/EN Read
ProfCon/SchedBLC/CV/010LIC2016_OP UM
/010LIC2016_OP/Get/ExecStateConnect
/ExecState2
/ExecState1
ProfCon/SchedBLC/CV/010TIC2025_PV 010TIC2025.CEESTATE/EN Read
/010TIC2025_PV/Get/ExecStateConnect UM
/ExecState2

ProfCon/SchedBLC/CV/010C2inLPG_P UM
V/010C2inLPG_PV/Get/ExecStateConne
ct/ExecState1
ProfCon/SchedBLC/CV/010C2inLPG_P M
V/010C2inLPG_PV/Get/ExecStateConne
ct/ExecState2
ProfCon/SchedBLC/CV/010DPRF_PV/0 UM
10DPRF_PV/Get/ExecStateConnect/Exe
cState1
ProfCon/SchedBLC/CV/010DPRF_PV/0 M
10DPRF_PV/Get/ExecStateConnect/Exe
cState2
ProfCon/SchedBLC/CV/010PIC2038_PV NUM
/ExecState1
ProfCon/SchedBLC/CV/010PIC2038_PV UM
/ExecState2
/ExecState1
ProfCon/SchedBLC/CV/010TIC2040_PV 010TIC2040.CEESTATE/EN Read
/010TIC2040_PV/Get/ExecStateConnect UM
/ExecState2
ProfCon/SchedBLC/CV/010TI2036_PV/0 010TI2036.EXECSTATE/EN Read
ecState1
ProfCon/SchedBLC/CV/010TI2036_PV/0 010TI2036.CEESTATE/ENU Read
ecState2
ProfCon/SchedBLC/CV/C3inC4_PV/C3in 010DEDP.EXECSTATE/EN Read
C4_PV/Get/ExecStateConnect/ExecStat UM
e1
ProfCon/SchedBLC/CV/C3inC4_PV/C3in 010DEDP.CEESTATE/ENU Read
C4_PV/Get/ExecStateConnect/ExecStat M
e2

6.2 BLC Configuration

Base Level Controls (BLC) are required for Mode change and Mode shed of the PID loops
in APC controllers. The following templates are used in DCU unit
6.2.1 HW_EPKS_Ctrl-PAuto_Shed-OAuto_custom
Parameter Function Logic
Mode Determine If PID MODEATTR = PROGRAM AND MODE =
Controllable AUTO
Mode Determine If Downstream MODEATTR = OPERATOR AND MODE =
PID(s) Controllable CAS
Mode Set PID Controllable MODEATTR=PROGRAM;MODE=AUTO;
Mode Set Downstream PID(s) MODEATTR=PROGRAM;MODE=CAS;MOD
Controllable EATTR=OPERATOR;
ModeShed Set PID To Shed MODEATTR=OPERATOR;MODE=AUTO;
ModeShed Set Downstream PID(s) To MODEATTR=OPERATOR;MODE=CAS;MO
Shed DEATTR=PROGRAM;
Execution Determine execution status /EXECSTATE = ACTIVE AND /CEESTATE =
State RUN
Windup Determine if PID(s) are ARWNET[1] = HI
Status Woundup High
Windup Determine if PID(s) are ARWNET[1] = LO
Status Woundup Low
Windup Determine if PID(s) are ARWNET[1] = HILO
Status Woundup HighLow
MV Sent High SPHILM
Value
MV Sent Low SPLOLM
Value
MV Sent Output SP
Value
MV Read Read Value SP
Value
MV Read Read OP Value OP
Value
MV Read Read Process Value PV
Value
MV Read Read OP Process High OPHILM
Value
MV Read Read OP Process Low OPLOLM

Value
MV Read Low Limit PV[1]
Value
MV Read High Limit PV[2]
Value
MV Read Use This MV PV
Value
MV Sent Low Limit PV[1]
Value
MV Sent High Limit PV[2]
Value
MV Sent Current Move PV[3]
Value
MV Sent Status PV[4]
Value
MV Sent Use This MV PV
Value
MV Sent SS Value PV[5]
Value
6.2.2 HW_EPKS_Ctrl-PMan_Shed-OMan_Custom
Mode Determine If PID MODEATTR = PROGRAM AND MODE =
Controllable MAN
Mode Determine If Downstream MODEATTR = OPERATOR AND MODE =
PID(s) Controllable CAS
Mode Set PID Controllable MODEATTR=PROGRAM;MODE=MAN;
Mode Set Downstream PID(s) MODEATTR=PROGRAM;MODE=CAS;MOD
Controllable EATTR=OPERATOR;
ModeShed Set PID To Shed MODEATTR=OPERATOR;MODE=MAN;
ModeShed Set Downstream PID(s) To MODEATTR=OPERATOR;MODE=CAS;MO
Shed DEATTR=PROGRAM;
Execution Determine execution status ../EXECSTATE = ACTIVE AND
State ../CEESTATE = RUN
Windup Determine if PID(s) are ARWOP = HI
Status Woundup High
Windup Determine if PID(s) are ARWOP = LO
Status Woundup Low
Windup Determine if PID(s) are ARWOP = HILO


MV Sent High OPHILM
Value
MV Sent Low OPLOLM
Value
MV Sent Output OP
Value
MV Read Read Value OP
Value
MV Read Read OP Value OP
Value
MV Read Read Process Value OP
Value
MV Read Read OP Process High OPHILM
Value
MV Read Read OP Process Low OPLOLM
Value
MV Read Low Limit PV[1]
Value
MV Read High Limit PV[2]
Value
MV Read Use This MV PV
Value
MV Sent Low Limit PV[1]
Value
MV Sent High Limit PV[2]
Value
MV Sent Current Move PV[3]
Value
MV Sent Status PV[4]
Value
MV Sent Use This MV PV
Value
MV Sent SS Value PV[5]
Value
6.2.3 HW_EPKS_CV_PV_Custom


CV Read Read Value DCS PV
Value
CV Read Read OP Process High PVEUHI
Value
CV Read Read OP Process Low PVEULO
Value
CV Read Low Limit PV[1]
Value
CV Read High Limit PV[2]
Value
CV Read Control This CV PV
Value
CV Sent Low Limit PV[1]
Value
CV Sent High Limit PV[2]
Value
CV Sent SS Value PV[3]
Value
CV Sent Status PV[4]
Value
CV Sent Control This CV PV
Value
6.2.4 HW_EPKS_CV_PV_Calculated
CV Read Read Value DCS PV[5]
Value
Value
Value
Value
Value

Value
Value
Value
Value
6.2.5 HW_EPKS_CV_OP_Custom
CV Read Read Value DCS OP
Value
Value
Value
Value
Value
Value
Value
Value
Value
6.2.6 HW_EPKS_DV_PV
Status Woundup High
Status Woundup Low


DV Read Read Value PV
Value
6.2.7 HW_EPKS_DV_OP
Status Woundup High
Status Woundup Low
DV Read Read Value OP
Value

7 SAT Summary
7.1 SAT Summary for Profit Controllers
The AVYU SAT was carried out from 29th February 2020 16:00:00 to 15th March
2020 16:00:00. The following tables lists the summary of the activities carried out
during the SAT Period.
Controller Name Description APC SAT Uptime

010AVU Atmospheric Column Controller 100%
010VDU Vacuum Column Controller 99.93%
010VDUCAS Vacuum Column Cascade Controller 98.38%
010NSU Naphtha Stabilizer Column 99.6%
De-Ethanizer and De-Propanizer
010DEDP 100%
Controller
7.2 SAT Summary for Inferentials

Inferential Property Accuracy to be Proved Actual Accuracy
NAPHTHA RVP 95% 96.01%
NAPHTHA 95% 95% 98.33%
KERO FLASH POINT 90% 98.14%
KERO FREEZE POINT 95% 97.81%
AGO 5% 95% 99.26%
AGO 95% 95% 99.28%
VD 95% 95% 97.38%
VGO 95% 95% 98.47%
HVGO 95% 95% 99.50%
VR 5% 95% 98.56%
C2 IN LPG 80% 50.68%
C3 IN C4 80% 51.91%
LPG WEATHERING 85% 62.00%

Appendix:
A. 010AVU

B. 010VDU

C. 010VDUCAS
D. 010NSU

E. 010DEDP

Changes made in FDS from previous revision:
Date Revision Changes made Reason for changes

13/8/2019 1 DV-2 included in 010CDU Controller After input from
(Page 19) customer
13/8/2019 1 CV-17,18 and Note 7 Included in After input from
010CDU Controller (Page 19) customer
13/8/2019 1 CV-19,20 and Note 8 Included in After input from
010CDU controller (Page 19) customer
13/8/2019 1 DV-2 included in 010VDU controller After input from
(page 20) customer

CLIENT NAME INDIAN OIL CORPORATION LTD (IOCL)
PROJECT TITLE PARADIP REFINERY PROJECT (PDRP)
PROJECT LOCATION PARADIP, ORISSA, INDIA
VENDOR NAME PETRON ENGINEERING CONSTRUCTION LIMITED
CONTRACT NO. 1-14-4200/ 399
IOCL ORDER NO.
CONSULTANT (FW)
0459/ 4200 REQ NO.: DSN – 15555
P.O. NO.
REQ ITEM NO.: TAG NO.:
OPERATING & MAINTENANCE MANUAL FOR CRUDE CHARGE

DOCUMENT TITLE
HEATERS 010-F-101/201
VENDOR DOC NO.: PECL/C-908/1145/AVU/C-149 VENDOR REV. O1
DOC TYPE CODE & CONSULTANT

SEQUENCE NO. (FW) REV. NO.
STATUS CODE: BY: DEPT: DATE:

CLIENT: INDIAN OIL CORPORATION LIMITED
CONSULTANT: FOSTER WHEELER
PARADIP REFINERY PROJECT, ORISSA
OPERATING & MAINTENANCE MANUAL FOR

CRUDE CHARGE HEATERS 010-F-101/201
FOR
LSTK- 1 - AVU FIRED PROCESS HEATERS
CONTRACT NAME : LSTK-1 AVU

PROCESS FIRED HEATERS
CONTRACT NO : 0459/4200
PECL CONTRACT NO : C – 908
UNIT NO : 010 ATMOSPHERIC VACUUM UNIT
O1 24-05-2016 Issued For Information VKJ SKS AKJ

Rev Date Purpose of Issue Prepared Checked Approved
PETRON ENGINEERING
CONSTRUCTION LTD.,
MUMBAI PECL
PECL/C-908/1145/
Document
AVU/C-149
No.
ENEREFF ENGINEERS PVT. LTD. REV No.
O1
FW
FOSTER WHEELER Document
No.
will not be reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the borrower.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they
SECTION DESCRIPTION PAGE NO.
I INTRODUCTION 3
II PROCESS DESCRIPTION 5
III INTERLOCK SCHEMES AND ALARM SET POINTS 8
IV PRE COMMISIONING INSPECTION 18
V HEATER DRY OUT INSTRUCTIONS 22
VI PROCEDURE FOR PRESSURE TESTING OF BURNER LINES 26
VII NORMAL HEATER STARTUP 31
VIII HEATER SHUTDOWN 40
IX OPERATING INSTRUCTIONS 46
X AIRPREHEATER OPERATING INSTRUCTIONS 52
XI WHB & STEAM DRUM OPERATING INSTRUCTIONS 56
XII PROCEDURE FOR GAS FREEING & ISOLATION FOR SAFE 60
ENTRY
XIII MAINTENANCE INSTRUCTIONS 62
XIV ENCLOSURES 70
SHT 2 OF 72
OPERATING & MAINTENANCE DOCUMENT NO. REV.
ENEREFF ENGINEERS PVT. LTD.
MANUAL FOR CRUDE CHARGE PECL/C-908/
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
NEW DELHI
SECTION - I
HEATERS 010-F-101/201
INTRODUCTION
OPERATING & MAINTENANCE

PECL/C-908/ MANUAL FOR CRUDE CHARGE
1145/AVU/C-149
DOCUMENT NO.
SHT 3 OF 72
O1
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - I
INTRODUCTION
This Operating Manual covers various aspects of the operation of Crude Charge
Heaters (010-F-101/201) with an outboard Cast & Glass Airpreheater (010-APH-
001) & Waste Heat Boiler (010-WHB-001) and is being issued for the purpose of
assisting operating personnel to run the Heaters / APH / WHB system efficiently.
The instructions can only supplement the experience and judgment of those in
charge of operation. They should be interpreted and applied after due consideration
to the requirements of other equipment and for any particular set of circumstances,
since no amount of instructions can cover all the situations that may arise.
Instructions for operation and maintenance instructions for the Heaters / APH /
WHB system have been given in the following sections of this Operating &
Maintenance Manual. Vendors’ Operating Manuals of bought out items like
Burners, Forced Draft Fans, Induced Draft Fans, Airpreheater, Waste Heat Boiler,
Steam Drum & Dampers etc. should be read carefully before the Heaters / APH /
WHB system is commissioned.
SHT 4 OF 72
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NEW DELHI
SECTION - II
HEATERS 010-F-101/201
MANUAL FOR CRUDE CHARGE
PROCESS DESCRIPTION
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
SHT 5 OF 72
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - II
PROCESS DESCRIPTION
2.1 CRUDE CHARGE HEATERS 010-F-101/201
Crude Charge Heaters (010-F-101/201) are an eight pass vertical tube Box Heaters
with vertical tubes in the Radiant section and horizontal tubes in Convection
section. Feed is first equally split into eight streams and the flow rate of each
stream is metered. Crude oil at a temperature of around 300.7°C enters into the
Convection section and is heated to a temperature around 366.5°C before it leaves
the radiant section. The mixed temperature of the eight streams coming out from
radiant section is controlled by Temperature Controllers (010-TIC- 1069/ 1569)
which give signal to Heaters firing control loop.
The Radiant section of the each Heater is provided with 184 tubes in 4 identical
vertical cells with each cell having 2 passes. Each pass has 23 tubes as follows:
Last 8 tubes are of A 335 Gr P9 of 219.1mm OD x Sch 40 & subsequent tubes are
of A 335 P9 of 168.3 mm OD x 6.5 mm thickness (Minimum Wall). Each pass
consists of 6 double fired tubes of 219.1 mm OD and 2 single fired tubes of 219.1
mm OD alongwith 15 single fired tubes of 168.3 mm OD. All tubes are placed at 2
D spacing with D being the nominal tube size. Convection section has 8 tubes per
row and consists of 24 bare and 80 finned rows of tubes The first 2 shield (bare)
rows (16 tubes) of HC Process Convection tubes shall be of A 335 P9 of 168.3 mm
OD x 6.5 mm thickness (Minimum Wall). The last shield (bare) row (8 tubes) of
HC Process Convection Tubes and all the Process coil finned tubes (56 tubes with
118 Fins/ m of 19.1 mm height and 2.5 thickness of 11Cr metallurgy) shall be of A
335 P5 of 168.3 mm OD x 6.4 mm thickness (Minimum Wall). All the MP SSH &
LP SSH Convection coil finned tubes (24 tubes with 118 Fins/ m of 19.1 mm
height and 2.5 thickness of 11Cr metallurgy) shall be of A 335 Gr P11 of 168.3 mm
OD x Sch 40.
2.2 THE AIR PREHEATING CIRCUIT
There is a common outboard Air Preheating System for the Crude Charge Heaters
010-F-101/201. Combustion air required for the each Heater is fed by the two
Forced draft fans 010-K-001A and 010-K-001B and is preheated in a Steam Air
Preheater (010-E-030) upto a temperature of 68°C (for the Heater Design case) and
then heated in a Cast & Glass Airpreheater (010-APH-001) upto a temperature of
280°C (for the Heater Design case). The total air requirement signal for the two FD
fans comes from controller 010-FIC-1082 & 010-FIC-1582. The air flow rate from
fans is adjusted by varying the position of the Inlet Box Dampers (010-FV-1089A
& 010-FV-1089B).
Flue Gases from the Convection sections of the Crude Charge Heaters (010-F-
101and 010-F-201) is combined in a collector box and then enters the outboard
Waste Heat Boiler (010-WHB-001) at 460°C and then exit the Waste Heat Boiler
and enters the Cast & Glass APH at 310°C and are cooled down to 150°C. The cold
flue gas from the APH then enters ID fans (010-K-002A/B) and finally leave
through the common ground mounted Stack 010-SK-001. The pressure developed
SHT 6 OF 72
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they by the ID fan is adjusted by varying the position of the Inlet Box Damper (010-PV-
1214A/B). The signal to the Inlet Box Damper actuators are controlled so as to
ensure at least 2.5 mmWC of draft at Arch of the each Heater. In the event of
failure of the ID fans, the Stack Damper 010-PV-1098 will open fully and the flue
gases shall be vented directly through the common grade mounted Stack by natural
draft.
Necessary Dampers/ SOB’s have been provided in the flue gas circuit to ensure that
the Heaters can be operated in the event of Cast & Glass APH or Waste Heat Boiler
bypass.
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AND
SECTION - III
HEATERS 010-F-101/201
ALARM SET POINTS

INTERLOCK SCHEMES
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION – III
INTERLOCK SCHEMES AND ALARM SET POINTS
3.0 GENERAL
This chapter has been prepared with the intention of providing the Heater operating
personnel with basic information on how interlock scheme works and how they
should be operated safely. Operating personnel should understand the interlock
scheme thoroughly for safe operation of the Heater during any abnormalities.
3.1 INTERLOCK SCHEME
Following interlocks have been provided for the safe operation of the Heater in the
event of failure of any operating equipment or any abnormality in the process
condition.
3.1.1 High- High or Low- Low Pilot Gas Pressure (IZ-0644)
In the event of High- High or Low- Low Pilot gas pressure, as sensed by High-
High or Low- Low setting limit of two out of three 010-PZSHH–1167 / PZSLL–
1167 A/B/C or 010-PZSHH–1667 / PZSLL–1667 A/B/C continuing for 5 seconds,
Fuel oil, Main fuel gas and Pilot gas supply to the Heaters shall be cut off. Stack
Damper (010-PV-1098) and Flue gas Dampers of the Heaters (010-PV-1035/1535)
shall open. All drive of the APH system shall trip.
3.1.2 High- High Arch Pressure (IZ-0106/ 0506)
 In the event of High- High pressure at Heater Arch, as sensed by High- High
setting limit of two out of three 010-PZSHH–1124 A/B/C or 010-PZSHH–1624
A/B/C, Stack Damper 010-PV-1098 and Flue gas Dampers of the Heaters
(010-PV-1035/1535) shall open. If the Dampers fails to open or Arch pressure
does not reduce within 30 seconds, Fuel oil & Main fuel gas supply to the
Heaters shall be cut off. Pilot gas shall remain on line.
 In the event of the failure of both ID fans as sensed by motor contact MZL-
1018C and MZL-1019C, Stack Damper (010-PV-1098) and Flue gas Dampers
of the Heaters (010-PV-1035/1535) shall open automatically. If the Dampers
fail to open within 30 Seconds, Fuel oil & Main fuel gas supply to the Heater
shall be cut off. Pilot gas shall remain on line.
3.1.3 IZ-0107/ 0507
 In the event of Low- Low feed flow to Heaters as sensed by 010-FZSLL-1016
A/B/C or any 010-FZSLL-9307A to H (A/B/C) or 010-FZSLL-1516 A/B/C or
any 010-FZSLL-9308A to H (A/B/C), Fuel oil & Main fuel gas supply to the
Heaters shall be cut off, Stack Damper (010-PV-1098) and Flue gas Dampers of
the Heaters (010-PV-1035/1535) shall open. Pilot gas shall remain on line.
 In the event of High- High Process outlet temperature, as sensed by High- High
setting limit of two out of three 010-TZSHH–1123 A/B/C or 010-TZSHH–1623
A/B/C, Fuel oil & Main fuel gas supply to the Heaters shall be cut off. Stack
SHT 9 OF 72
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they Damper 010-PV-1098 and Flue gas Dampers of the Heaters (010-PV-
1035/1535) shall open. Pilot gas shall remain on line.
 In the event of failure of both the FD fans as sensed by motor contacts 010-
MZL-1020AC/ 1020BC or Combustion air Low- Low flow to Heater & Low-
Low FD fan discharge pressure as sensed by 010-FZSLL-1084/1584 A/B/C &
010-PZSLL-9319 A/B/C, Fuel oil & Main fuel gas supply to the Heaters shall
be cut off. Stack Damper 010-PV-1098 and Flue gas Dampers of the Heaters
(010-PV-1035/1535) shall open. Pilot gas shall remain on line.
3.1.4 High- High or Low- Low Main Fuel Gas Pressure (IZ-0118/ 0518)
In the event of High- High or Low- Low main fuel gas pressure, as sensed by High-
High or Low- Low setting of two out of three 010- PZSHH -1165/ PZSLL–1165
A/B/C or 010- PZSHH / PZSLL–1665 A/B/C, Main fuel gas to the Heaters shall be
cut off by closing both the Block Valves 010-XZV–1022/1522 & 010-XZV–
1049/1549 and opening the Bleed valve 010-XZV-1050/1550. Pilot gas shall
remain on line.
3.1.5 Fuel oil & Main Fuel Gas Cut off to Heaters (IZ-0634/ 0664)
In the event of Fuel Oil and Main fuel gas cut off to the Heater, following actions
will take place sequentially:
a) Stack Damper 010-PV-1098 and flue gas Dampers of the Heaters (010-PV-
1035/1535) shall open.
b) FD Fans will trip after a period of 30 seconds.
c) ID Fans will trip after a period of 30 seconds.
3.1.6 FD Fan Maximum/ Normal Operation & Failure of Operating Fan (IZ-0635)
During normal operation at maximum/ normal/ turndown (50%) loads, both the FD
fans shall be operating at 50% process load. In the event of failure of one of the
working fans as sensed by respective motor contacts 010-MZL-1020AC/ 1020BC,
working Fan shall attain 100% process load and the discharge Damper 010-XZV-
1037/1038 of the tripped fan shall close automatically isolating the tripped Fan.
Suction damper shall be closed manually.
3.1.7 High- High or Low- Low Temperature at APH Outlet of Fuel Gas (IZ-0633)
In the event of High- High or Low- Low temperature of flue gas at APH outlet, as
sensed by High- High or Low- Low setting of two out of three 010- TZSHH-1212 /
TZSLL–1212 A/B/C, APH by-pass Damper 010- XZV-1030 shall open & APH
inlet Damper 010-XZV-1031) shall close automatically. If Dampers fail to open/
close 30 seconds respectively, ID Fan will trip, Fuel oil & Main fuel gas supply to
both Heaters shall be cut off. Pilot gas shall remain on line.
3.1.8 IZ-0119/ 0519
 In the event of High- High or Low- Low fuel oil pressure, as sensed by High-
High or Low- Low setting of two out of three 010- PZSHH-1172/ 010-PZSLL–
1172 A/B/C or 010- PZSHH-1672/ 010-PZSLL–1672 A/B/C, fuel oil shall be
cut off by closing valves 010-XZV-1024/1026/1046A to P & 010-XZV-
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 1524/1526/1546A to P and opening oil gun steam purge shutdown valves 010-
XZV-1057A to P & 010-XZV-1557A to P. Pilot gas & Main Fuel gas shall
remain on line.
 In the event of Low- Low differential pressure between atomizing steam & fuel
oil, as sensed by Low- Low setting of two out of three 010- PZSLL–1583
A/B/C, fuel oil shall be cut off by closing valves 010-XZV-1024/1026/1046A
to P & 010-XZV-1524/1526/1546A to P and opening oil gun steam purge
shutdown valves 010-XZV-1057A to P & 010-XZV-1557A to P. Pilot gas &
Main Fuel gas shall remain on line.
3.1.9 IZ-0637
Stack Damper 010-PV-1098 cannot be closed unless ID Fan is running.
3.1.10 BURNER MANAGEMENT SYSTEM
3.1.10.1 IZ-0638/ 0665
Double block and bleed valves on the Pilot gas line to open only when individual
Pilot shut down valves of all the Pilot Burners are closed and a successful leak test
for both pilot & main fuel gas has been carried out.
3.1.10.2 IZ-0639/ 0666
Double block and bleed valves on main fuel gas line to open only when successful
leak test has been carried out and Pilot of at least one Burner is on.
3.1.10.3 IZ-0646/ 0669
In the event of loss of any of Main Flames as sensed by 010-BZSLL-1002/1502 A
to P, the respective Fuel oil shutdown valves 010-XZV-1046/1546 A to P shall
close & opening oil gun steam purge valves 010-XZV-1057/1557 A to P shall
open.
3.1.11 WASTE HEAT BOILER SYSTEM
3.1.11.1 IZ-0640
In the event of activation of steam drum level transmitter Low- Low as sensed by
010-LZSLL-1055, Flue gas inlet damper 010-XZV-1028 to WHB shall close and
by pass duct Damper 010-XZV-1029 shall open. If the Dampers fail to close/ open
within seconds respectively, ID fan will trip. Fuel oil & Main fuel gas to both
Heaters shall be cut off. Pilot gas shall remain on line.
3.1.12 MP & LP SUPERHEATED STEAM SYSTEM
3.1.12.1 IZ-0121
In the event of Low- Low MP De-superheated steam temperature, as sensed by
Low- Low setting limit of 010-TZSLL-1136, Boiler feed water to De-superheater
to be cut off by closing shutdown valve 010-XZV-1025.
3.1.12.2 IZ-0122/ 0522
In the event of Low- Low LP superheated steam from Convection section as sensed
by Low- Low setting limit of 010-TZSLL-1137/ 010-TZSLL-1637, LP superheated
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they steam from Convection section to be cut off by closing shutdown valve 010-XZV-
9302/ 010-XZV-1529 & vented to atmosphere by opening shutdown valve 010-
XZV-9301/ 010-XZV-1528 on LP steam vent line.
3.1.13 ID FAN SAFEGUARDING
3.1.13.1 IZ-0642
In the event of activation of interlocks IZ-0640 & IZ-0633 simultaneously, Stack
Damper 010-PV-1098 & Flue gas Damper of Heater (010-PV-1035/ 010-PV-1535)
shall open & APH by pass Damper (010-XZV-1030) shall close. Both the ID fans
shall trip.
3.1.13.2 IZ-0643
During operation at Max/Nor Loads, both the ID fans shall run (Each at 50%
process load). In case of failure of one of the working fans as sensed by respective
motor contact 010-MZL-1018C/ 1019C, working fan shall attain 100% process
load. Suction Damper of the tripped fan to be closed manually. In case of APH or
WHB by pass mode (APH or WHB inlet damper closed position input as sensed by
010-XZSL-1028 or 010-XZSL-1031) and if one of the ID fans trips, stack damper
(010-PV-1098), Heater flue gas outlet dampers (010-PV-1035/ 010-PV-1535) shall
open, WHB flue gas inlet damper (010-XZV-1028) or APH flue gas inlet damper
(010-XZV-1031) respectively & Flue gas by pass damper (010-XZV-1030) on
APH shall close. Running ID fan shall also trip.
3.1.14 SOOT BLOWER OPERATION (I-0632/ 0662/ 0663)
 On pressing Soot blower start sequence the inlet shutdown valve 010-XV-1042/
010-XV-1543 shall open and a timer for 10 mins. shall start. Once the pressure
transmitter 010-PSLL-1006/ 010-PSLL-1506 & temperature transmitter 010-
TSLL-1125/ 010-TSLL-1625 becomes healthy the drain shutdown valve 010-
XV-1043/ 010-XV-1543 shall close. Only on completion of time delay of 10
mins. with both pressure transmitter 010-PSLL-1006/ 010-PSLL-1506 &
temperature transmitter 010-TSLL-1125/ 010-TSLL-1625 being healthy , Soot
blowing operation to start.
 During Soot blower operation, in case either of 010-PSLL-1006/ 010-PSLL-
1506 & 010-TSLL-1125/ 010-TSLL-1525 are not healthy, soot blower
operation to stop, soot blower to retract, inlet shutdown valve 010-XV-1042/
010-XV-1542 to close & drain shutdown valve 010-XV-1043/ 010-XV-1543 to
open.
3.1.15 TRIPPING OF HEATERS (IZ-0645/ 0668)
In the event of tripping of the Heater 010-F-201/010-F-101 other than emergency &
Pilot shutdown, Fuel oil, main Fuel gas to the Heater 010-F-101/201 shall be cut
off, Stack Damper (010-PV-1098) & Flue gas Damper of the Heater (010-PV-
1035/1535) shall open.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 3.1.16 EMERGENCY (IZ-0631)
One emergency push button (010-HZS-3000A) shall be provided on hardwire
console panel (Auxiliary Control Panel) pressing which Fuel oil, Main fuel gas,
Pilot gas & Feed to the Heaters shall be cut off, all drives of APH system shall trip,
Stack damper (010-PV-1098) & Flue gas damper of the Heaters (010-PV-
1035/1535) shall open even if interlocks are in bypass mode. In addition, Local
emergency push button (Mushroom Head type pressed to lock in position) 010-
HZS-3000BA/010-HZS-3000BB shall be provided 15m away from Heater inside
“Break glass” enclosure (located at grade).
3.2 SET POINTS
Following are the indicative values of set points of alarms and trips for different
instruments. The set points have been indicated for the “Heater Design” conditions.
The set points shall need to be revised to take care of any other operating Heater
conditions based on the data received from the various equipment suppliers.
These set points may require tuning during actual plant operation after assessing the
performance of the Heater & the WHB / APH system.
P&ID: PECL/C-908/1145/AVU/C-1011/ 2011
Tag No. Service/Location Initial Set Point
FZALL – 1016/1516
Combined HC Feed
FZSLL – 1016/1516 Low Low 350,000 kg/ hr (Adj.)
Inlet Flow
A/B/C
Combined HC Feed
FIC – 1017/1517 Low 437,500 kg/ hr (Adj.)
Inlet Flow
FZALL – 9307 A to H
FZSLL – 9307 A to H
A/B/C Individual Pass HC
Low Low 43,750 kg/ hr (Adj.)
FZALL – 9308 A to H Feed Inlet Flow
FZSLL – 9308 A to H
A/B/C
FIC – 1018 A to H Individual Pass HC High 120,000 kg/ hr (Adj.)
FIC – 1518 A to H Feed Inlet Flow Low 54,700 kg/ hr (Adj.)
TZAHH – 1123/1623
Combined Coil
TZSHH – 1123/1623 High High 376°C (Adj.)
Outlet Temperature
A/B/C
TIC – 1067 A to H Individual Pass Coil High 371°C (Adj.)
TIC – 1567 A to H Outlet Temperature Low 351°C (Adj.)
TIC – 1069 Combined Coil High 370°C (Adj.)
TIC – 1569 Outlet Temperature Low 350°C (Adj.)
TDAH – 1067/1567 High 3°C (Adj.)
Individual Pass Coil
A to H
Outlet Temperature
TDAL – 1067/1567 Low 0°C (Adj.)
Difference
A to H
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TAH – 1127 A to H Tube Skin
High 500°C (Adj.)
TAH – 1627 A to H temperature
High 500°C (Adj.)
High 500°C (Adj.)
TAH – 1103 A to H Individual Pass Coil
High 310°C (Adj.)
TAH – 1603 A to H Inlet Temperature
Combined HC Feed
PAH – 1001/1501 High 19 kg/cm²g (Adj.)
Inlet Pressure
PAH – 1034 A to H Individual HC Feed
High 17 kg/cm²g (Adj.)
PAH – 1534 A to H Inlet Pressure
Combined HC Feed
PAH – 1098/1598 High 3 kg/cm²g (Adj.)
Outlet Pressure
P&ID: PECL/C-908/1145/AVU/C-1012/ 2012
High 5% (Vol.) (Adj.)
AIC – 1002/ 1502 Oxygen Analyser
Low 1.5% (Vol.) (Adj.)
TAH – 1111/1611
High 925°C (Adj.)
A/B/C/D Flue Gas Temp.
TAL – 1111/1611 (Firebox)
Low 700°C (Adj.)
A/B/C/D
Flue Gas Temp. (Ex
TAH – 1148/1648 A/B High 480°C (Adj.)
Conv.)
PZAHH – 1124/1624
High High Arch
PZSHH – 1124/1624 High High + 5 mm WC (Adj.)
pressure
A/B/C
PIC – 1035/1535 High Arch pressure High + 2.5 mm WC (Adj.)
FZALL – 1084/1584
Combustion air Flow
FZSLL – 1084/1584 Low Low 22500 kg/ hr (Adj.)
at Heater Inlet
A/B/C
FAH– 1082/1582 Combustion air Flow High 135000 kg/ hr (Adj.)
FAL– 1082/1582 at Heater Inlet Low 25000 kg/ hr (Adj.)
PALL –
1006/1506/1701 Soot Blowing Steam
Low Low 12.5 kg/cm²g (Adj.)
PSLL – Header Pressure
1006/1506/1701
TALL –
Soot Blowing
1125/1625/1717
Condensate Line Low Low 180°C (Adj.)
TSLL –
Temp.
1125/1625/1717
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P&ID: PECL/C-908/1145/AVU/C-1013/2013
Superheated LP
TAH – 1133/1633 High 385°C (Adj.)
Steam Outlet Temp.
Superheated LP High 345°C (Adj.)
TIC – 1134/1634
Steam Outlet Temp. Low 305°C (Adj.)
TZALL – 1137/1637 Superheated LP
Low Low 270°C (Adj.)
TZSLL – 1137/1637 Steam Outlet Temp.
Superheated MP High 345°C (Adj.)
TIA – 1132/1632
MP Steam De- High 315°C (Adj.)
TIC – 1135 Superheater Outlet
Temp. Low 295°C (Adj.)
MP Steam De-
TZALL – 1136
Superheater Outlet Low Low 280°C (Adj.)
TZSLL – 1136
Temp.
P&ID: PECL/C-908/1145/AVU/C-1014/2014
PZALL – 1167/1667
PZSLL – 1167/1667 Pilot gas pressure Low Low 0.5 kg/cm²g (Adj.)
A/B/C
PZAHH – 1167/1667
PZSHH– 1167/1667 Pilot gas pressure High High 1.5 kg/cm²g (Adj.)
A/B/C
PZAH– 1167/1667
High 0.95 kg/cm² g (Adj.)
A/B/C
Pilot gas pressure
PZAL – 1167/1667
Low 0.55 kg/cm² g (Adj.)
A/B/C
PIC – 1166/1666 Main FG pressure Low 0.35 kg/cm² g (Adj.)
PZALL – 1165/1665
PZSLL – 1165/1665 Main FG pressure Low Low 0.2 kg/cm²g (Adj.)
A/B/C
PZAHH – 1165/1665
PZSHH – 1165/1665 Main FG pressure High High 2.0 kg/cm²g (Adj.)
A/B/C
PZAH – 1165/1665
High 1.85 kg/cm²g (Adj.)
A/B/C
Main FG pressure
PZAL – 1165/1665
Low 0.35 kg/cm²g (Adj.)
A/B/C
High 7065 kg/ hr (Adj.)
FIA – 1074/1574 Main FG flow
Low 1615 kg/ hr (Adj.)
Main FG Header
TIA – 1213/1713 Low 20°C (Adj.)
temp.
Fuel Oil Supply
FAL – 1079/1579 Low 3000 kg/ hr (Adj.)
Header Flow
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Atomising Steam High 2385 kg/ hr (Adj.)
FIA – 1078/1578
Flow Low 900 kg/ hr (Adj.)
Differential Pressure High 2.4 kg/cm²g (Adj.)
PDIC – 1162/1662 between Atomising
Steam & Fuel Oil Low 1.8 kg/cm²g (Adj.)
PDZALL – 1083/1583 Differential Pressure
PDZSLL – 1083/1583 between Atomising Low Low 1.5 kg/cm²g (Adj.)
A/B/C Steam & Fuel Oil
PDAH – 1076/1576 Pressure drop across High 0.3 kg/cm²g (Adj.)
PDAL – 1076/1576 Strainer for Fuel Oil Low 0.1 kg/cm²g (Adj.)
PIC – 1161/1661 Fuel Oil Pressure
PZALL – 1172/1672
PZSLL – 1172/1672 Fuel Oil Pressure Low Low 2.4 kg/cm²g (Adj.)
A/B/C
PZAHH – 1172/1672
PZSHH – 1172/1672 Fuel Oil Pressure High High 7 kg/cm²g (Adj.)
A/B/C
Fuel Oil Return High 3000 kg/ hr (Adj.)
FIA – 1080/1580
Header Flow Low 1620 kg/ hr (Adj.)
P&ID: PECL/C-908/1145/AVU/C-1015
PZAL – 9309/9310 Comb. air Pressure at Low + 50 mm WC (Adj.)
PZALL – 9309/9310 FD Fan Outlet Low Low + 40 mm WC (Adj.)
PZALL – 9319 Comb. air Pressure at Low Low + 30 mm WC (Adj.)
PZSLL – 9319 A/B/C FD Fan Outlet Low + 50 mm WC (Adj.)
P&ID: PECL/C-908/1145/AVU/C-1016
AAH – 1004 SOx Analyser High 0.0045% (Vol.) (Adj.)
AAH – 1006 NOx Analyser High 350 mg/Nm³ (Adj.)
High 250 ppm (Adj.) - CO
AIA – 1001 CO/O2 Analyser
Low 2% (Vol.) (Adj.) - O2
High 92 mg/Nm³ (Adj.)
AIA – 1009 VOC Analyser
Low 5 mg/Nm³ (Adj.)
High 50 mg/Nm³ (Adj.)
AIA – 1010 PM Analyser
Low 5 mg/Nm³ (Adj.)
Flue Gas Temp. (Ex
TAL –1208 Low 420°C (Adj.)
Conv.)
Flue Gas Pressure
PAH – 1039 High + 5 mm WC (Adj.)
(Ex Conv.)
Flue Gas Temp. (Ex
TAL – 1017 Low 270°C (Adj.)
WHB)
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P&ID: PECL/C-908/1145/AVU/C-1016
Flue Gas Pressure
PAH – 1040 High 0 mm WC (Adj.)
(Ex WHB)
Flue Gas Temp. (Ex High 175°C (Adj.)
TIC – 1072
APH) Low 132°C (Adj.)
Flue Gas Pressure
PAH – 1138 High -50 mm WC (Adj.)
(Ex APH)
TZALL – 1212 Flue Gas Temp. (Ex
TZSLL – 1212 A/B/C APH)
TZAHH – 1212 Flue Gas Temp. (Ex
High High 205°C (Adj.)
TZSHH – 1212 A/B/C APH)
Flue Gas Pressure at
PAHH – 9311/9312 High High - 25 mm WC (Adj.)
ID Fan Suction
Hot Air Pressure at
PAL – 1023 Low + 25 mm WC (Adj.)
APH Outlet
Hot Air Temperature
TAL – 1150 Low 225°C (Adj.)
at APH Outlet
Hot Air Temperature High 290°C (Adj.)
TIA – 1229
at APH Outlet Low 215°C (Adj.)
Hot Flue Gas Temp. High 260°C (Adj.)
TIA – 1230 A/B
inside APH Low 190°C (Adj.)
APH Cast Tube Skin High 200°C (Adj.)
TIA – 1209 A/B
TC Temperature Low 142°C (Adj.)
P&ID: PECL/C-908/1145/AVU/C-1017
BFW Temperature to
TAL – 1205 Low 95°C (Adj.)
Steam Drum
BFW Flow to Steam
FIC – 1131 Low 3100 kg/ hr (Adj.)
Drum
Steam Drum
TAL – 1206 Low 200°C (Adj.)
Temperature
Steam Drum High 18 kg/cm²g (Adj.)
PIA – 1075
Pressure Low 16 kg/cm²g (Adj.)
High +150 mm
LIC – 1057/1059 Steam Drum Level
Low - 150 mm
LY – 1057 Steam Drum Level High 50 mm
LZALL – 1055
Steam Drum Level Low Low - 240 mm
LZSLL – 1055
P&ID: PECL/C-908/1145/AVU/C-1019
LAL – 9302 Dosing Tank Level Low +150 mm
Dosing Chemical to
PAL – 9304/9305 Steam Drum Low 18 kg/cm²g (Adj.)
Pressure
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SECTION - IV
HEATERS 010-F-101/201
PRE-COMMISSIONING INSPECTION
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
O1
SHT 18 OF 72
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - IV
Following pre-commissioning inspection should be carried out for the Heaters/
APH/ WHB System and Burners.
4.1 BURNERS
It is quite important that a positive check be made to see that all Burners have been
properly installed in accordance with the Heater drawings and the Burner vendor
drawings. Burner should be free of any debris or other material which might cause
faulty operation. The position of gas tips with respect to refractory burner blocks is
very important. If burners are not properly installed, flame impingement on tubes
and refractory can result.
Burner Vendor manual contains a number of instructions and DOs and DON'Ts
concerning the operation of these fuel gas Burners. Company’s Safety Department
should ensure that operating personnel are well aware of these points during
training period. In the Burner Vendor manual the installation procedure has been
given and perhaps this procedure is of more interest to the maintenance than
operating staff.
4.2 DAMPERS
If the Dampers are not functioning properly the capacity and performance of the
Heaters/ APH/ WHB System can be seriously affected. The Stack Damper and
other Dampers should be checked for proper installation (e.g. in case of instrument
air failure, the automatic Dampers/ FO type should open full by the counter
weight), easy operation and easy maintenance. In addition to the actuator assembly
(power cylinder assembly), Dampers are generally provided with winch and cable
arrangement. Complete opening and closing of the Dampers should be checked
visually after installation and external markings are to be made, so that at any time,
the actual Damper opening in the field can be cross-checked with the control room
indication.
The actuator assemblies should be checked properly to ensure that Dampers can be
operated within the specific operation time, positioner respond accurately to the
variations in signal pressure and Dampers attain fail safe position during instrument
air failure to ensure safety of the Heaters/ APH/ WHB System.
The vendor’s drawings, sketches, control schemes and other documents should be
referred and instructions if any, followed.
4.3 FANS (FORCE DRAFT & INDUCED DRAFT)
For erection and installation of fans, Vendor's manual/instructions must be
followed. After proper installation and erection, following pre-commissioning
checks are to be carried out:
 Ensure fan casing is cleared of debris and/or tools.
 Inlet cone clearances checked.
SHT 19 OF 72
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Non-drive and Drive end expansion clearances checked.
 Fan coupling alignment checked.
 Bearing cleaned and flushed of debris.
 Bearing reservoir has complete quantity of lubricating oil.
 Seal housing clearances checked.
 Coupling packed with recommended grease.
 Recommended lubricating oil/grease for bearing is used.
 Check impeller for rotation in correct direction.
 Rotate fan shaft to ensure freedom of movement.
 All the access doors are properly closed/ sealed.
 Check to be done to ensure proper erection of the Fans properly aligned. Other
instructions provided in fan vendor’s manual to be followed.
 Check all electrical connections are in accordance with the manufacturer's
instructions.
 Operating instructions as given by the fan vendor in their manual should be
strictly followed.
4.4 SOOT BLOWERS
Soot Blowers are electrically operated retractable type. Soot blower instruction
manual is comprehensive and should be referred by operating and maintenance
personnel.
4.5 PIPES/TUBES
All tube ends should be checked to see that fittings are properly attached. It is
advisable to leave header box doors open during start-up to ensure that any leaks
that might result are quickly observed and taken care of.
Tubes should be blown out with compressed air in sufficient pressure and quantity
to ensure tubes are clear and unobstructed for satisfactory flow. Each pass must be
blown independently. Burner piping for fuel gas, fuel oil and pilot fuel gas should
be cleaned first with steam and then with compressed air to remove all loose
deposits, water droplets, and scales. This should be done with burners disconnected
from flanges/unions. Piping of one burner should be cleaned at a time with steam/
air.
Snuffing steam piping and Soot Blower steam piping should be blown out
thoroughly with steam to remove all loose scales and deposits prior to its
connection with the Heater.
If the piping is already connected with system, wedge gap the individual flange at a
time and put a blind gasket toward Heater/ Soot Blower and blow the line with
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they steam. Please note that during steam blowing at one connection, all other
connections should be blinded for effective cleaning.
4.6 REFRACTORY LINING
A) Brick Work
The refractory brick work should be thoroughly inspected and following
conditions of the lining fully ensured:
 All the bricks are intact and in position.
 The brick surfaces are free from cracks and chipped corners.
 Any air setting mortar used for laying the bricks has set properly.
 The expansion joints are free and the filling materials like ceramic fibre
are held intact in the joints.
B) Castable Lining
Inspection of lining should aim at ensuring the following conditions:
 The lining has set hard and is strong.
 No segregation of material on the lining surface is observed.
 The lining is free from all visible void, lamination, loose pocket (honey
comb), cracks (excluding hair-line cracks) etc.
4.7 INSTRUMENTS
All instruments should be carefully checked because it is upon these that a large
part of the Heaters/ APH/ WHB System operation must rely. Flow recorders should
be checked for true readings; thermocouples for reversal of leads; temperature, flow
and pressure control equipment for proper readings. All draft gauge piping should
be properly connected.
4.8 MISCELLANEOUS
The pressure relief doors/explosion doors should be checked and maintained clear
of any obstructions for its proper functioning. Tube supports and guides, peep
holes, access doors, and other mechanical parts should be inspected and checked as
per Heater drawings.
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SECTION - V
HEATERS 010-F-101/201
1145/AVU/C-149
DOCUMENT NO.
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HEATER/ APH/ WHB SYSTEM DRY OUT INSTRUCTIONS
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - V
DRY OUT PROCEDURE
Heater dry out instructions, given below, should be followed for carrying out the
dry out for the Heater.
5.1 PURPOSE
Heater dry-out procedures are utilised as a means of curing Heater refractory before
initial process operation. At the same time, the dry-out period is also used as a
means of checking the operation of certain Heater components such as burners and
such control devices as may be used during the dry-out period.
5.2 DURATION
A 3-5 day dry-out cycle is generally required during which Heater temperature is
gradually increased to the point at which refractory is completely dry. If linings are
excessively wet, then only the pilots should be left alight for a day or two to dry off
this excess moisture. During the dry-out cycle, moisture in the Heater refractory
close to the Burners is evaporated within a very short time. Generally, over a three
day cycle moisture inside the refractory is removed.
5.3 TUBE PROTECTION
During the dry-out cycle, it is customary to circulate steam through all process
tubes in order to prevent over-heating. Steam is only introduced after warm up to
prevent undue condensation and water hammering. The tube metal temperature
should be measured regularly and limited to 350°C for the Hydrocarbon. It is
advisable to pass cooling steam even if the TMT is within the maximum allowable
figure specified in the datasheet.
5.4 START-UP FOR DRY-OUT
Start-up procedures of vendors are to be referred for commissioning of FD fans and
Burners.
For the initial phase of dry-out, only fuel gas should be used when available, to
facilitate control and easy changeover of Burners.
This of course is an opportune moment for testing out the stack damper
mechanism, and any rectification of faults of adjustment should be carried out
before proceeding with the dry-out.
5.5 PURGE FIRE BOX
Before even de-spading fuel lines, the Heater firebox must be thoroughly purged
with steam/air for approximately 30 minutes. Following this purge a gas free test
must be carried out. After the test is proved negative, proceed with the de-blanking
of the fuel gas lines and light up the pilot burner. If there is undue delay in
removing fuel gas line spades or any other delay which prevents the lighting of the
burners, the fire box must be re-purged with steam and retested for gas freeness.
SHT 23 OF 72
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they Never de-spade the fuel lines, particularly fuel gas lines and leave the Heater
overnight with unlit Burners i.e. a delayed or interrupted start-up. If there is any
leak, a serious build up of fuel gas in the Heater can result in explosion
5.6 BURNER VENDOR INSTRUCTIONS
Vendor's standing instructions on lighting Burners and all directions concerned
with Heater firing must be followed in totality and recommendations in this manual
are to be considered complementary to these instructions.
5.7 LIGHTING-UP BURNERS
It is recommended that drying out operation be done on fuel gas as control of firing
will be much easier. When the firebox has been certified "gas free" light all the
pilot Burners and raise the temperature with lighting sufficient main Burners to
bring arch temperature upto 120°C at a rate of 25°C/ hr.
5.8 DRY OUT
Hold the temperature at 120°C for 12 hours (minimum) by lighting-up the Burners
by rotation for heat uniformity and then increase the temperature to 200°C at the
rate of 25°C/ hr. Introduce flow of steam/ air/ N2 through the tubes at 200°C after
making sure that all the condensate has been drained off. Check all Burners,
observe conditions inside the firebox and inspect areas of expansion. Hold at 200°C
for 12 hours.
Following this, increase the arch temperature to 400°C again at 25°C/hr. Hold at
this temperature for 24 hours and repeat checks as above. Increase the flow of
steam if the tube metal temperature is found exceeding maximum temperature
specified in the data sheet.
The heat duty requirement during dry out may not warrant firing of all the Burners
during dry out. Sufficient number of Burners, with good flames, may be fired and
the operation of Burners rotated every 2 hours to maintain uniformity. This shall
not, however, be construed that only 1 or 2 burners may be fired as it may not be
possible to maintain uniform firing.
Before proceeding to the final stage of drying out, check that ample supply of
steam is available to prevent over-heating of the tubes. Increase the arch
temperature at a rate of 25°C/hr to 500°C and hold for 24 hours. Make a thorough
check of the unit during this period and in particular, expansion should be noted
and Damper movements checked.
During dry out, it is advisable to try all instruments and controllers on automatic
control and see that all alarms, warning lights, etc. are functioning properly.
At the end of the 500°C drying out period, reduce the arch temperature at a rate of
50°C per hour and accordingly start reducing the steam/ N2/ Air flow through the
tubes.
When the system is proven satisfactory and arch temperature is around 200°C,
firing can be cut off together with the steam flow through the tubes. Spade off the
fuel lines immediately.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 5.9 During dry-out the outboard Waste Heat Boiler (WHB) & Airpreheater (APH) shall
be taken in line subject to the following conditions:
 Flue gas exit temperature from Cast APH/ Stack shall be sufficiently above acid
dew point of flue gas.
 The tube metal temperature at the cold end of cast air preheater shall not fall
below 145°C.
 Flue gas temperature at the interface of Cast and Glass Air preheater is not
above 240 to 260°C.
The above conditions may be possible only for arch temperature above 400°C. Start
ID fans and slowly regulate the capacity using the Inlet box Dampers, so that a
controlled amount of flue gas will pass through the duct. The bypassing of air may
also be regulated to meet the above conditions.
When it is not possible to maintain the above temperature conditions, by-pass Air
preheater and stop ID fans as per the Vendor's instructions.
5.10 When the firebox is cool enough and entry permits are available, inspect the
refractory for any signs of failure.
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SECTION - VI
BURNER LINES
HEATERS 010-F-101/201
PROCEDURE FOR PRESSURE TESTING OF
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
O1
SHT 26 OF 72
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - VI
PROCEDURE FOR PRESSURE TESTING OF BURNER LINES
This procedure is to be followed for normal start up of the Heaters.
6.1 BURNER TESTING PROCEDURE
In accordance with requirement of Project Specification No. PDRP-8470-SP-0002,
there is need to have a formal Pressure testing of Burner lines before normal
lighting up of Burners can be undertaken for Crude Charge Heaters, AVU Unit,
IOCL Paradip.
This Procedure has accordingly been prepared based on the above referred Project
Specification, discussions with M/S Foster Wheeler/ IOCL and the approved
P&IDs and Control & Shutdown Narrative for the Heaters. Nitrogen is being used
as the testing fluid to provide a safe and secure medium for pressure testing.
6.2 GENERAL
The panel shall have a LAMP TEST push button.
The Local Panel shall accept signals from the plant BMS to energize the lamps.
The panel shall have a lamp to indicate FIREBOX TEMPERATURE LOW when
the temperature at the bridge wall is below 750°C.
6.3 PILOT HEADER / MAIN HEADER LEAK TEST
The system shall include automatic double block and bleed valves to shut off the
pilot gas supply to the heater, and a downstream automatic isolation valve local to
each pilot.
The BMS shall not permit the pilot double block and bleed valves 010-XZV-
1023/1053 & 1054 (010-XZV-1523/1553 & 1554 for Crude Charge Heater 010-F-
201) to be switched to the open & closed position respectively until a successful
leak test has been carried out to confirm that the pilot isolation valves 010-XZV-
1045 A to P (010-XZV-1545 A to P for Crude Charge Heater 010-F-201) & manual
isolation valves of the Main FG are closed.
The leak test procedure shall be as follows:
 Operator initiates a BMS controlled sequence by pressing a button 010-HZS-
1801 (010-HZS-1901 for Crude Charge Heater 010-F-201) on the local panel to
“START PILOT LEAK TEST”.
 The BMS switches Block valves 010-XZV-1055 (010-XZV-1555 for Crude
Charge Heater 010-F-201) in the Nitrogen line to the open position for a limited
period.
 Pressurization period and a restriction orifice allow a quantity of nitrogen to
flow equivalent to the flow through one open pilot isolation valve
 A lamp on the local panel indicates “PILOT LEAK TEST IN PROGRESS”.
SHT 27 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  If the downstream pressure fails to reach the upper set point 0.95 kg/cm² (g)
within the pressurization period (2 mins & adjustable) the BMS switches the
leak test Nitrogen block valve 010-XZV-1055 (010-XZV-1555 for Crude
Charge Heater 010-F-201) to the closed position, a “PILOT LEAK TEST
FAILED” lamp illuminates on the local panel and the test-in-progress light goes
off. The operator must then find the cause of the leak, rectify it and re-start the
test.
 When the upper test pressure is reached within the pressurization period the
BMS switches the leak test Nitrogen block valve 010-XZV-1055 (010-XZV-
1555 for Crude Charge Heater 010-F-201) to the closed position, the test-in
progress light remains on and the depressurization timer starts.
 If the downstream pressure falls below the lower test set point 0.55 kg/cm² (g)
during the depressurization period (2 mins & adjustable) a “PILOT LEAK
TEST FAILED” lamp illuminates on the local panel and the test-in-progress
light goes off. The operator must then find the cause of the leak, rectify it and
restart the test
 Provided the pressure holds above the lower set point during the
depressurization period (5 mins & adjustable) the test has been successful, the
test-in-progress lamp goes off and a “PILOT LEAK TEST CLEAR” lamp
In similar way, leak test of the main FG header is also be carried out. Following
shall be carried out:
1803 (010-HZS-1903 for Crude Charge Heater 010-F-201) on the local panel to
“START MAIN FG LEAK TEST”.
 The BMS switches Nitrogen block valve 010-XZV-1047 (010-XZV-1547 for
Crude Charge Heater 010-F-201) to the open position for a limited period
 Pressurization period and a restriction orifice allow a quantity of Nitrogen to
flow equivalent to the flow through one open main FG manual isolation valve.
 A lamp on the local panel indicates “BURNER LEAK TEST IN PROGRESS”.
 If the downstream pressure fails to reach the upper set point 1.85 kg/cm² (g)
leak test Nitrogen block valve 010-XZV-1047 (010-XZV-1547 for Crude
Charge Heater 010-F-201) to the closed position, a “BURNER LEAK TEST
FAILED” lamp illuminates on the local panel and the test-in-progress light goes
off. The operator must then find the cause of the leak, rectify it and re-start the
test.
BMS switches the leak test Nitrogen block valve 010-XZV-1047 (010-XZV-
1547 for Crude Charge Heater 010-F-201) to the closed position, the test-in
progress light remains on and the depressurization timer starts
SHT 28 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  If the downstream pressure falls below the lower test set point 1.45 kg/cm² (g)
during the depressurization period (5 mins & adjustable) a “BURNER LEAK
restart the test
depressurization period the test has been successful, the test-in-progress lamp
goes off and a “BURNER LEAK TEST CLEAR” lamp illuminates on the local
panel.
6.4 PRE - PURGE
Once Pilot Leak Test followed by Main Leak Test has been successful, then Pre-
purge of the Firebox is carried out. Pre-purge or ventilation of the firebox chamber
and downstream flue gas passages will be a manually regulated operation using air
from FD fans for a period of 15 minutes. The Fans should not be stopped once
started for purging i.e. Fans shall be kept in running condition during Pilot Ignition.
A Field operator will confirm that the pre-purge is complete by checking that the
chamber is free from combustibles using a portable device using the Sampling
Connections for the same.
6.5 PILOT IGNITION
 On completion of a successful leak test the operator is permitted by the BMS to
switch the pilot double block and bleed valves to the open position by pressing
a push button 010-HZS-1802 (010-HZS-1902 for Crude Charge Heater 010-F-
201) on the local panel to “OPEN PILOT BLOCK VALVES”. A lamp on the
panel will indicate “PILOT BLOCK VALVES OPEN” 010-XZL-1007 (010-
XZL-1507 for Crude Charge Heater 010-F-201)
 The Burner pilots can now be ignited manually. One operator will insert the
igniter and initiate the spark while another opens the individual pilot automatic
isolation valve by pressing a PILOT #1 push button on the local panel. Ignition
of the first pilot should be taken up within 10 minutes of opening the Pilot
Block valves & closing the Bleed Valves. The Local Panel operator opens the
pilot isolation valve. The valve shall remain open for 10 seconds (adjustable). If
the pilot flame rod senses the presence of a flame during this time the isolation
valve remains open, otherwise it closes. More than three consecutive attempts
of Pilot ignition should not be attempted
 Lamps on the local panel indicate whether the monitoring system detects
PILOT # 1 ON or PILOT #1 OFF
 When the first pilot is alight the other pilots can each be ignited in the same
manner as the first
 If the BMS does not detect the first pilot flame within 10 mins (adjustable) of
opening the Pilot Block valves & closing the Bleed Valves, it will switch the
pilot double block and bleed valves to the closed & open position respectively
& a new leak test must be performed.
SHT 29 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  When the BMS confirms that all configured Burner pilots are alight it will
permit the burner ignition to be started
6.6 MAIN BURNER IGNITION
 The Main Burner shall be ignited using Fuel Gas (in case sufficient refinery
Fuel Gas or LPG is available) as the fuel and only after then should the Burner
be taken on Fuel Oil firing.
 The system shall include automatic double block and bleed valves to shut off
the main fuel gas supply to the heater, and a downstream manual isolation valve
local to each burner.
 The BMS shall not permit the fuel gas double block and bleed valves to be
switched to the open position until a successful leak test has been carried out to
confirm that the burner isolation valves are closed and all configured pilots are
lit. This is permissive to open FG double block valves.
 The operator can switch the fuel gas double block and bleed valves to the open
position by pressing a push button 010-HZS-1804 (010-HZS-1904 for Crude
Charge Heater 010-F-201) on the local panel to “OPEN FUEL GAS BLOCK
VALVES”. A lamp on the panel 010-XZL-1028 (010-XZL-1528 for Crude
Charge Heater 010-F-201) will indicate “FUEL GAS BLOCK VALVES
OPEN”.
 The burners can now be ignited manually. The burner isolation valves shall be
quarter turn type ball valve or similar, and each shall be located adjacent to a
peep door so that the burner it controls can be clearly viewed whilst operating
the valve. Under no circumstances shall the burner isolation valves be located
so that personnel need to be underneath the heater when operating them.
 The operator will slowly open the burner isolation valve whilst observing the
flame.
 If a flame is not established within 3 seconds of the valve being fully open the
operator shall quickly close it again. Further ignition attempts must not be made
for at least five minutes.
 Once a stable flame is observed the operator may light other burners using the
procedure described above.
 Operator can then take each Burner on Fuel Oil as required after opening the
individual FO/atomizing steam valves 010-XZV-1046/1057 A to P (010-XZV-
1546/1557 A to P for Crude Charge Heater 010-F-201) using push buttons 010-
HZS-9302 A to P (010-HZS-9322 A to P for Crude Charge Heater 010-F-201)
in the local panel 010-LP-101 (010-LP-201 for Crude Charge Heater 010-F-
201).
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NEW DELHI
SECTION - VII
HEATERS 010-F-101/201
NORMAL HEATER START-UP
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
O1
SHT 31 OF 72
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - VII
This procedure is to be followed for normal start up of the Heater.
7.1 NORMAL START-UP OPERATION
The most hazardous periods in the operation of a Heater are during start-up and
shut down. Explosions, for example, will occur if a source of ignition is introduced
into a firebox containing a flammable mixture of fuel and air. It is therefore, vital
that no source of ignition is introduced until the firebox has been purged and
checked to be gas free. The following procedures are designed to avoid this and
other dangerous situations. They should be studied closely and the reasoning
behind each successive step fully understood. It is most important that two-way
communication is maintained at all times between the field operator (at Heater/
WHB/ APH site) and the control room.
When lighting up, shutting down or working on an operating Heater always wear
helmet, gloves and face- shield.
7.2 START-UP PROCEDURE
For the purpose of this manual, it has been assumed that the Heater has been
mechanically completed in all aspects, that the process pressure tests have been
carried out and that the set points for all the alarms and minimum stop positions
have been established according to the design requirements.
All fire and safety equipment must be in place.
7.2.1 Preparation of Heater
 Check Heater isolation, i.e. all blanks are in place.
 Carry out an external and internal inspection of the Heater, checking that all
auxiliary equipment is in place and that there is no oil or extraneous material in
the firebox.
 Check that the Heater Dampers operate freely over their full travel range. Make
sure that the Damper indicators correspond to the actual position of the
Dampers.
 Check the Burners for correct positioning and the gaskets are fitted and in good
conditions.
 Check that all Burner air registers move freely.
 Make sure that purge, snuffing steam and instrument tapping openings are free
and are not covered by refractory or choked with brick dust or rust.
 Brick up access openings and box up the Heater.
 Leave Header box doors open.
 Check that pilot gas, fuel gas and fuel oil systems have no open ends and that
all vents and drains are plugged or capped.
SHT 32 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Check that all fuel valves and cocks nearest to the Burners are shut.
 Check that all instrumentation is complete and provided.
 Check that ignitors are available and tested in a safe condition.
 De-blank and test snuffing and atomising steam systems.
7.2.2 Testing of Fuel Lines
Testing of various Fuel gas and Pilot gas lines shall be in accordance with Section
VI of this document. For Fuel oil lines, testing shall be as mentioned below:
 Connect a nitrogen supply down-stream of the main block valve and isolating
blank in fuel oil line to the Heaters.
 Nitrogen purge through the Fuel Oil lines and each individual Burner in turn.
 Pressurize each fuel system with nitrogen up to the last Burner valve and test
for leaks. Test pressure is 2.5 kg/cm²g.
 De-pressurize to a slight positive pressure (0.3 kg/cm²g) when leak free.
7.3 FD FAN & ID FAN
7.3.1 Fans start-up and stopping
Following procedure should be followed for the starting and stopping of FD fans &
ID fans:
 Prepare sufficient quantity of the right grade of lubricating oil as specified by
the Vendor and supply to the right level. Prepare hydraulic oil and supply it,
when it is needed for auxiliary machines.
 Supply the cooling water, when the water-cooled type bearing box is used.
 In principle, the fan should be started after suction or the delivery damper is
closed completely.
 Confirm the indication of starting conditions completed.
 Rotate the machine in a twinkle to confirm the rotating direction and observe
how the machine stops and confirm that there is no unusual noise.
7.3.2 Operation of fan
 Start the fan.
 If any unusual vibration or noise occurs during starting, stop immediately and
trace its cause.
 Open the suction or delivery dampers gradually after the speed comes up to
normal. It is prohibited to run with the damper closed for a long time, because it
increases the inner temperature of the fan and may result in damage to the fan
or some accident.
SHT 33 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Select such expansion joints that respond to the fan movement and ensure that
their reaction force to the fan is minimum, when they are set on the suction and
the delivery flange.
 The gas temperature should be increased gradually for the high temperature fan.
 In case of extra high temperature fan, confirm the situation of thermal
expansion, because its axis is decided. (see the installation drawing).
a) Axial : The rotor expands to the plane bearing

Expansion from the thrust bearing. The casing
expands from axial expansion axis.
b) Horizontal : The casing expands from the horizontal
Expansion expansion axis.
c) Vertical : The casing expands from the casing
Expansion foundation
7.3.3 Caution during operation

 Record the pressure, capacity, motor current, bearing temperature etc., at certain
regular interval.
 During operation, patrol around the fan at certain regular interval, and check,
measure and record all the parameters, mentioned above and make adjustments,
if needed.
 Inspect the lube oil and hydraulic oil (where applicable) at certain regular
interval, and replace deteriorated oil.
 Pay attention to any abnormal situation in vibration, noise, and temperature rise
of bearing.
7.3.4 Stoppage of Fan
 Switch off the motor of the fan after preventing the blow-back of gas by closing
the suction or delivery damper gradually.
 In case of emergency stop, accident, etc., switch off the mains and close the
valve quickly.
This is only a general guideline for FD & ID Fan operation. Fan vendor’s
Operating manual should be read carefully before starting these equipments. If
there is any deviation in operating procedures as indicated in the foregoing
paragraphs and Vendors manual then later should hold good.
7.4 COMMISSIONING OF THE HEATER/ WHB / APH SYSTEM
7.4.1 Establishing flows through tubes and purging the Heater
 Establish good flows through the Heater tubes in accordance with data sheet.
SHT 34 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Check frequently that instrument flow readings are correct. Water may be swept
forward from various parts of the plant if steaming out or pressure testing have
been previously carried out. Instrument lead lines may be partially filled with
water giving false readings.
 Open the stack or flue gas damper fully. In purging a Heater interconnected by
a common flue duct or stack with other operating Heater, a check must be made
to ensure that the purging operations do not upset the firing of the online
Heater.
 Re-check that all the pilot gas burner valves are tightly shut. Commission steam
tracing on fuel gas lines to the Heater and check that the fuel gas knock-out
drum is free of liquid.
 Open snuffing steam to the firebox or run FD fans and purge the Heater for 15
minutes (minimum) or until fire box become free of any hydrocarbons.
 Test the firebox at representative points for the presence of inflammable gas/
vapour. Use inspection ports.
7.4.2 Gas freeing
Before the fuel line blinds are turned to the open position, the Heater must be tested
and declared "gas free". It is essential to air purge the firebox on all occasions
before lighting any Burner (or re-lighting Burners, for instance after an emergency
shutdown). The air purge should continue for 15 minutes, followed by a gas free
test. When a gas free certificate has been issued, proceed without delay to start the
fuel lines and lighting the Burners. If there is a delay between the gas free test and
lighting of the Burners, the firebox must be re-purged and re-tested. The gas free
certificates should specifically state the length of this delay.
7.4.3 Lighting Pilot Burners
 Refer 6.5 for pilot ignition.
 Do not attempt to light pilot Burners from an adjacent pilot Burner or hot
firebrick work.
 After all the pilots are alight check that the pilots cannot be blown out by
increasing the opening of air registers to the maximum possible. After the test,
reset the air registers to the normal main Burner start-up position.
 At least one pilot burner must be stable and burning satisfactorily before
charging the main fuel gas/ fuel oil line to Burners.
7.4.4 Lighting Fuel Gas Burners from pilot Burners
 Refer 6.6 for burner ignition
 Under no circumstances should gas Burners be lit off from adjacent Burners or
hot brickwork
 Adjust combustion air flow
SHT 35 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Gradually open the Burner gas valve until the Burner ignites from the pilot.
Continue opening the valve until a stable flame is obtained. If at first burner
fails to ignite within five seconds, shut the valve and wait five minutes before
making a further attempt. (Initial failure of the gas to ignite may be due to
residual nitrogen in the system). Adjust air registers for proper flame shape
 Light additional gas Burners as required in the same manner described above
 The fuel gas pressure at the Burner (i.e. downstream of the individual isolating
valves) must be maintained above the manufacturer's specified minimum
required pressure at all times. Failure to observe this may result in flame
instability, the liberation of unburnt gas and a resultant explosion
 Inspect Burner flames frequently and certainly after each increase in fuel gas
flow. Should a Burner flame go out, shut off the gas to that Burner and establish
the cause of flame failure before attempting to relight. Adjust air damper of
burner if necessary, to maintain a bluish coloured flame with a slightly yellow
tip
 When the demand for gas comes within the control range of the fuel gas
controller, gradually open the Burner isolating valves fully, simultaneously
adjusting gas flow to maintain constant heat input. Place the fuel gas pressure
controller on automatic control and maintain Burner light up pressure. Continue
lighting further Burners as dictated by the required rate of warm up until all are
operating at minimum light up pressure. Thereafter increase fuel gas pressure as
required to continue the warm up. Place fuel gas pressure control on automatic
from the control room.
 Wherever possible modern practice is to set air rates at light up to sustain
combustion throughout the warm up period without any further adjustment. The
large initial quantities of excess air provide for better temperature control and
more even temperature distribution. Once the Heater is at operating conditions,
fine adjustments are made to obtain efficient combustion.
7.4.5 Lighting Fuel Oil Burner
 Under no circumstances should attempts be made to light oil Burners from an
adjacent Burner or from hot brickwork
 Check that the correct type of Burner guns have been installed and are properly
positioned within the assembly. Where fitted, set the Burner interlocks to the
fire position.
 Re-check that all individual Burner valves and main supply/ return block valves
are shut and that all drains and vents are plugged or capped.
 Deblank the fuel oil supply/ return lines.
 The fuel oil must be circulating steadily at the required temperature, pressure
and at a sufficient rate of flow. Check that the steam/ electric tracing on the
Heater fuel oil supply system is commissioned and operating satisfactorily.
SHT 36 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Commission the atomizing steam supply to all Burners, then adjust the desired
light up pressure.
 Re-check that the individual Burner oil valves are closed, and that all pilot
Burners are alight and stable.
 For forced draught Burners, open Burner isolating Damper, adjust the stack
damper to obtain the recommended Heater draft through the Heater and set the
fan to provide specified flow.
 Slowly open the main fuel oil supply valve, reset the shut-down valve and
pressurise the system up to the Burner valves and check for leaks, if any. Adjust
the main fuel oil supply valve (such that) to give the recommended fuel oil
pressure at the Burner.
 Open the individual Burner purge steam valve and purge the gun barrel. Close
the purge valve.
 Gradually open the Burner oil valve until the oil spray ignites from the pilot
flame. Continue opening oil to the gun until a stable flame is obtained. Adjust
air registers for proper flame shape.
 Light additional oil Burners as necessary to achieve the specified rate of warm
up. This may require further manual adjustment of the fuel oil control valve. At
the first opportunity open individual Burner valves fully and place the fuel oil
on automatic control. Make final adjustments to the atomising steam supply
pressure and place on pressure controller.
 Inspect the flames frequently. If any one of them is unsatisfactory or goes out,
shut off the fuel, replace the oil gun with a clean one, and re-ignite
7.4.6 Raising Heater outlet temperature
On start up, each Burner, whether it is firing fuel oil or fuel gas may have to be
individually controlled until the flow is sufficient to bring the fuel controller within
its control range (usually greater than 10% of the full scale reading).
The Burner flame must be fully supervised until the individual Burner valves are
fully open and the low fuel pressure alarms are out.
The rate of increase of Heater outlet temperature is usually not greater than 25°C
per hour and the fuel pressure should not be allowed to fall below the minimum
allowable pressure for the type of Burner in use. Other points to be observed are:
 Increase the Heater outlet temperature in small steps and avoid big temperature
peaks.
 Where a Heater is connected to common ducting or stack and the other Heater
is in operation, it may be necessary to adjust the draft of other Heater also, as
the Heater being commissioned warms up. Commissioning of additional
Burners should be spaced out in such a manner, as to give an even heat
distribution in the firebox.
SHT 37 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Inspect the firing conditions frequently. Check that all instrumentation is
working correctly.
 Check each Heater pass outlet temperature after every increase in temperature
or flow through the tubes. All process outlet thermocouples must show a steady,
even increase in temperature.
 If no increase in temperature is evident on all or any one pass, shut-off all main
Burners until the reason for the condition is understood and rectified.
 If firing fuel oil, it may be necessary to adjust the atomising steam pressure to
maintain the specified pressure.
 Continue to increase Heater outlet temperature by adjusting the fuel header
pressure and lighting more Burners. Individual Burner valves should be fully
open unless there is some good reason for pinching down these valves, e.g.
flame impingement. If the Burner valve is pinched, care must be taken that the
fuel header pressure is reduced.
 When the fuel pressure controller is well within its control range, the Heater
outlet temperature control can be taken up by manual operation of the Heater
coil outlet TIC. All temperature increase must be coordinated between the
Heater field operator and the control room operator so that burners can be
adjusted or additional burners lit to hold the fuel header pressure within range
and maintain good firing conditions.
 Switch the coil outlet TIC to automatic once process conditions are reasonably
steady and the instrument is working within its control range.
 During the warming up period frequent checks for leaks from headers, flanges,
etc must be made. The header box doors must not be closed until the heater
outlet temperature reaches the normal outlet temperature.
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SECTION - VIII
HEATERS 010-F-101/201
HEATER SHUTDOWN
NORMAL AND EMERGENCY
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
O1
SHT 39 OF 72
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - VIII
HEATER SHUTDOWN
This procedure is to be followed for shutdown of the Heater.
8.1 GENERAL
During shutdown it is again important to realise that operation should be
maintained on manual control. Therefore, automatic coil outlet temperature
control should not be used during this cycle. Normally, the firing rate on the
Burners is decreased under manual control lowering the process outlet
temperature at a rate of 25°C per hour until the point of approximately 150°C
arch temperature is reached.
At this point, Burners may be turned off, but process circulation continued until
there is no possibility of potential damage to process equipment or tubes. When
all Burners are turned off, spade main fuel gas and fuel oil lines immediately.
Depending on process requirements, keep the process fluid circulating in the
Heater for cooling down to ambient temperature.
On shutdown resulting from an emergency in the Unit other than the Heater, the
procedure is to shut off Burners and flow immediately and continue to steam out.
Local instructions usually cover such occurrences and these must be followed.
On Heater emergency shutdown resulting from such case as tube rupture, closing
the Damper for example, will cause flames to emerge from the Burner and peep
hole openings, thus causing personnel injury and/ or equipment damage.
8.2 NORMAL SHUTDOWN
8.2.1 Detailed Procedure for Normal Shutdown
All pilot gas Burners must be kept in commission until all main fuel gas and fuel
oil Burners are shutdown and the main fuel systems purged. All Burners must be
steam purged. All oil Burner guns must be removed.
Take the Heater coil outlet TIC out of service and place the fuel on manual
pressure control. As the feed rate to the unit associated with the Heater is reduced
to the specified level, reduce the number of main Burners in service so that the
desired temperature is maintained and fuel supply pressure does not fall below
flame stability limits. The shutdown of Burners should be staggered so that the
remaining Burners are spaced to give even firing and heat distribution throughout
the firebox.
The Heater must not be left un-attended during this period and checks must
be made frequently to ensure that pilot Burners remain alight and Burner
firing conditions are satisfactory.
 If the WHB/ APH are in line, gradually open the APH air bypass damper to
avoid exit flue gas being cooled below its dew point in the APH
SHT 40 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  At 400°C Arch temperature or when the Heater duty nears 50% of Design,
both the WHB/ APH are to be completely bypassed and allow flue gases to go
directly to the Stack
 The flow rates through the Heater passes must be maintained above the
minimum specified in the data sheet until all fires including pilot Burners are
shut off.
 When all the main Burners are shut off, close the main fuel gas supply valve
to the Heater. This assumes that the fuel oil supply has been shut down,
purged and guns removed earlier.
 Open all intermediate valves between the main fuel gas supply to the Heater
and the individual Burner block valves.
 Check again that all pilot Burners are still burning satisfactorily, then slowly
open one main gas Burner block valve and burn off gas to depressurise the
system.
 Close the Burner block valve when the flame goes out. Do not leave the
Burner unattended during this operation.
 Check again that all pilots remain alight and burning satisfactorily. Then
slowly open one gas Burner at the farthest end of the fuel gas header until it
ignites and burns all the fuel gas purged out of the system. Take care not to
blow out the pilot Burner and do not leave the Burner unattended during this
operation
 As soon as the flame goes out shut off the Burner supply valve
 Continue purging all lines to individual Burners one at a time until each
becomes free of combustibles
 When all the main Burners have been purged, shut off the purge and
depressurise the system
 Blank off the fuel gas supply to the Heater
 Shutdown all pilot gas Burners except one at the farthest end of the pilot gas
header
 When only one pilot gas Burner remains lit, shut the main pilot gas supply,
allow the single Burner to go out and close its valves
 When the above has been completed the pilot gas system to the Heater should
be isolated and blanked off
At this stage the following checks should be carried out to ensure that:
 All the flames are extinguished
 The main fuel gas system to the Heater is free of gas and isolated with
spectacle blind
SHT 41 OF 72
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HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  The fuel oil system to the Heater is purged clear of oil, isolated with spectacle
blind and the Burner guns are removed from the Heater.
 The pilot gas system is free of gas and isolated with spectacle blind.
 In case of a major Shutdown when Heater Tubes need to worked upon, then
ensure that the Heater tubes have been oil or gas freed.
8.3 EMERGENCY PROCEDURE
8.3.1 Total Flame Failure
Shut off immediately all fuels supplied to the Heater by either tripping all
automatic safety tight shut off fuel valves or closing a main block valve in each
fuel supply line. Fuels supplied include fuel gas, fuel oil and pilot gas (and any
off-gas, if applicable).
 Open up the steam purge to the firebox and header box.
 Complete the valve isolation of the fuel to the Heater by closing the main
block valves and then all the individual Burner valves in each fuel supply
system.
 Continue steam purge for at least 30 minutes then shut off all steam and allow
it to clear from the Heater.
 Where forced draft fan is used for purging instead of steam, operate the fans
for the specified time.
 Inspect the Heater floor for oil and arrange for a gas test to be carried out on
the firebox through inspection doors, at high and low locations.
If the gas test shows the presence of an explosive mixture, the purging must be
repeated and gas tests carried out. If further gas tests show the continued presence
of combustibles, the cause must be found and rectified immediately.
The Heater can now be restarted as per the Start-up Procedure as explained in
Section VII.
8.3.2 Flame failure where pilot Burners remain alight
 Trip the automatic main fuel shut off valves or close the main fuel supply
block valves.
 Close all the individual valves to main Burners.
 Where automatic safety shut off valves in the fuel lines to the Heater have
tripped shut, they may now be reset open. (Never attempt to reset safety shut
off valves until all individual Burner isolating valves have been shut, and the
cause of the trip rectified).
 Check that all pilot Burners are burning satisfactorily.
 Re-light main Burners from pilot Burners in the approved manner and as
process conditions permit.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 8.3.3 Failure of individual Burners
 Close the fuel supply valve to the Burner affected.
 Check and rectify the cause of the failure.
 Check the pilot Burner to the failed main Burner and if burning satisfactorily,
relight the main Burner from the pilot in the approved manner.
 Should both the individual pilot and main Burner flame be out, both the pilot
and main Burner valves must be closed immediately.
 Relight the pilot Burner using an igniter in the approved manner and when the
pilot is burning satisfactorily, re-light the main Burner.
 Where igniters are not fitted, the Burner should be relit using an ignitor
designed for that application.
8.3.4 Failure of Pilot Burner Gas Supply
 Close the pilot gas supply main block valve
 Close all individual pilot Burner valves
 Establish the cause of failure and rectify
 Re-open the main pilot gas supply valve after following the proper Start-up
procedure
 Re-light pilots using the approved igniter
While the pilot Burners are off, the main Burners must be closely supervised
by the operator.
8.3.5 Liquid carry over into the Firebox
Flammable liquid can inadvertently enter the firebox from the fuel gas systems or
due to a faulty fuel oil Burner.
A substantial carry-over will cause a large uncontrolled fire in the firebox that
may spread outside and underneath the Heater.
In this event this happening immediately shut off all these fuel sources from a
safe distance, but leave the pilot Burners in operation if the pilot gas system is
free of liquid. Immediately establish the cause of the carry-over, e.g. high level in
knock out drums or separators and rectify at once.
Consider whether other Heaters are likely to be affected if the liquid carry-over is
from a common fuel gas main and take immediate preventive action.
The choice of whether to continue fuel oil firing or not will largely depend on the
extent of the carry-over, the temperature generated within the Heater by the
burning liquid carry over, the possible external damage to Burner assemblies,
control cabling and instruments in the vicinity. Do not continue oil firing if
combustion is occurring within the windbox or Burner chambers.
SHT 43 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they Once the emergency has passed, and before resuming fuel gas firing, ensure that
all liquid is thoroughly drained from the affected lines (draining must be to a safe
system and location; do not run off to surface drains in the vicinity of the Heater).
A large uncontrolled fire in a firebox may be due to either a ruptured tube or
liquid carry over, action should be taken appropriately.
8.3.6 Heater Tube Failure
In general, when tube failure occurs, the following actions should be carried out
immediately:
 Open snuffing steam to headers and firebox.
 Shut off all fuels including gas.
Prior knowledge of the fuel system and location of various isolation valves is
very essential to handle this type of emergency because the intensity of the
fire may be such that isolation of the Heater becomes necessary through the
isolation valves on fuel lines located at a safe distance.
 Stop the FD fan.
 Shut the drop out doors (if these are open) to isolate the combustible. Do not
close the Damper in stack.
The manner in which the leakage from the tubes into the firebox is dealt with will
depend on the process, the location of the leak and the isolation and blow
through/ blow down facilities provided. Effort must be directed to reduce air, stop
the flammable material feeding the fire by isolation, de-pressurising the tube side,
pumping out associated equipment or blowing through tubes.
8.3.7 Failure of operating FD / ID Fan
FD/ ID fan failure can occur due to any of the following reasons:
 Failure of coupling
 Failure of electric power
 Failure of fan motor
 Failure of capacity/pressure control
 Failure of any other mechanical part
Failure of FD fan capacity/pressure control will make fan control inoperable,
which must be detected by regular monitoring of operating parameters. Alarms
should sound when any of the parameter exceeds safe value.
8.3.8 Low Flow in Heater Coil / High Temperature of the Process Fluid at outlet
In case of low flow of process fluid through heater coil or high process fluid
temperature at Heater outlet, fuel supply to Heater cuts off automatically.
8.3.9 Low pressure in fuel supply line
In case of low pressure in fuel supply line, fuel supply cuts off automatically as
per the set point of low pressure switch of individual fuel.
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SECTION - IX
HEATERS 010-F-101/201
OPERATING INSTRUCTIONS
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
O1
SHT 45 OF 72
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - IX
9.1 GENERAL
Proper operation of any Heater is important since poor operating techniques can
result in injury to operating personnel, pose a danger to the adjacent equipment
and endanger the life and limbs of the other staff or visitors in the neighborhood.
It can also result in unnecessary shutdown and reduction in life of the equipment.
If the Heater run is ended at an unscheduled time, the loss of production can
result in a substantial financial loss.
In addition, improper operation of the Heaters/ WHB/ APH System can result in
reduction in the life of fundamental parts of the Heater and excessive wear on
Heater tubes can give rise to a dangerous situation. If a few basic simple rules of
operation are observed, Heater should give long and satisfactory service.
Of course, many variables including the service of the Heater play important roles
in the operation and life of the Heater. Coking or cracking service or other similar
high temperature and sensitive operating conditions will limit both the life and
run-length of the Heater.
However, with proper operation, the on-stream time (run length) and the
equipment life will be kept to a maximum. The conditions below should be
followed as closely as possible.
9.2 FIRING CONDITIONS
The Heater should be fired so that at no time flames impinge on the tubes. The
Burners should be operated to provide flames, which are as uniform in length and
size as can be obtained. It is normally desirable to fire all Burners even when
running at reduced capacity to ensure a uniform heat distribution to all tubes.
Excess air required for satisfactory combustion of fuel is normally 20% for fuel
oil and 15% for fuel gas firing in case of balanced/ forced draft burners. The
amount of excess air should be measured at the bridge wall or where the flue
gases enter the convection section.
It is possible to operate the Heater at excess air below 15-20% as specified and it
may, in fact, be desirable since this will increase the efficiency of the Heater.
However, a gas analysis of the flue gas should indicate that no carbon monoxide
is present (for cross checking).
If a gas analysis does indicate carbon monoxide, the excess air must be increased
to ensure complete combustion. With carbon monoxide, harmful after-burning
may result which would be indicated by a rapid increase in stack temperature.
Immediate steps should be taken to correct this, since its continuation can result
in severe damage to the stack metal and upper structural members. This may be
done by first reducing the firing rate, then increasing the air rate and then
increasing the firing rate to the desired amount. If this does not improve the
SHT 46 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they situation, the rate of firing should be cut back substantially until after-burning
ceases before the rate is increased.
If a total fuel gas failure occurs, the gas pilots and gas Burners should be
shutdown and the Heater purged for 15 minutes with steam/ running of FD fan
before the firebox is checked as gas free and the pilots and Burners are relit.
Repeat the procedure if the gas test shows presence of an explosive mixture.
9.3 DRAFT
The Burners require sufficient draft to meet the heat liberation requirements of
the Heater and only sufficient excess air quantity to optimise efficiency.
To minimise air leakage in the firebox minimum draft (negative pressure) is to be
maintained. Draft is measured at the arch of the radiant chamber and should under
normal circumstances be kept at 2.5 mm WC. This is necessary to ensure that in case
of a leak cool ambient air flows into the Heater, rather than hot flue gases coming out.
There should never be a case when a positive pressure exists at the arch. In the
case of an emergency when the arch pressure tends towards positive value, the
stack Damper should be opened immediately through winch and cable, if it fails
to open through safety interlocks.
9.4 FLOW
Maintenance of adequate flow through Heater tubes is important to prevent tube
damage. However, total Heater flow is not the only criterion. Extreme care must
be exercised to be certain that equal flow distribution is established to all passes
throughout the life of it.
Many operators will adjust flow to one or more passes by means of flow
controllers in order to maintain the same pass outlet temperature. This can be a
very dangerous procedure unless certain precautions are taken. Before any
adjustment in the flow to each pass is made, all Burners must be first trimmed to
ensure identical firing rates. If adjustment of Burners does not result in even pass
outlet temperature, some variation in process flow to each coil can be tolerated.
However, as a general rule, no more than 5% variation between the flow in each
of the passes should be allowed. Flow through the tubes should not be allowed to
fall below the minimum required as per design.
9.5 PEEP DOORS
The peep doors should be tightly closed to prevent air ingress which will result in
a decrease in the system thermal efficiency. In addition, uneven distribution of air
infiltration will result in more cooling of one area than the other areas. Thus a
variation or imbalance of heat transfer to different coils will result.
9.6 BURNER OPERATION
When the firebox is clear and does not have a smoky appearance, Burner flames
are steady and well shaped. This indicates that air supply to the Heater is properly
controlled.
SHT 47 OF 72
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they In forced draft gas Burners, it is better to use more primary air and minimise the
use of secondary air to get shorter and more compact flames. A rapidly pulsating
Burner can be cured by increasing primary air and for oil firing, flame lift can be
overcome by reducing differential pressure between oil and steam slightly.
Clinker formation on Burner guards is due to impingement of flame on unburnt
oil droplets and will interfere with flame pattern. Therefore, it must be removed
otherwise firing conditions will deteriorate even further. The impingement
normally may run down the Burner block and collect in the Burner. The best way
to remove the clinker is to burn-off by firing the Burner on gas and
commissioning atomising steam only through the oil gun.
Burners should be checked regularly for any signs of blockage or unusual flame
conditions. If there is any doubt about the quality of flame from an oil Burner,
shut off that particular Burner and clean/replace oil/gas tips before putting it back
in operation.
If desired turndown is not achievable with all Burners firing, some Burners may
be turned off so that firing Burners have a stable flame and operate satisfactorily.
However, it must be ensured that Burners be shut off judiciously ensuring that
heat distribution remains uniform throughout the firebox.
All the Burners should be in operation even during Heater operation at lower
than normal loads to avoid uneven heat distribution in firebox.
Pilot Burners should be kept running all the times as these are essential part
of the Heater safety system.
Some indication of faulty Burner operation and their probable causes and
corrective actions are as follows:
INDICATIONS PROBABLE CAUSE CORRECTIVE ACTION
Bad flame * Overfiring, insufficient air * Increase combustion air flow and
appearance, * Fouled or damaged burners avoid substoichiometric
smoky stack * Incorrectly set air registers combustion
* Too low steam pressure * Check Burner tip for correct
* Too low fuel temp. location, damaged condition
* Incorrect Burner tip location * Check fuel pressure and temp. to
ensure fuel oil viscosity of 25
cSt at Burner tip
* Check steam pressure
Flames lift * Combustion air flow too high * Reduce combustion air
* Atomizing steam flow too high * Maintain fuel oil viscosity
* Oil temperature too high below 25 cSt (max) at Burner
tip.
SHT 48 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they Clinker/ hard * Incorrect oil gun location * Reset Burner tip/gun
coke build-up on * Fuel oil temperature low * Correct Burner tip location
quarl, primary * Atomising steam flow too low * Increase fuel oil temp.
block fuel gun * Wet atomising steam * Increase atomising steam flow
and temperature
* Ensure dry steam with min
20°C superheat
* Atomising steam quantity
0.20-0.4 Kg/kg fuel
Sparklers in the * Atomising steam temperature * Increase steam pressure
oil flame low * Increase fuel oil temperature
* Steam pressure too low * Increase atomising steam
* Oil temperature too low temp. to get min 20°C
* Wet atomising steam superheat
20°C superheat
* Maintain fuel oil viscisity
below 25 cSt
*Organize a structured
maintenance schedule for
cleaning burner oil tip,
oil/steam filter
Airpreheater * Firing of heavy & dirty fuel * Improved water washing
fouling * Inadequate washing arrangement implemented in
new design
* Proper washing frequency
Instrumentation * Improper maintenance of * Periodic calibration and better
instruments/ controls and house keeping
analysers
9.7 ROUTINE INSPECTION
The Heater must be inspected at regular intervals. Inspection of firebox must be
carried out carefully utilising all inspection/ peep doors to enable a complete
examination of Heater tubes and Burner flames. Particular attention must be paid
to the following points:
 Individual pass flow
 Heater pass outlet temperature and skin temperature
 Heater firebox temperature
 Burner flame appearance and size
 Heater tube appearance and movement
 Free movement of vertical Heater tube guides through the Heater floor.
 Condition of refractory and tube hangers. Any abnormality should be reported
immediately to the proper authority.
 Airpreheater inlet and outlet temperature
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 9.8 ROUTINE TESTING
All emergency shutdown and alarm systems must be checked at regular intervals.
When the plant is shutdown, the Heater emergency systems should be checked,
the fuel shutdown valves checked for tightness and the results recorded.
Regular testing of all burners should be carried out to ensure that the flame
stability has not deteriorated due to natural wear and tear of the equipment, and
that fuel pressure alarm settings are correct for the type of Burner used.
Following procedure is to be followed:
Ensure a draft of (-) 2.5 mmWC at Arch. Slowly close the individual Burner
isolation valve until the flame becomes unstable and note the fuel pressure
downstream of the isolation valve (i.e. pressure at the Burner). This pressure
should be lower than the low pressure alarm set point. If the oil Burners are on
differential steam/ oil pressure control then individual Burner steam pressure can
be turned down to suit the oil pressure.
The following points must be observed:
 The tests should be carried out under strict supervision ensuring that all pilot
Burners are firing correctly.
 Burners must be tested one at a time and a test pressure gauge installed at the
burner.
 Faulty Burners must be removed from service, repaired and retested.
 The tests should only be carried out when the heater load is at least 60% of
normal operating load.
 As soon as the Burner shows sign of instability, the isolation valve must be
slowly reopened.
 The fuel low pressure alarm set point should be set above the instability
pressure.
 A record should be kept of all tests undertaken.
When possible the gas Burner tests should be carried out when fuel is at different
values of the molecular weight range, and in all cases the tests must be related to
the analysis of the fuel.
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SECTION - X
HEATERS 010-F-101/201
1145/AVU/C-149
DOCUMENT NO.
AIRPREHEATER OPERATING INSTRUCTIONS
O1
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REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - X
These instructions are based on the assumption that air and flue gas are uniformly
distributed at the inlet flanges and throughout the Airpreheater.
10.1 Design Data
Design data specifying the performance of the Cast/ Glass Tube Airpreheater at
Design conditions shall be as per the equipment datasheet.
10.2 General Description of Cast Tube Airpreheater
The cast tube air preheater is an assembly of rectangular cast tubes. The heat
exchange surface is made up of hot end and cold end sections. The cast iron tubes
in hot end have integral fins on both internal and external surfaces. Tubes in cold
end have integral fins only on the outside surfaces.
The entire tube assembly is built inside a steel frame made by beams and fully
insulated casings. Flue gas and air terminal connections are made of rectangular
flanges formed from rolled steel sections and forms an integral part of the air
preheater frame. The entire Airpreheater assembly can be considered as part of
the ducting system because of its general arrangement.
The tube is made up of two half sections, cast independently and then bolted
together. To prevent air leakage in the longitudinal direction ceramic ropes are
placed on the tube flange before bolting. The flanges provide the necessary gap
for the flue gas passage. The flanges also have peripheral grooves on all four
sides to accommodate asbestos rope to ensure all tightness between adjacent
tubes.
The cold end bank is placed at the cold end of the APH as the lowermost rows/
pass of the Cast iron tubes. All the modules of the APH are connected with air
return headers to make the APH multi-pass on the air side. The APH thus behaves
as a true cross-current flow heat exchanger.
Flue gas enters at the top of the hot end and flows vertically down over the
outside of tubes and leaves the Air preheater at the bottom of the cold end. Air
enters the Air preheater at the side of the cold end and flows first through the cold
end tubes. On leaving the cold end the air is turned through 180° and flows
horizontally through the hot end tubes of the Air preheater. The flue gas in is a
single pass, which flows vertically down from top to bottom and the air is on
single or multiple passes, as the case may be.
10.3 General Description of Glass Tube Airpreheater
The glass tube air preheater is an assembly of round temperature resistant boro
silicate tubes. The heat exchange surface is made up of these bare tubes which are
fixed inside tubesheets using appropriate Teflon/ PTFE bushes. These bushes
permit sealing of the tube to tubesheet gap so that minimum leakage of air occurs
into the flue gas side.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they The tubesheets are themselves lined with Teflon to avoid acid dew point
corrosion. The glass tube bank is placed below the cast tube bank (with flue gas
flowing downwards and air flowing sideways from the glass bank to the cast tube
bank).
Normally only one pass of the glass bank is adequate to permit low level heat
recovery while ensuring that the tube metal temperature in the cast tube bank is
still maintained above the minimum metal temperature specified for the type of
fuel/ excess air being used in the Heater.
10.4 Commissioning Instructions
Commissioning procedure for an Airpreheater has to be formulated considering
the process Heater it is going to serve and the overall system conditions. The
instructions mentioned here for commissioning assistance are meant for the
general safety of the Airpreheater equipment alone.
To avoid fouling and corrosion of the heat exchange surface it is recommended
that the heat load be brought upto design conditions as early as possible. This
procedure is aimed at rapidly elevating the cast iron tube wall temperature above
the acid dew point to minimise acid condensation on the cast APH tube surfaces.
It is to be noted that the air bypass may be necessary during winter/ turndown
conditions. The user shall review the actual quantity to be bypassed considering
the other equipment in the system like Dampers, Heater etc.
However, it is recommended that under no circumstances the flue gas exit
temperatures be allowed to go below the recommended values and the air bypass
may need to be adjusted accordingly to avoid acid condensation under all
operating conditions and special care need to be taken when the Airpreheater is
taken on line. The tube skin temperature on the last row of tubes in the cast APH
section should be monitored closely and should be kept atleast 10°C above the
dew point of the flue gases.
10.5 Maintenance During Operation
Due to the tubular construction of the cast fin air preheater there are neither
extensive flat surfaces, nor small ducts or no flow zones. The whole working
surface is swept by the flow of flue gases thus preventing soot deposit.
Since the flue gas is only cooled in cast Airpreheater to a point where the
minimum tube wall temperature is still safely above the acid dew point, there is
no condensation on the flue gas side surfaces and hence no sticky deposits. No
frequent cleaning of the tubes is therefore required during normal operation.
However some soot deposition does take place due to abnormally poor
combustion in the heater and for the safe operation, it is recommended to monitor
the flue gas pressure drop and when this approaches the limit of ID Fans capacity,
the Airpreheater should be taken out of line and washed.
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Washing of Airpreheater has to be done by taking it off line. Vendor’s
instructions for carrying out the washing of the APH should be followed
thoroughly. A separate washing arrangement is provided for the Cast tube &
Glass tube banks of the APH.
Commissioning, Maintenance and Washing Instructions above are general only
and vendor’s instructions with regard to above must be followed thoroughly. In
case of any contradiction, vendor’s instructions shall overrule these general
guidelines.
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SECTION - XI
HEATERS 010-F-101/201
WASTE HEAT BOILER & STEAM DRUM
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
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REV.
SECTION - XI
WASTE HEAT BOILER & STEAM DRUM OPERATING INSTRUCTIONS
These instructions are based on the assumption that boiler feed water supply to steam
drum is un-interrupted and the flue gases are uniformly distributed at the inlet flanges
and throughout the Waste heat boiler.
11.1 Design Data
Design data specifying the performance of the Waste Heat Boiler / Steam Drum
at Design conditions shall be as per the equipment datasheets. The Waste heat
Boiler package includes the following:
 Boiler section (Evaporator)
 Steam drum & Safety relief valves
 Instrumentation & Controls
 Boiler piping which includes risers & down comers, blow down valves etc
 Other Valves & fitting
 Common Phosphate dosing package for CDU & VDU Heaters
 Soot Blowers for Waste Heat Boiler
11.2 General Description of Waste Heat Boiler
The Waste Heat Boiler (WHB) is an assembly of carbon steel tubes with inlet and
outlet headers also of carbon steel. These carbon steel tubes have integral fins.
The entire assembly is built inside a steel frame made by beams and fully
insulated casings with Header boxes for return bends. Flue gas terminal
connections are made of rectangular flanges formed from steel sections which
form an integral part of the WHB. The entire WHB assembly can be considered
as part of the ducting system because of its general arrangement. Two down-
comers from the Steam drum are connected to the inlet header of the WHB and
three risers from outlet Header of WHB are connected to the Steam drum. The
WHB is of water tube type with natural thermo-syphon water circulation.
The Flue gas is a single pass which enters at the top of the hot end and flows
vertically down over the outside of finned tubes and leaves the WHB at the
bottom of the cold end. Water from Steam drum through down-comer pipes
enters in the inlet Header of WHB at the side of the cold end and flows first
through the cold end multiple pass tubes. On leaving the cold end the steam-water
mixture is turned through 180° and then it flows horizontally through the hot end
tubes and enters in the outlet Header of the Waste Heat Boiler. Steam-water
mixture from the outlet Header through riser pipes enters in the Steam Drum. 6
Nos. of Soot Blowers have been provided for outside cleaning of finned tubes.
Soot Blowers are electrically operated retractable type. Soot Blower Instruction
manual is comprehensive and should be referred to by the operating and
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they maintenance personnel. Requisite Dampers/ SOBs have been provided at the inlet
and outlet of the WHB for isolation as and when required.
11.3 General Description of Steam Drum
The Steam Drum is fabricated from boiler quality plate and is mounted
horizontally on a supporting structure having platforming all around for ease of
operation/ maintenance. Hemispherical dished ends alongwith Manway have
been provided at each end of Steam drum. The Steam drum has a Design Pressure
of 19 kg/cm²(g), Design Temperature 350°C and Steam flow rate of 18.7 TPH.
2 Nos. of Pressure Safety valves with set pressures of 18.5 kg/cm²(g) &
19kg/cm²(g) have been provided on the Steam drum. The Steam drum internals
consist of a vortex breakers, demister pad etc.
The Steam drum has been provided with the following nozzles:
 Feed water Inlet
 Riser
 Down comer
 Chemical feed
 Continuous Blow down & Intermittent Blow down
 Steam Outlet
 Vent
 Instrumentation nozzles
Commissioning procedure for WHB has to be formulated considering the
operating cycle that the main Heater is going to serve and the overall system
conditions. The instructions mentioned here for commissioning assistance are
meant for the general safety of the WHB alone.
To avoid fouling and corrosion of the heat exchange surface, it is recommended
that the heat load be brought upto design conditions as quickly as possible.
The Steam drum level should be maintained at the center-line of the Steam drum.
Some soot deposition does take place on the heat transfer surface of the Boiler.
Regular soot blowing operation should be carried out to remove the deposited
soot on the heat transfer surface.
Apart from continuous blow down from the Steam drum to maintain the quality
of water being re-circulated in the WHB tubes, intermittent blow down operation
should be carried out regularly to drain out the slug/ sediment from the steam
drum to avoid build-up of impurities in the Steam drum.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 11.6 Chemical Dosing Procedure
The desired pH value of the steam produced in Steam drum is ensured by
chemical/ Phosphate dosing system. The Phosphate Dosing system includes a
dosing tank with a capacity of 860 liters, 3 Nos. Metering pumps with motors out
of which two are running and one standby. Necessary instrumentation/ valves
have been provided to ensure proper operation of the Dosing system. Vendor’s
instructions for carrying out the chemical dosing should be followed thoroughly.
Commissioning, maintenance and chemical dosing Instructions above are general
only and vendor’s instructions with regard to above must be followed thoroughly.
In case of any contradiction, vendor’s instructions shall overrule these general
guidelines.
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AND
SECTION - XII
HEATERS 010-F-101/201
ISOLATION FOR SAFE ENTRY
PROCEDURE FOR GAS FREEING
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - XII
PROCEDURE FOR GAS FREEING & ISOLATION FOR SAFE ENTRY
When it be necessary to enter a Heater firebox for inspection or repair, the
following steps must be carried out after completion of normal shutdown
procedure:
 Open wide the stack Damper and all primary and secondary air registers.
 Open snuffing steam to the firebox and purge or use forced draught fans for
specified period. Carry out gas test to ensure proper purging.
Isolation by spectacle blinds on the firebox side of the Heater must include:
 Fuel oil lines
 Fuel gas lines
 Pilot gas lines
 Atomising steam lines
 Snuffing steam lines
Check that all purge connections to fuel gas headers have been disconnected.
Where the Heater shares a common stack with other Heater, close the Damper in
the flue ducting. In this case open the inspection/ entry doors in the upper section
of the Heater to provide continued ventilation.
Following complete isolation permission may be given to enter the Heater
provided that:
 The Heater is adequately ventilated
 The Heater is tested and certified gas free and tested for oxygen deficiency
 The Heater has cooled sufficiently to allow personnel to enter
The procedure does not cover the gas freeing and isolation of the tube side of the
Heater which will form part of the associated unit shut down procedure
Instructions given above are general in nature and procedures/ instructions of the
Safety Department of the operating refinery should be adhered to in letter and
spirit.
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SECTION - XIII
HEATERS 010-F-101/201
MAINTENANCE INSTRUCTIONS
PECL/C-908/
1145/AVU/C-149
DOCUMENT NO.
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REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - XIII
13.1 GENERAL
Preventive maintenance of Heaters/ WHB/ APH System should be carried out
regularly and as per a fixed program. This should be a result of regular inspection
during operation at which time the extent of general damage and deterioration
may be visually determined. It is important to have a regularly scheduled
shutdown to make a detailed mechanical inspection and to repair or replace any
auxiliary equipment that does not meet the minimum requirements.
If equipment breaks down during normal run time, unnecessary delays due to
unavoidable maintenance as well as possible dangerous conditions may result.
The very nature of the service required of a Heater makes proper maintenance of
the component parts essential.
Visual inspection of Heater should be performed on a frequent schedule and
particular emphasis placed upon the tubes, fittings and setting. It is these three
items that are generally considered to receive the greatest amount of wear during
the normal operation of the Heater. Any flame impingement and hot spots should
be noted and the exact location recorded. In addition, any indication of tube
bowing or refractory surface cracks should be recorded.
Operating instruments should be checked to assure proper functioning. The
thermocouples in particular should be carefully checked. Any improperly
operating piece of equipment should be reported and repairs be carried out
immediately.
The operating data of the Heater for the inspection period should be assembled
and compared. The flow and temperature information on the Heater charge
should be available for calculation of the Heater duty. The temperatures for each
pass in the Heater should also be obtained. In addition, the firebox and flue gas
temperatures, the fluid and fuel pressures and the draft in all sections of the
Heater should be measured. An Orsat analysis should be made of the flue gas
composition to find out the amount of excess air. Any unusual changes in
operating loads should be checked by means of the Heater log sheets.
The entire record including operating, inspection and maintenance results should
be summarized in a report for each inspection period. This may result in
unexpected problems and indications of unusual, significant changes from
previous inspection reports.
The Heater operational information should then be checked with the design
condition of the Heater to determine the cause of these results and immediate
corrections then made if the reports suggest faulty or dangerous operation.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they Some indications of faulty operation of the Heater/WHB/APH system are as
follows:
S. NO. INDICATIONS PROBLEM CAUSE CORRECTIVE ACTION
1. Positive pressure at * Stack Damper excessively * Open stack damper to maintain
top of firebox (Arch) closed (-) 2.5 mmWC pressure at Arch
* Excessive firing rates * Reduce firing rate and rectify air
* Excessive fouling or leakage points
blockage of convection * Carry out 'ON-LINE' tube cleaning
section * Water wash Airpreheater
* Problem in ID fan * Check ID fan operation/capacity
2. High/ Uneven tube * Overfiring; flame * Trim Burners to achieve uniform
skin temperature impingement firing rates
* Unbalanced Low process * Adjust process fluid flow
fluid flow * Reduce fuel firing rate
* Excessive firing * Decoke Heater coils
* Coking in side Tubes * Check skin thermocouple
* Wrong/ detached
thermocouple
3. Excessive * Overfiring * Check process fluid inlet temperature
temperature in * Excess air too high * Analyse fuel composition
firebox/ leaving the * After burning * Check burner tips/ burner design for
Heater * Heat release too high fuel fired
* Reduce fuel firing
4. High fuel * Incorrect combustion air * Limit excess air to: Fuel gas: 5-15%,
consumption Flow Fuel oil: 10-20%
* Dirty or blocked Burners. Remember every 5% increase in
* High Excess Air excess air reduces Heater efficiency
* Fouling of Tubes by 0.4%
* Plug leakage through peep hole and
reduce combustion air flow through fan
* Ensure uniform combustion air flow
through each Burner
* Carry out flow modeling of air duct,
if required
* Organise structured maintenance
schedule for cleaning Burners & tubes
5. Variation in outlet * Unequal flow distribution * Reduce fuel firing rate
temperature of * Uneven firing * Adjust process flow through each
multipass Heater * Uneven firing pass to ensure variation in flow is
within 5%
* Avoid two phase flow at Heater
inlet
6. High pressure drop * Coke build-up * Decoke Heater coil
through tubes * High flow-rate * Reduce process flow rate
* High vaporization rate/ * Check feed composition
excessive fouling
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follows:
7. Low pressure drop * Low flow rate * Increase process flow rate
through tubes * Change in Heater inlet/ * Check feed composition
outlet conditions
8. High flue gas * External fouling of * Decoke the Heater periodically
temperature ex- Convection tubes Remember every 20°C increase in
convection bank * Coking / fouling of inside flue gas temperature reduces
of radiant tubes Heater efficiency by 1%
9. Corrosion in Heater * Fuel ash & acid dew point * Check fuel oil composition for
tubes, support corrosion sodium, vanadium and sulphur
castings
The mechanical inspection of the Heater should be generally performed in the
sequence that results in the inspection of the most critical items first.
13.2 REFRACTORY SETTING
The refractory setting provides the enclosure for containing the heat liberated in
the Heater and must protect the exterior structural members that support the coil
tube supports of the Heater. The setting is also important in that the amount of
heat which passes through these walls will affect the thermal efficiency of the
equipment. The prime factors causing deterioration of the Heater settings are
climatic conditions, operating temperature and products of combustion. Damp,
humid atmosphere in the vicinity of the Heater resulting either from geographic
location or location within the plant itself can result in deterioration of the
refractory and insulation. Cracks or openings in the external housing of the
Heater can allow rain or moisture to attack this material particularly when the
Heater is not in operation. The operating temperature and manner in which the
Heater is fired is a major cause of the deterioration of the Heater refractory. At
high temperatures the refractories will deteriorate by spalling as a result of long
time exposure, failure of binding material, melting and loss of mechanical
strength. The products of combustion very often contain sulphur and vanadium. If
cracks or openings are present in the refractory lining, these gases can reach the metal
and the formation of sulphurous acid could result and cause harmful deterioration. In
addition when these ash products and the refractory are in contact at high
temperature, a fluxing action may occur producing a slag that may be
more or less fluid. Vanadium pentoxide is such a fluxing agent, and can result
in the decrease in the refractory thickness and thus the heat insulation with
ultimate result of high temperature of supporting steel structures
The insulating concrete and expansion joints should be carefully checked for
damage from heat, distortion, debris or open joints. The inspection should include
check for breakage, slag formation, crumbling or open joints, any of which, if
allowed to go un-checked can result in damage to the supporting steel from high
metal temperature oxidation and corrosion. The supporting steel for the roof
should be thoroughly inspected and any supports that indicate excessive damage
should be replaced.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they If cracks have occurred and are more than a hairline separation, they should be
cleaned for the full thickness of the material so that the faces of each side of the
opening are parallel to one another for the entire thickness before inserting repair
material. If spalling has occurred, the entire area affected should be replaced.
In the case of castable material care must be exercised to use reinforcing material
tied back to the casing and it is necessary to place one layer of castable on
another. This is important since layers of castable material should be mixed in the
exact proportions and quantities recommended. After initial set they should be
cured for approximately 24 hours by keeping the surface moist or until the time
when the finger can be drawn across the refractory without picking up any moist
material. Without this procedure the surface may crack and become trouble-some.
Occasionally a split tube or firing without charge will result in overheating of the
refractory. The refractory surface becomes plastic and begins to flow. The surface
upon cooling solidifies and forms a hard glazed surface. This is not normally
repaired since this condition does not seriously affect the setting performance.
In the case of mechanical damage to the setting, the refractory affected should be
replaced.
13.3 STRUCTURAL SUPPORTS
A visual inspection should be made of all load carrying structural steel members,
such as, columns, supporting structures, stairways, walkways and roof. If this
inspection indicates any unusual conditions such as deflection or bending in any
members or corrosion, which might result in substantial weakening of the
support, the cause of the trouble should be immediately determined.
Bending or deflection may result from over-loading, over-heating or forces due to
expansion of some element in the Heater. Once the cause of the problem has been
determined, it should be relatively simple to either protect or reinforce the
member so that the condition resulting in the bending or deflection can no longer
affect it.
On members that have corroded, the remaining metal area should be determined
and a check should be made to determine the suitability of the member to perform
its function. If not satisfactory, corrective measures should immediately be taken.
The connection between columns, beams and girders should be checked to see
that bolts are tight and not broken. This should be done particularly where
corrosion is a problem.
13.4 BURNERS
Burners should be checked visually during operation and any changes required
should be made at this time. If mechanical repairs are required, the Burner should
be removed and replaced by a spare Burner (if available) immediately to ensure
proper and uniform firing conditions. A more detailed examination for erosion,
corrosion and oxidation should be made when the unit is shutdown.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 13.5 CLEANING OF BURNER
Ideally there should be tailor-made burner stripping bench and solvent bath
available for Burner cleaning.
13.5.1 Fuel Oil Burners
Normally fuel oil Burners are cleaned by using steam as a cleaning medium on
the Burner cleaning bench. Even after cleaning by using steam, if the
performance of the Burner is not found to be upto the mark, gun should be
dismantled to allow cleaning of the oil and steam orifices. Burner vendor's
instruction for this purpose must be available to the operating and maintenance
personnel.
If steam/ air blowing is in-adequate, use soft copper and bronze wire brush for
cleaning out the holes or removal of carbon from surfaces. Wash all parts in a
suitable solvent. Both steam and oil orifice dimensions should be checked, if
wear is suspected. During re-assembling, proper gasket or O-ring should be used.
Do not allow parts of Burners for some other Heater to get mixed. Also check
gaskets or O-ring on the burner block while putting back the gun again
13.5.2 Fuel Gas Burners
Normally fuel gas Burners require less often cleaning than oil guns. For proper
flame envelope and good combustion, during annual turn-around the spud, central
gas guns and rings must be cleaned. While cleaning gas Burners care should be
taken so that holes are not enlarged. If tips are found to be with oversized holes,
then the tips must be changed / replaced after consultation with Burner vendor.
13.5.3 Pilot Gas Burners
Correctly positioned pilots with a proper flame are one of the most vital safety
devices in a Heater.
During shutdown or turn-around, pilot tips, tip retention jets or orifice holes are to
be cleaned. Any blockage of the tip retention jets may cause flame instability.
Care should be taken so that orifice holes are not enlarged during cleaning.
13.6 BREECHING/ DUCTS/ DAMPERS
Breeching may be visually inspected externally while in operation. The
inspection should give an indication of external oxidation that may be a result of
overheating of the metal after refractory lining has failed. The indication of
overheating and oxidation may mean failure of some part of this lining. The
lining should then be carefully inspected on shutdown.
Bolts and welds should be checked to ensure that they are in good condition. If
the ducts or breechings are painted and flaking or other failure is indicated, the
area affected should be cleaned and re-painted.
An internal inspection should be made on shutdown to determine any damaged
area. If the breeching or duct is un-lined, the metal thickness can be checked for
thinned area by means of the hammer test.
The Dampers should be checked for corrosion and operability with particular
emphasis made around the shaft and linkages of the operating mechanism.
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 13.7 STEAM AIR DECOKING OF PROCESS COILS
Ideally Heaters should be decoked periodically (during Heater shutdown) to
ensure that there is no fouling / coking inside the Heater process coils. Need for
taking the Heater for de-coking can be reviewed based on increased tube metal
temperature, increase in process fluid pressure drop, need for over-firing to obtain
process duty. One Heater shall be decoked at a time.
Due to the nature of the Crudes proposed to be processed and in order to have
flexibility in operation, there is a need felt to have a forward as well as reverse
steam-air de-coking during a planned plant maintenance shut-down. Steam-Air
De-coking Systems for the Crude Heaters have the provision of being Steam-air
de-coked pass by pass or all passes together – whether in the forward or in the
reverse de-coking mode.
The following are the steps for decoking the Heater process coils:
 Once Heater is shutdown completely ensure that there is no process fluid
inside the process coils
 Using the swing elbows disconnect the Heater coils from the process inlet &
outlet piping and connect Heater coils to decoking headers
 Open the MP steam valve to allow de-coking steam to pass through Heater
coils. The globe valve along with Flow element 010-FE-1073A to H (010-FE-
1573 A to H for Crude Charge Heater 010-F-201) provided on the MP steam
line can be used to set the flow through each pass.
 After ensuring MP Steam is flowing through the tubes, start a few Burners to
heat the firebox to at least 500°C.
 Open the Plant air valve to allow Plant air to pass through Heater coils. The
globe valve along with Flow element 010-FE-1019 (010-FE-1519 for Crude
Charge Heater 010-F-201) provided on the Plant air line can be used to set the
flow. Rotameters are provided on each pass of Plant Air for decoking.
 Now gradually increase the Firebox temperature. During initial decoking keep
the air flow at minimum so that the temperature rise due to the burning of the
coke does not lead to overheating of the tube. Then gradually increase the air
quantity to the specified figure for proper decoking of the tubes.
 During De-coking operation, firebox temperature & Skin Thermocouples
readings should be carefully monitored to avoid over-heating of the tubes.
 Once decoking is started, simultaneously open the service water for
quenching of effluents entering into Decoking drum. Ensure sufficient water
is supplied to the Drum using the globe valve on service water line and
Temperature gauge 010-TG-1076 (close to the Decoking drum) on decoking
line to decoking drum
 Also ensure water supply to the spraying arrangement provided inside the
Decoking drum
 During decoking the gaseous waste from the decoking drum shall be vented
to the Stack and unwanted liquid shall be drained out to OWS
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Once the decoking is complete, stop the Plant air to the Heater. Then
gradually start reducing the firing and finally stop all the Burners. Once the
Firebox reaches 400°C, cut off the MP steam supply to Heater coils. Also
close quench water/ spray water to the Drum
 Allow the Heater and connected piping to cool. Then connect the swing
elbows to Process inlet & outlet piping.
 On completion of decoking the removable quick opening type flange at the
bottom of the decoking drum can be used to remove any slug from the drum
 The total MP Steam, Plant Air and Service Water required for Decoking
operation are 48000 kg/hr, 4770 kg/hr and 24000 kg/hr respectively.
 During Decoking operation the followings shall be Set Points of the
Instruments:
P&ID: PECL/C-908/1145/AVU/C-1011/ 2011
TIC – 1067 A to H Individual Pass Coil
High 650°C (Adj.)
TIC – 1567 A to H Outlet Temperature
High 700°C (Adj.)
High 700°C (Adj.)
High 700°C (Adj.)
Individual HC Feed
PAH – 1001/1501 High 8 kg/cm2g (Adj.)
Inlet Pressure
 Note that individual 6" NPS decoking lines from each CDU Heater are
connected to a common 24" NPS header which is feeding decoking effluent to
common decoking drum (010-V-023). Each 6" NPS decoking line is provided
with a manual isolation valve. Further, an isolation blind is provided on the
common header downstream of Heater 010-F-101 and upstream of Heater
010-F-201 (there being no isolation blind on the downstream of Heater 010-F-
201). When Heater 010-F-201 is decoked, the manual isolation valves on
individual decoking lines of Heater 010-F-101 as well as the isolation blind
on the common header shall be closed, and hence, the decoking effluent from
Heater 010-F-201 cannot enter into Heater 010-F-101. Similarly, when Heater
010-F-101 is decoked, the manual isolation valves on individual decoking
lines of Heater 010-F-201 shall be closed. However the isolation blind on the
common header shall remain open. Hence the decoking effluent from Heater
010-F-101 cannot enter Heater 010-F-201. Accordingly decoke Heater 010-F-
101 first followed by decoking of Heater 010-F-201.
SHT 68 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
NEW DELHI
ENCLOSURES
SECTION - XIV
HEATERS 010-F-101/201
1145/AVU/C-149
DOCUMENT NO.
O1
SHT 69 OF 72
REV.
NO. OF
S. NO. DOCUMENT NO. DESCRIPTION
SHEETS
API Datasheet for Crude Charge Heater 010-F-
1. PECL/C-908/1145/AVU/C-011
101
13
API Datasheet for Vacuum Charge Heater 010-F-

2. PECL/C-908/1145/AVU/C-012
201
13
Burner Data sheet for Crude Charge Heater 010-

3. PECL/C-908/1145/AVU/C-014
F-101
5
Burner Data sheet for Crude Charge Heater 010-

4. PECL/C-908/1145/AVU/C-016
F-201
5
APH Data sheet for Crude Charge Heater 010-F-

5. PECL/C-908/1145/AVU/C-020
101/201
6
FD Fans Data sheet for Crude Charge Heater

6. PECL/C-908/1145/AVU/C-022
010-F-101/201
7
Motor Data sheet for Crude Charge Heater 010-

7. PECL/C-908/1145/AVU/C-023
F-101/201
3
ID Fans Data sheet for Crude Charge Heater 010-

8. PECL/C-908/1145/AVU/C-025
F-101/201
7

9. PECL/C-908/1145/AVU/C-026
F-101/201
3
SAPH Data sheet for Crude Charge Heater 010-

10. PECL/C-908/1145/AVU/C-034
F-101/201
3
WHB Data sheet for Crude Charge Heater 010-F-

11. PECL/C-908/1145/AVU/C-036
101/201
4
WHB Steam Drum Data sheet for Crude Charge

12. PECL/C-908/1145/AVU/C-038
Heater 010-F-101/201
5
Soot Blower Data sheet for Crude Charge Heater

13. PECL/C-908/1145/AVU/C-040
010-F-101/201
6

14. PECL/C-908/1145/AVU/C-041
F-101/201
3
Decoking Drum Data sheet for Crude Charge

15. PECL/C-908/1145/AVU/C-044
Heater 010-F-101/201
4
Damper/ SOB Data sheet for Crude Charge

16. PECL/C-908/1145/AVU/C-046
Heater 010-F-101/201
15
Data sheet for Expansion Joints for Crude Charge

17. PECL/C-908/1145/AVU/C-048
Heater 010-F-101/201
2
Data sheet for De-Superheater for Crude Charge

18. PECL/C-908/1145/AVU/C-202
Heater 010-F-101/201
5
Data sheet for Silencer for Crude Charge Heater

19. PECL/C-908/1145/AVU/C-206
010-F-101/201
4
Soot Blower Data sheet for WHB for Crude

20. PECL/C-908/1145/AVU/C-210
Charge Heater 010-F-101/201
6
Motor Data sheet for Soot Blower for Crude

21. PECL/C-908/1145/AVU/C-211
3
Utility Summary for Crude Charge Heater 010-F-

22. PECL/C-908/1145/AVU/C-147
101/201 & Vacuum Charge Heater 010-F-002
4
SHT 70 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
NO. OF
SHEETS
P&ID for Process Section for Crude Charge
23. PECL/C-908/1145/AVU/C-1011
Heater 010-F-101
1
P&ID for Heater Casing & Soot Blowers for

24. PECL/C-908/1145/AVU/C-1012
Crude Charge Heater 010-F-101
1
P&ID for Convection Section LP & MP

25. PECL/C-908/1145/AVU/C-1013
Superheating for Crude Charge Heater 010-F-101
1
P&ID for Firing Section Heater for Crude Charge

26. PECL/C-908/1145/AVU/C-1014
Heater 010-F-101
1
P&ID for FD Fans & SAPH for Crude Charge

27. PECL/C-908/1145/AVU/C-1015
Heater 010-F-101/201
1
P&ID for Air Preheating System for Crude

28. PECL/C-908/1145/AVU/C-1016
1
P&ID for WHB & Steam Drum for Crude Charge

29. PECL/C-908/1145/AVU/C-1017
Heater 010-F-101/201
1
P&ID for Decoking Facility for Crude Charge

30. PECL/C-908/1145/AVU/C-1018
Heater 010-F-101
1
P&ID for Phosphate Injection Package for Crude

31. PECL/C-908/1145/AVU/C-1019 Charge Heater 010-F-101/201 & Vacuum Charge 1
Heater 010-F-002
P&ID for General Notes & Interlock Description
32. PECL/C-908/1145/AVU/C-1020
for Crude Charge Heater 010-F-101
1
P&ID for Process Section for Crude Charge

33. PECL/C-908/1145/AVU/C-2011
Heater 010-F-201
1
P&ID for Heater Casing & Soot Blowers for

34. PECL/C-908/1145/AVU/C-2012
1

35. PECL/C-908/1145/AVU/C-2013
Superheating for Crude Charge Heater 010-F-201
1
P&ID for Firing Section Heater for Crude Charge

36. PECL/C-908/1145/AVU/C-2014
Heater 010-F-201
1
P&ID for Decoking Facility for Crude Charge

37. PECL/C-908/1145/AVU/C-2015
Heater 010-F-201
1

38. PECL/C-908/1145/AVU/C-2016
for Crude Charge Heater 010-F-201
1
Cause & Effect Table for Crude Charge Heater

39. PECL/C-908/1145/AVU/C-1021
010-F-101
3
Cause & Effect Table for Crude Charge Heater

40. PECL/C-908/1145/AVU/C-2021
010-F-201
3
GA Cross Section & Longitudinal Section for

41. PECL/C-908/1145/AVU/C-1051
1
PECL/C-908/1145/AVU/C-1061-
42. 1067
GA Plans for Crude Charge Heater 010-F-101 7
43. PECL/C-908/1145/AVU/C-1068 GA Details for Crude Charge Heater 010-F-101 1
SHT 71 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
NO. OF
SHEETS
General Notes & Details of Auxiliary
44. PECL/C-908/1145/AVU/C-1071
Connections for Crude Charge Heater 010-F-101
1
GA Cross Section & Longitudinal Section for

45. PECL/C-908/1145/AVU/C-2051
1
PECL/C-908/1145/AVU/C-2061-
46. 2067
GA Plans for Crude Charge Heater 010-F-201 7
47. PECL/C-908/1145/AVU/C-2068 GA Details for Crude Charge Heater 010-F-201 1

48. PECL/C-908/1145/AVU/C-2071
Connections for Crude Charge Heater 010-F-201
1
PECL/C-908/1145/AVU/C-3011- APH GA Plans for Crude Charge Heater 010-F-

49. 3015 101/201
5
PECL/C-908/1145/AVU/C-3021- APH GA Elevations for Crude Charge Heater

50. 3022 010-F-101/201
2
PECL/C-908/1145/AVU/C-3031- Miscellaneous Details & Notes for APH System

51. 3032 for Crude Charge Heater 010-F-101/201
2
PECL/C-908/1145/AVU/C-3041- GA for Ground Mounted Stack for Crude Charge

52. 3042 Heater 010-F-101/201
2
Data sheet for Flue Gas Analyzer for Crude

53. PECL/C-908/1145/AVU/C-8211
22
Data sheet for Skin Thermocouples for Crude

54. PECL/C-908/1145/AVU/C-8671
12
Control & Shutdown Narrative for Crude Charge

55. PECL/C-908/1145/AVU/C-8861
Heater 010-F-101/201
34
SHT 72 OF 72
NEW DELHI O1
HEATERS 010-F-101/201 1145/AVU/C-149
CLIENT NAME INDIAN OIL CORPORATION LTD (IOCL)
PROJECT TITLE PARADIP REFINERY PROJECT (PDRP)
PROJECT LOCATION PARADIP, ORISSA, INDIA
VENDOR NAME PETRON ENGINEERING CONSTRUCTION LIMITED
CONTRACT NO. 1-14-4200/ 399
IOCL ORDER NO.
CONSULTANT (FW)
0459/ 4200 REQ NO.: DSN – 15556
P.O. NO.
REQ ITEM NO.: TAG NO.:
OPERATING & MAINTENANCE MANUAL FOR VACUUM CHARGE

DOCUMENT TITLE
HEATER 010-F-002
VENDOR DOC NO.: PECL/C-908/1145/AVU/C-150 VENDOR REV. O1
DOC TYPE CODE & CONSULTANT

SEQUENCE NO. (FW) REV. NO.
STATUS CODE: BY: DEPT: DATE:

CLIENT: INDIAN OIL CORPORATION LIMITED
CONSULTANT: FOSTER WHEELER
PARADIP REFINERY PROJECT, ORISSA
OPERATING & MAINTENANCE MANUAL FOR

VACUUM CHARGE HEATER 010-F-002
FOR
LSTK- 1 - AVU FIRED PROCESS HEATERS
CONTRACT NAME : LSTK-1 AVU

PROCESS FIRED HEATERS
CONTRACT NO : 0459/4200
PECL CONTRACT NO : C – 908
UNIT NO : 010 ATMOSPHERIC VACUUM UNIT
O1 24-05-2016 Issued For Information VKJ SKS AKJ

Rev Date Purpose of Issue Prepared Checked Approved
PETRON ENGINEERING
CONSTRUCTION LTD.,
MUMBAI PECL
PECL/C-908/1145/
Document
AVU/C-150
No.
ENEREFF ENGINEERS PVT. LTD. REV No.
O1
FW
FOSTER WHEELER Document
No.
SECTION DESCRIPTION PAGE NO.
I INTRODUCTION 3
II PROCESS DESCRIPTION 5
III INTERLOCK SCHEMES AND ALARM SET POINTS 8
IV PRE COMMISIONING INSPECTION 18
V HEATER DRY OUT INSTRUCTIONS 22
VI PROCEDURE FOR PRESSURE TESTING OF BURNER LINES 26
VII NORMAL HEATER STARTUP 31
VIII HEATER SHUTDOWN 39
IX OPERATING INSTRUCTIONS 45
X AIRPREHEATER OPERATING INSTRUCTIONS 51
XI WHB & STEAM DRUM OPERATING INSTRUCTIONS 55
PROCEDURE FOR GAS FREEING & ISOLATION FOR SAFE
XII 59
ENTRY
XIII MAINTENANCE INSTRUCTIONS 61
XIV ENCLOSURES 69
SHT 2 OF 71
MANUAL FOR VACUUM PECL/C-908/
NEW DELHI O1
CHARGE HEATER 010-F-002 1145/AVU/C-150
NEW DELHI
SECTION - I
INTRODUCTION
MANUAL FOR VACUUM

CHARGE HEATER 010-F-002
PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
SHT 3 OF 71
O1
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - I
INTRODUCTION
This Operating Manual covers various aspects of the operation of Vacuum Charge
Heater (010-F-002) with an outboard Cast & Glass Airpreheater (010-APH-002) &
Waste Heat Boiler (010-WHB-002) and is being issued for the purpose of assisting
operating personnel to run the Heater / APH / WHB system efficiently. The
instructions can only supplement the experience and judgment of those in charge of
operation. They should be interpreted and applied after due consideration to the
requirements of other equipment and for any particular set of circumstances, since
no amount of instructions can cover all the situations that may arise.
Instructions for operation and maintenance instructions for the Heater / APH /
WHB system have been given in the following sections of this Operating &
Maintenance Manual. Vendors’ Operating Manuals of bought out items like
Burners, Forced Draft Fans, Induced Draft Fans, Airpreheater, Waste Heat Boiler,
Steam Drum & Dampers etc. should be read carefully before the Heater / APH /
WHB system is commissioned.
SHT 4 OF 71
NEW DELHI O1
NEW DELHI
SECTION - II
MANUAL FOR VACUUM

PROCESS DESCRIPTION
PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
SHT 5 OF 71
O1
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - II
PROCESS DESCRIPTION
2.1 VACUUM CHARGE HEATER 010-F-002
Vacuum Charge Heater (010-F-002) is a twelve pass Box Heater with horizontal
tubes in the Radiant section and Convection section. Feed is first equally split into
twelve streams and the flow rate of each stream is metered. Atmospheric residue at
a temperature of around 349.3°C enters into the Convection section and is heated to
a temperature around 401.8°C before it leaves the radiant section. The mixed
temperature of the twelve streams coming out from radiant section is controlled by
Temperature Controllers (010-TIC-3003) which give signal to Heater firing control
loop.
The Radiant section of the Heater is provided with 132 tubes in 2 identical cells
with each cell having 6 passes. Each pass has 1 tubes as follows: Last tube is of A
335 Gr P9 of 406.4mm OD x Sch 40, Last but one tube is of A 335 Gr P9 of
323.8mm OD x 9.45 mm thickness (Minimum Wall), Last but two tube is of A 335
Gr P9 of 273 mm OD x 8.55 mm thickness (Minimum Wall) & subsequent eight
tubes are of A 335 P9 of 219.1 mm OD x 7.6 mm thickness (Minimum Wall). All
tubes are placed at 2 D spacing with D being the nominal tube size. Convection
section has 12 tubes per row and consists of 36 bare and 48 finned rows of tubes
The HC Process Convection tubes shall be of A 335 P9 of 168.3 mm OD x 6.75
mm thickness (Minimum Wall). The Process coil finned tubes shall have 118 Fins/
m of 19.1 mm height and 2.5 thickness of CS metallurgy. All the MP SSH & LP
SSH Convection coil finned tubes (24 tubes with 118 Fins/ m of 19.1 mm height
and 2.5 thickness of CS metallurgy) shall be of A 335 Gr P11 of 168.3 mm OD x
Sch 40.
2.2 THE AIR PREHEATING CIRCUIT
There is an outboard Air Preheating System for the Vacuum Charge Heater 010-F-
002. Combustion air required for the each Heater is fed by the two Forced draft
fans 010-K-004A and 010-K-004B and is preheated in a Steam Air Preheater (010-
E-031) up to a temperature of 68°C (for the Heater Design case) and then heated in
a Cast & Glass Airpreheater (010-APH-002) up to a temperature of 280°C (for the
Heater Design case). The total air requirement signal for the two FD fans comes
from controller 010-FIC-3001A & 010-FIC-3001B. The air flow rate from fans is
adjusted by varying the position of the Inlet Box Dampers (010-FV-3001A & 010-
FV-3001B).
Flue Gases from the Convection sections of the Vacuum Charge Heater (010-F-
002) enters the outboard Waste Heat Boiler (010-WHB-002) at 460°C and then exit
the Waste Heat Boiler and enters the Cast & Glass APH at 310°C and are cooled
down to 150°C. The cold flue gas from the APH then enters ID fans (010-K-
005A/B) and finally leave through the ground mounted Stack 010-SK-002. The
pressure developed by the ID fan is adjusted by varying the position of the Inlet
Box Damper (010-PV-3020/3021). The signals to the Inlet Box Damper actuators
are controlled so as to ensure at least 2.5 mmWC of draft at Arch of the Heater. In
SHT 6 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they the event of failure of the ID fans, the Stack Damper 010-PV-3118 will open fully
and the flue gases shall be vented directly through the grade mounted Stack by
natural draft.
Necessary Dampers/ SOB’s have been provided in the flue gas circuit to ensure that
the Heater can be operated in the event of Cast & Glass APH or Waste Heat Boiler
bypass.
SHT 7 OF 71
NEW DELHI O1
NEW DELHI
AND
SECTION - III
MANUAL FOR VACUUM

ALARM SET POINTS

INTERLOCK SCHEMES
PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
SHT 8 OF 71
O1
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION – III
INTERLOCK SCHEMES AND ALARM SET POINTS
3.0 GENERAL
This chapter has been prepared with the intention of providing the Heater operating
personnel with basic information on how interlock scheme works and how they
should be operated safely. Operating personnel should understand the interlock
scheme thoroughly for safe operation of the Heater during any abnormalities.
3.1 INTERLOCK SCHEME
Following interlocks have been provided for the safe operation of the Heater in the
event of failure of any operating equipment or any abnormality in the process
condition.
3.1.1 High- High or Low- Low Pilot Gas Pressure (IZ-0312)
In the event of High- High or Low- Low Pilot gas pressure, as sensed by High-
High or Low- Low setting limit of two out of three 010-PZSHH–3078 / PZSLL–
3078 A/B/C continuing for 5 seconds, Fuel oil, Main fuel gas, Treated Vent Gas
and Pilot gas supply to the Heater shall be cut off. Stack Damper (010-PV-3118)
shall open. All drive of the APH system shall trip.
3.1.2 High- High Arch Pressure (IZ-0302)
 In the event of High- High pressure at Heater Arch, as sensed by High- High
setting limit of two out of three 010-PZSHH–3053 A/B/C, Stack Damper 010-
PV-3118 shall open. If the Damper fails to open or Arch pressure does not
reduce within 30 seconds, Fuel oil, Main fuel gas & Treated vent gas supply to
the Heater shall be cut off. Pilot gas shall remain on line.
 In the event of failure of the both ID fans as sensed by motor contact 010-MZL-
3028C & 010-MZL-3029C, Stack Damper (010-PV-3118) shall open
automatically. If the Damper fail to open within 30 Seconds, Fuel oil, Main fuel
gas & Treated vent gas supply to the Heater shall be cut off. Pilot gas shall
remain on line.
3.1.3 IZ-0317
 In the event of Low- Low feed flow to Heater as sensed by 010-FZSLL-9305
A/B/C or any 010-FZSLL-9306A to L (A/B/C), Fuel oil, Main fuel gas &
Treated vent gas supply to the Heater shall be cut off, Stack Damper (010-PV-
3118) shall open. Pilot gas shall remain on line.
 In the event of High- High Process outlet temperature, as sensed by High- High
setting limit of two out of three 010-TZSHH–3047 A/B/C, Fuel oil, Main fuel
gas & Treated vent gas supply to the Heater shall be cut off. Stack Damper 010-
PV-3118 shall open. Pilot gas shall remain on line.
 In the event of failure of both the FD fans as sensed by motor contacts 010-
MZL-3001A/ 3001B or Combustion air Low- Low flow to Heater & Low- Low
FD fan discharge pressure, as sensed by 010-FZSLL-3072/3073 A/B/C & 010-
PZSLL-9318 A/B/C, Fuel oil, Main fuel gas & Treated vent gas supply to the
SHT 9 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they Heater shall be cut off. Stack Damper 010-PV-3118 shall open. Pilot gas shall
remain on line.
3.1.4 High- High or Low- Low Main Fuel Gas Pressure (IZ-0313)
In the event of High- High or Low- Low main fuel gas pressure, as sensed by High-
High or Low- Low setting of two out of three 010- PZSHH -3080/ PZSLL–3080
A/B/C, Main fuel gas to the Heater shall be cut off by closing both the Block
Valves 010-XZV–3026 & 010-XZV–3048 and opening the Bleed valve 010-XZV-
3049. Pilot gas and Fuel Oil shall remain on line.
3.1.5 IZ-0314
 In the event of High- High or Low- Low fuel oil pressure, as sensed by High-
High or Low- Low setting of two out of three 010- PZSHH-3084/ 010-PZSLL–
3084 A/B/C, fuel oil shall be cut off by closing valves 010-XZV-
3023/3024/3044A to T and opening oil gun steam purge shutdown valves 010-
XZV-3059A to T. Pilot gas & Main Fuel gas shall remain on line.
 In the event of Low- Low differential pressure between atomizing steam & fuel
oil, as sensed by Low- Low setting of two out of three 010- PZSLL–3095
A/B/C, fuel oil shall be cut off by closing valves 010-XZV-3023/3024/3044A
to T and opening oil gun steam purge shutdown valves 010-XZV-3059A to T.
Pilot gas & Main Fuel gas shall remain on line.
3.1.6 Fuel oil & Main Fuel Gas Cut off to Heater (IZ-0604)
In the event of Fuel oil & Main fuel gas cut off to the Heater, following actions will
take place sequentially:
a) Stack Damper 010-PV-3118 shall open.
b) FD Fans will trip after a period of 30 seconds.
c) ID Fans will trip after a period of 30 seconds.
3.1.7 FD Fan Maximum/ Normal Operation & Failure of Operating Fan (IZ-0605)
During normal operation at maximum/ normal/ Turndown (50%) loads, both the
FD fans shall be operating at 50% process load. In the event of failure of one of the
working fans as sensed by respective motor contacts 010-MZL-3001A/ 3001B,
working Fan shall attain 100% process load and the discharge Damper 010-XZV-
3001A/3001B of the tripped fan shall close automatically isolating the tripped Fan.
Suction damper shall be closed manually.
3.1.8 High- High or Low- Low Temperature at APH Outlet of Fuel Gas (IZ-0603)
In the event of High- High or Low- Low temperature of flue gas at outlet, as sensed
by High- High or Low- Low setting of two out of three 010- TZSHH-3107 /
TZSLL–3107 A/B/C, APH by-pass Damper 010- XZV-3022 shall open & APH
inlet Damper 010-XZV-3011) shall close automatically. If Dampers fail to open/
close 30 seconds respectively, ID Fan will trip, Fuel oil & Main fuel gas supply to
Heater shall be cut off. Pilot gas shall remain on line.
SHT 10 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 3.1.9 IZ-0607
Stack Damper 010-PV-3118 cannot be closed unless ID Fan is running.
3.1.10 BURNER MANAGEMENT SYSTEM
3.1.10.1 IZ-0608
Double block and bleed valves on the Pilot gas line to open only when individual
Pilot shut down valves of all the Pilot Burners are closed and a successful leak test
for both Pilot & Main FG has been carried out.
3.1.10.2 IZ-0609
Double block and bleed valves on main fuel gas line to open only when successful
leak test has been carried out and Pilot of at least one Burner is on.
3.1.10.3 IZ-0615
In the event of loss of any of Main Flames as sensed by 010-BZSLL-3002A to T,
the respective Fuel oil shutdown valves 010-XZV-3044A to T shall close &
opening oil gun steam purge valves 010-XZV-3059A to T shall open.
3.1.11 WASTE HEAT BOILER SYSTEM
3.1.11.1 IZ-0610
In the event of activation of steam drum level transmitter Low- Low as sensed by
010-LZSLL-3054, Flue gas inlet damper 010-XZV-3012 to WHB shall close and
by pass duct Damper 010-XZV-3061 shall open. If the Dampers fail to close/ open
within seconds respectively, ID fan will trip. Fuel oil, Main fuel gas & Treated vent
gas to both Heater shall be cut off. Pilot gas shall remain on line.
3.1.12 MP & LP SUPERHEATED STEAM SYSTEM
3.1.12.1 IZ-0310
In the event of High- High liquid level in Vacuum Column (010-C-007), as sensed
by High- High setting limit of 010-LZSHH-3023, LP superheated steam from
Convection section to be cut off by closing shutdown valve 010-XZV-3002 &
shutdown valve 010-XZV-3003 on LP steam vent line shall open
3.1.12.2 IZ-0315
In the event of Low- Low LP superheated steam from Convection section as sensed
by Low- Low setting limit of 010-TZSLL-3081, LP superheated steam from
Convection section to be cut off by closing shutdown valve 010-XZV-3002 &
shutdown valve 010-XZV-3003 on LP steam vent line shall open.
3.1.12.3 IZ-0316
In the event of Low- Low MP De-superheated steam temperature, as sensed by
Low- Low setting limit of 010-TZSLL-3073, Boiler feed water to De-superheater
to be cut off by closing shutdown valve 010-XZV-3035.
SHT 11 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 3.1.13 ID FAN SAFEGUARDING
3.1.13.1 IZ-0612
In the event of activation of interlocks IZ-0610 & IZ-0603 simultaneously, Stack
Damper 010-PV-3118 shall open & APH by pass Damper (010-XZV-3022) shall
close. Both the ID fans shall trip.
3.1.13.2 IZ-0613
During operation at Max/Nor Loads, both the ID fans shall run (Each at 50%
process load). In case of failure of one of the working fans as sensed by respective
motor contact 010-MZL-3028C/ 3029C, working fan shall attain 100% process
load. Suction Damper of the tripped fan to be closed manually. In case of APH or
WHB by pass mode (APH or WHB inlet damper closed position input as sensed by
010-XZSL-3011 or 010-XZSL-3012) and if one of the ID fans trips, stack damper
(010-PV-3118) shall open, WHB flue gas inlet damper (010-XZV-3012) or APH
flue gas inlet damper (010-XZV-3011) respectively & Flue gas by pass damper
(010-XZV-3022) on APH shall close. Running ID fan shall also trip.
3.1.14 SOOT BLOWER OPERATION (I-0602/ 0614)
 On pressing Soot blower start sequence the inlet shutdown valve 010-XV-3042/
010-XV-3063 shall open and a timer for 10 mins. shall start. Once the pressure
transmitter 010-PSLL-3011/ 010-PSLL-3128 & temperature transmitter 010-
TSLL-3095/ 010-TSLL-3194 becomes healthy the drain shutdown valve 010-
XV-3043/ 010-XV-3064 shall close. Only on completion of time delay of 10
mins. with both pressure transmitter 010-PSLL-3011/ 010-PSLL-3128 &
temperature transmitter 010-TSLL-3095/ 010-TSLL-3194 being healthy , Soot
blowing operation to start.
 During Soot blower operation, in case either of 010-PSLL-3011/ 010-PSLL-
3128 & 010-TSLL-3095/ 010-TSLL-3194 are not healthy, soot blower
operation to stop, soot blower to retract, inlet shutdown valve 010-XV-3042/
010-XV-3063 to close & drain shutdown valve 010-XV-3043/ 010-XV-3064 to
open.
3.1.15 EMERGENCY (IZ-0601)
One emergency push button (010-HZS-3001A) shall be provided on hardwire
console panel (Auxiliary Control Panel) pressing which Fuel oil, Main fuel gas,
Treated vent Gas, Pilot gas & Feed to the Heater shall be cut off, all drives of APH
system shall trip Stack damper (010-PV-3118) shall open even if interlocks are in
bypass mode. In addition, Local emergency push button (Mushroom Head type
pressed to lock in position) 010-HZS-3001B shall be provided 15m away from
Heater inside “Break glass” enclosure (located at grade).
3.2 SET POINTS
Following are the indicative values of set points of alarms and trips for different
instruments. The set points have been indicated for the “Heater Design” conditions.
The set points shall need to be revised to take care of any other operating Heater
conditions based on the data received from the various equipment suppliers.
SHT 12 OF 71
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they These set points may require tuning during actual plant operation after assessing the
performance of the Heater & the APH system.
P&ID: PECL/C-908/1145/AVU/C-4011
FZALL – 9305 Combined HC Feed
Low Low 480,000 kg/ hr (Adj.)
FZSLL – 9305A/B/C Inlet Flow
Combined HC Feed High 1,300,000 kg/ hr (Adj.)
FIC – 3003A
Inlet Flow Low 533,000 kg/ hr (Adj.)
FZALL – 9306A to L
Individual Pass HC
FZSLL – 9306A to L Low Low 40,000 kg/ hr (Adj.)
Feed Inlet Flow
A/B/C
Individual Pass HC High 110,000 kg/ hr (Adj.)
FIC – 3004A to L
Feed Inlet Flow Low 44,400 kg/ hr (Adj.)
Individual Pass
FIC – 3034A to L Turbulising Steam Low 653 kg/ hr (Adj.)
Flow
TZAHH – 3047 Combined Coil
TZSHH – 3047A/B/C Outlet Temperature
Individual Pass Coil High 405°C (Adj.)
TIC – 3002A to L
Outlet Temperature Low 395°C (Adj.)
Individual Pass Coil High 3°C (Adj.)
TDAH – 3002A to L
Outlet Temperature
TDAL – 3002A to L Low 0°C (Adj.)
Difference
Tube Skin
TAH – 3032A to L High 575°C (Adj.)
temperature
Tube Skin
temperature
Tube Skin
temperature
Inlet Temperature
Combined HC Feed
PAH – 3001 High 10 kg/cm²g (Adj.)
Inlet Pressure
PAH – 3003A to L High 8 kg/cm²g (Adj.)
Inlet Pressure
P&ID: PECL/C-908/1145/AVU/C-4012
High 5% (Vol.) (Adj.)
AIC – 3001 Oxygen Analyser
Low 1.5% (Vol.) (Adj.)
TAH – 3031 A/B/C/D Flue Gas Temp. High 900°C (Adj.)
TAL – 3031 A/B/C/D (Firebox) Low 700°C (Adj.)
Flue Gas Temp. (Ex
TAH – 3027A/B High 480°C (Adj.)
Conv.)
PZAHH – 3053 High High Arch
High High + 5 mm WC (Adj.)
PZSHH – 3053A/B/C pressure
SHT 13 OF 71
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PIC – 3004 High Arch pressure High + 2.5 mm WC (Adj.)
PALL – 3011/3128 Soot Blowing Steam
Low Low 12.5 kg/cm²g (Adj.)
PSLL – 3011/3128 Header Pressure
Soot Blowing
TALL – 3095/3194
Condensate Line Low Low 180°C (Adj.)
TSLL – 3095/3194
Temperature
P&ID: PECL/C-908/1145/AVU/C-4013
Superheated LP
TAH – 3028 High 425°C (Adj.)
Steam Outlet Temp.
Superheated LP High 385°C (Adj.)
TIC – 3040
TZALL – 3081 Superheated LP
TZSLL – 3081 Steam Outlet Temp.
TAH – 3029 Superheated MP High 345°C (Adj.)
TAL – 3029 Steam Outlet Temp. Low 300°C (Adj.)
MP Steam De- High 315°C (Adj.)
TIC – 3021 Superheater Outlet
Low 295°C (Adj.)
Temp.
MP Steam De-
TZALL – 3073
Superheater Outlet Low Low 280°C (Adj.)
TZSLL – 3073
Temp.
P&ID: PECL/C-908/1145/AVU/C-4014
PZALL – 3078
Pilot gas pressure Low Low 0.5 kg/cm²g (Adj.)
PZSLL – 3078A/B/C
PZAHH – 3078
Pilot gas pressure High High 1.5 kg/cm²g (Adj.)
PZSHH– 3078A/B/C
PZAH – 3078 A/B/C High 0.95 kg/cm² g (Adj.)
Pilot gas pressure
PZAL – 3078 A/B/C Low 0.55 kg/cm² g (Adj.)
PIC – 3079 Main FG pressure Low 0.35 kg/cm² g (Adj.)
PZALL – 3080
Main FG pressure Low Low 0.2 kg/cm²g (Adj.)
PZSLL – 3080A/B/C
PZAHH – 3080
Main FG pressure High High 2.0 kg/cm²g (Adj.)
PZSHH – 3080A/B/C
PZAH – 3080 A/B/C High 1.85 kg/cm² g (Adj.)
Main FG pressure
PZAL – 3080 A/B/C Low 0.35 kg/cm² g (Adj.)
FAH – 3005 High 7850 kg/ hr (Adj.)
Main FG flow
FAL – 3005 Low 1795 kg/ hr (Adj.)
Main FG Header
TAL – 3106 Low 20°C (Adj.)
temp.
Fuel Oil Supply
FAL – 3006 Low 3300 kg/ hr (Adj.)
Header Flow
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P&ID: PECL/C-908/1145/AVU/C-4014
FAH – 3051 Atomising Steam High 2650 kg/ hr (Adj.)
FAL – 3051 Flow Low 1000 kg/ hr (Adj.)
Differential Pressure High 2.4 kg/cm²g (Adj.)
PDIC – 3085 between Atomising
Steam & Fuel Oil Low 1.8 kg/cm²g (Adj.)
Differential Pressure
PDZALL – 3095
between Atomising Low Low 1.5 kg/cm2g (Adj.)
PDZSLL – 3095A/B/C
Steam & Fuel Oil
PDAH – 9310 Pressure drop across High 0.3 kg/cm²g (Adj.)
PDAL –9310 Strainer for Fuel Oil Low 0.1 kg/cm²g (Adj.)
PIC – 3086 Fuel Oil Pressure
PZALL – 3084
Fuel Oil Pressure Low Low 2.4 kg/cm²g (Adj.)
PZSLL – 3084A/B/C
PZAHH – 3084
Fuel Oil Pressure High High 7 kg/cm²g (Adj.)
PZSHH – 3084A/B/C
FAH – 3052 Fuel Oil Return High 3325 kg/ hr (Adj.)
FAL – 3052 Header Flow Low 1800 kg/ hr (Adj.)
PAL – 3083 Fuel Oil Pressure Low 2.6 kg/cm²g (Adj.)
Diff. Pressure across
PDAH – 3104 Flame Arrestor of High 0.01 kg/cm²g (Adj.)
Treated Vent Gas
Treated Vent Gas
PAH – 3101 High 0.07 kg/cm²g (Adj.)
Pressure
P&ID: PECL/C-908/1145/AVU/C-4015
FZALL – 3072/3073
Combustion air Flow
FZSLL – 3072/3073 Low Low 25000 kg/ hr (Adj.)
at FD Fan Inlet
A/B/C
Combustion air Flow
FAL – 3001 A/B Low 30000 kg/ hr (Adj.)
at FD Fan Inlet
PZALL – 9313/9314 Comb. air Pressure at Low + 50 mm WC (Adj.)
PZSLL – 9313/9314 FD Fan Outlet Low Low + 40 mm WC (Adj.)
Comb. air Pressure at Low Low + 30 mm WC (Adj.)
PZALL – 9318
Combined FD Fan
PZSLL – 9318A/B/C Low + 50 mm WC (Adj.)
Outlet
P&ID: PECL/C-908/1145/AVU/C-4016
AAH – 3003 SOx Analyser High 0.0045% (Vol.) (Adj.)
AAH – 3002 NOx Analyser High 350 mg/Nm³ (Adj.)
AAH – 3005 High 250 ppm (Adj.) - CO
CO/O2 Analyser
AAL – 3005 Low 2% (Vol.) (Adj.) - O2
SHT 15 OF 71
NEW DELHI O1
P&ID: PECL/C-908/1145/AVU/C-4016
AAH – 3008 High 92 mg/Nm³ (Adj.)
VOC Analyser
AAL – 3008 Low 5 mg/Nm³ (Adj.)
AAH – 3007 High 50 mg/Nm³ (Adj.)
PM Analyser
AAL – 3007 Low 5 mg/Nm³ (Adj.)
Flue Gas Temp. (Ex
TAL –3100 Low 480°C (Adj.)
Conv.)
Flue Gas Pressure
PAH – 3096 High + 5 mm WC (Adj.)
(Ex Conv.)
Flue Gas Temp. (Ex
TAL – 3018 Low 270°C (Adj.)
WHB)
Flue Gas Pressure
PAH – 3097 High 0 mm WC (Adj.)
(Ex WHB)
Flue Gas Temp. (Ex High 175°C (Adj.)
TIC – 3019
APH) Low 132°C (Adj.)
Flue Gas Pressure
PAH – 3098 High -50 mm WC (Adj.)
(Ex APH)
TZALL – 3107 Flue Gas Temp. (Ex
TZSLL – 3107 A/B/C APH)
TZAHH – 3107 Flue Gas Temp. (Ex
TZSHH – 3107 A/B/C APH)
Flue Gas Pressure at
PAHH – 9315/9316 High High - 25 mm WC (Adj.)
ID Fan Suction
Hot Air Pressure at
PAL – 3043 Low + 25 mm WC (Adj.)
APH Outlet
Hot Air Temperature
TAL – 3078 Low 225°C (Adj.)
at APH Outlet
TAH – 3134 Hot Air Temperature High 290°C (Adj.)
TAL – 3134 at APH Outlet Low 215°C (Adj.)
Hot Flue Gas Temp. High 260°C (Adj.)
TIA – 3135 A/B
inside APH. Low 190°C (Adj.)
APH Cast Tube Skin High 200°C (Adj.)
TIA – 3101 A/B
TC Temperature Low 142°C (Adj.)
SHT 16 OF 71
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BFW Temperature to
TAL – 3105 Low 95°C (Adj.)
Steam Drum
BFW Flow to Steam
FIC – 3078 Low 6000 kg/ hr (Adj.)
Drum
Steam Drum
TAL – 3104 Low 200°C (Adj.)
Temperature
Steam Drum High 18 kg/cm²g (Adj.)
PIA – 3035
Pressure Low 16 kg/cm²g (Adj.)
High +150 mm
LIC – 3053/3043 Steam Drum Level
Low - 150 mm
LY – 3043 Steam Drum Level High 50 mm
LZALL – 3054
Steam Drum Level Low Low - 220 mm
LZSLL – 3054
SHT 17 OF 71
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NEW DELHI
SECTION - IV
MANUAL FOR VACUUM

PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 18 OF 71
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - IV
Following pre-commissioning inspection should be carried out for the Heater/
APH/ WHB System and Burners.
4.1 BURNERS
It is quite important that a positive check be made to see that all Burners have been
properly installed in accordance with the Heater drawings and the Burner vendor
drawings. Burner should be free of any debris or other material which might cause
faulty operation. The position of gas tips with respect to refractory burner blocks is
very important. If burners are not properly installed, flame impingement on tubes
and refractory can result.
Burner Vendor manual contains a number of instructions and DOs and DON'Ts
concerning the operation of these fuel gas Burners. Company’s Safety Department
should ensure that operating personnel are well aware of these points during
training period. In the Burner Vendor manual the installation procedure has been
given and perhaps this procedure is of more interest to the maintenance than
operating staff.
4.2 DAMPERS
If the Dampers are not functioning properly the capacity and performance of the
Heater/ APH/ WHB System can be seriously affected. The Stack Damper and other
Dampers should be checked for proper installation (e.g. in case of instrument air
failure, the automatic Dampers/ FO type should open full by the counter weight),
easy operation and easy maintenance. In addition to the actuator assembly (power
cylinder assembly), Dampers are generally provided with winch and cable
arrangement. Complete opening and closing of the Dampers should be checked
visually after installation and external markings are to be made, so that at any time,
the actual Damper opening in the field can be cross-checked with the control room
indication.
The actuator assemblies should be checked properly to ensure that Dampers can be
operated within the specific operation time, positioner respond accurately to the
variations in signal pressure and Dampers attain fail safe position during instrument
air failure to ensure safety of the Heater/ APH/ WHB System.
The vendor’s drawings, sketches, control schemes and other documents should be
referred and instructions if any, followed.
4.3 FANS (FORCE DRAFT & INDUCED DRAFT)
For erection and installation of fans, Vendor's manual/instructions must be
followed. After proper installation and erection, following pre-commissioning
checks are to be carried out:
 Ensure fan casing is cleared of debris and/or tools.
 Inlet cone clearances checked.
SHT 19 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Non-drive and Drive end expansion clearances checked.
 Fan coupling alignment checked.
 Bearing cleaned and flushed of debris.
 Bearing reservoir has complete quantity of lubricating oil.
 Seal housing clearances checked.
 Coupling packed with recommended grease.
 Recommended lubricating oil/grease for bearing is used.
 Check impeller for rotation in correct direction.
 Rotate fan shaft to ensure freedom of movement.
 All the access doors are properly closed/ sealed.
 Check to be done to ensure proper erection of the Fans properly aligned. Other
instructions provided in fan vendor’s manual to be followed.
 Check all electrical connections are in accordance with the manufacturer's
instructions.
 Operating instructions as given by the fan vendor in their manual should be
strictly followed.
4.4 SOOT BLOWERS
Soot Blowers are electrically operated retractable type. Soot blower instruction
manual is comprehensive and should be referred by operating and maintenance
personnel.
4.5 PIPES/TUBES
All tube ends should be checked to see that fittings are properly attached. It is
advisable to leave header box doors open during start-up to ensure that any leaks
that might result are quickly observed and taken care of.
Tubes should be blown out with compressed air in sufficient pressure and quantity
to ensure tubes are clear and unobstructed for satisfactory flow. Each pass must be
blown independently. Burner piping for fuel gas, fuel oil and pilot fuel gas should
be cleaned first with steam and then with compressed air to remove all loose
deposits, water droplets, and scales. This should be done with burners disconnected
from flanges/unions. Piping of one burner should be cleaned at a time with steam/
air.
Snuffing steam piping and Soot Blower steam piping should be blown out
thoroughly with steam to remove all loose scales and deposits prior to its
connection with the Heater.
If the piping is already connected with system, wedge gap the individual flange at a
time and put a blind gasket toward Heater/ Soot Blower and blow the line with
SHT 20 OF 71
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they steam. Please note that during steam blowing at one connection, all other
connections should be blinded for effective cleaning.
4.6 REFRACTORY LINING
A) Brick Work
The refractory brick work should be thoroughly inspected and following
conditions of the lining fully ensured:
 All the bricks are intact and in position.
 The brick surfaces are free from cracks and chipped corners.
 Any air setting mortar used for laying the bricks has set properly.
 The expansion joints are free and the filling materials like ceramic fibre
are held intact in the joints.
B) Castable Lining
Inspection of lining should aim at ensuring the following conditions:
 The lining has set hard and is strong.
 No segregation of material on the lining surface is observed.
 The lining is free from all visible void, lamination, loose pocket (honey
comb), cracks (excluding hair-line cracks) etc.
4.7 INSTRUMENTS
All instruments should be carefully checked because it is upon these that a large
part of the Heater/ APH/ WHB System operation must rely. Flow recorders should
be checked for true readings; thermocouples for reversal of leads; temperature, flow
and pressure control equipment for proper readings. All draft gauge piping should
be properly connected.
4.8 MISCELLANEOUS
The pressure relief doors/explosion doors should be checked and maintained clear
of any obstructions for its proper functioning. Tube supports and guides, peep
holes, access doors, and other mechanical parts should be inspected and checked as
per Heater drawings.
SHT 21 OF 71
NEW DELHI O1
NEW DELHI
SECTION - V
MANUAL FOR VACUUM

PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 22 OF 71
REV.
HEATER/ APH/ WHB SYSTEM DRY OUT INSTRUCTIONS
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - V
DRY OUT PROCEDURE
Heater dry out instructions, given below, should be followed for carrying out the
dry out for the Heater.
5.1 PURPOSE
Heater dry-out procedures are utilised as a means of curing Heater refractory before
initial process operation. At the same time, the dry-out period is also used as a
means of checking the operation of certain Heater components such as burners and
such control devices as may be used during the dry-out period.
5.2 DURATION
A 3-5 day dry-out cycle is generally required during which Heater temperature is
gradually increased to the point at which refractory is completely dry. If linings are
excessively wet, then only the pilots should be left alight for a day or two to dry off
this excess moisture. During the dry-out cycle, moisture in the Heater refractory
close to the Burners is evaporated within a very short time. Generally, over a three
day cycle moisture inside the refractory is removed.
5.3 TUBE PROTECTION
During the dry-out cycle, it is customary to circulate steam through all process
tubes in order to prevent over-heating. Steam is only introduced after warm up to
prevent undue condensation and water hammering. The tube metal temperature
should be measured regularly and limited to 350°C for the Hydrocarbon. It is
advisable to pass cooling steam even if the TMT is within the maximum allowable
figure specified in the datasheet.
5.4 START-UP FOR DRY-OUT
Start-up procedures of vendors are to be referred for commissioning of FD fans and
Burners.
For the initial phase of dry-out, only fuel gas should be used when available, to
facilitate control and easy changeover of Burners.
This of course is an opportune moment for testing out the stack damper
mechanism, and any rectification of faults of adjustment should be carried out
before proceeding with the dry-out.
5.5 PURGE FIRE BOX
Before even de-spading fuel lines, the Heater firebox must be thoroughly purged
with steam/air for approximately 30 minutes. Following this purge a gas free test
must be carried out. After the test is proved negative, proceed with the de-blanking
of the fuel gas lines and light up the pilot burner. If there is undue delay in
removing fuel gas line spades or any other delay which prevents the lighting of the
burners, the fire box must be re-purged with steam and retested for gas freeness.
SHT 23 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they Never de-spade the fuel lines, particularly fuel gas lines and leave the Heater
overnight with unlit Burners i.e. a delayed or interrupted start-up. If there is any
leak, a serious build up of fuel gas in the Heater can result in explosion
5.6 BURNER VENDOR INSTRUCTIONS
Vendor's standing instructions on lighting Burners and all directions concerned
with Heater firing must be followed in totality and recommendations in this manual
are to be considered complementary to these instructions.
5.7 LIGHTING-UP BURNERS
It is recommended that drying out operation be done on fuel gas as control of firing
will be much easier. When the firebox has been certified "gas free" light all the
pilot Burners and raise the temperature with lighting sufficient main Burners to
bring arch temperature upto 120°C at a rate of 25°C/ hr.
5.8 DRY OUT
Hold the temperature at 120°C for 12 hours (minimum) by lighting-up the Burners
by rotation for heat uniformity and then increase the temperature to 200°C at the
rate of 25°C/ hr. Introduce flow of steam/ air/ N2 through the tubes at 200°C after
making sure that all the condensate has been drained off. Check all Burners,
observe conditions inside the firebox and inspect areas of expansion. Hold at 200°C
for 12 hours.
Following this, increase the arch temperature to 400°C again at 25°C/hr. Hold at
this temperature for 24 hours and repeat checks as above. Increase the flow of
steam if the tube metal temperature is found exceeding maximum temperature
specified in the data sheet.
The heat duty requirement during dry out may not warrant firing of all the Burners
during dry out. Sufficient number of Burners, with good flames, may be fired and
the operation of Burners rotated every 2 hours to maintain uniformity. This shall
not, however, be construed that only 1 or 2 burners may be fired as it may not be
possible to maintain uniform firing.
Before proceeding to the final stage of drying out, check that ample supply of
steam is available to prevent over-heating of the tubes. Increase the arch
temperature at a rate of 25°C/hr to 500°C and hold for 24 hours. Make a thorough
check of the unit during this period and in particular, expansion should be noted
and Damper movements checked.
During dry out, it is advisable to try all instruments and controllers on automatic
control and see that all alarms, warning lights, etc. are functioning properly.
At the end of the 500°C drying out period, reduce the arch temperature at a rate of
50°C per hour and accordingly start reducing the steam/ N2/ Air flow through the
tubes.
When the system is proven satisfactory and arch temperature is around 200°C,
firing can be cut off together with the steam flow through the tubes. Spade off the
fuel lines immediately.
SHT 24 OF 71
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This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 5.9 During dry-out the outboard Waste Heat Boiler (WHB) & Airpreheater (APH) shall
be taken in line subject to the following conditions:
 Flue gas exit temperature from Cast APH/ Stack shall be sufficiently above acid
dew point of flue gas.
 The tube metal temperature at the cold end of cast air preheater shall not fall
below 145°C.
 Flue gas temperature at the interface of Cast and Glass Air preheater is not
above 240 to 260°C.
The above conditions may be possible only for arch temperature above 400°C. Start
ID fans and slowly regulate the capacity using the Inlet box Dampers, so that a
controlled amount of flue gas will pass through the duct. The bypassing of air may
also be regulated to meet the above conditions.
When it is not possible to maintain the above temperature conditions, by-pass Air
preheater and stop ID fans as per the Vendor's instructions.
5.10 When the firebox is cool enough and entry permits are available, inspect the
refractory for any signs of failure.
SHT 25 OF 71
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NEW DELHI
SECTION - VI
BURNER LINES
MANUAL FOR VACUUM

PROCEDURE FOR PRESSURE TESTING OF
PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 26 OF 71
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - VI
PROCEDURE FOR PRESSURE TESTING OF BURNER LINES
6.1 BURNER TESTING PROCEDURE
In accordance with requirement of Project Specification No. PDRP-8470-SP-0002,
there is need to have a formal Pressure testing of Burner lines before normal
lighting up of Burners can be undertaken for Vacuum Charge Heater, AVU Unit,
IOCL Paradip.
This Procedure has accordingly been prepared based on the above referred Project
Specification, discussions with M/S Foster Wheeler/ IOCL and the approved
P&IDs and Control & Shutdown Narrative for the Heater. Nitrogen is being used as
the testing fluid to provide a safe and secure medium for pressure testing.
6.2 GENERAL
The panel shall have a LAMP TEST push button.
The Local Panel shall accept a signals from the plant BMS to energize the lamps.
The panel shall have a lamp to indicate FIREBOX TEMPERATURE LOW when
the temperature at the bridge wall is below 750°C.
6.3 PILOT HEADER / MAIN HEADER LEAK TEST
The system shall include automatic double block and bleed valves to shut off the
pilot gas supply to the heater, and a downstream automatic isolation valve local to
each pilot.
The BMS shall not permit the pilot double block and bleed valves 010-XZV-
3027/3052 & 3054 to be switched to the open and closed position respectively until
a successful leak test has been carried out to confirm that the pilot isolation valves
010-XZV-3045 A to T & manual isolation valves of the Main FG are closed.
The leak test procedure shall be as follows:
3101 on the local panel to “START PILOT LEAK TEST”.
 The BMS switches Block valves 010-XZV-3057 in the Nitrogen line to the
open position for a limited period.
 Pressurization period and a restriction orifice allow a quantity of nitrogen to
flow equivalent to the flow through one open pilot isolation valve
 A lamp on the local panel indicates “PILOT LEAK TEST IN PROGRESS”.
leak test Nitrogen block valve 010-XZV-3057 to the closed position, a “PILOT
LEAK TEST FAILED” lamp illuminates on the local panel and the test-in-
SHT 27 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they progress light goes off. The operator must then find the cause of the leak,
rectify it and re-start the test.
BMS switches the leak test Nitrogen block valve 010-XZV-3057 to the closed
position, the test-in progress light remains on and the depressurization timer
starts.
during the depressurization period (2 mins & adjustable) a “PILOT LEAK
restart the test
depressurization period (5 mins & adjustable) the test has been successful, the
test-in-progress lamp goes off and a “PILOT LEAK TEST CLEAR” lamp
In similar way, leak test of the main FG header is also be carried out. Following
shall be carried out:
3103 on the local panel to “START MAIN FG LEAK TEST”.
 The BMS switches Nitrogen block valve 010-XZV-3047 to the open position
for a limited period
 Pressurization period and a restriction orifice allow a quantity of Nitrogen to
flow equivalent to the flow through one open main FG manual isolation valve.
 A lamp on the local panel indicates “BURNER LEAK TEST IN PROGRESS”.
leak test Nitrogen block valve 010-XZV-3047 to the closed position, a
“BURNER LEAK TEST FAILED” lamp illuminates on the local panel and the
test-in-progress light goes off. The operator must then find the cause of the
leak, rectify it and re-start the test.
BMS switches the leak test Nitrogen block valve 010-XZV-3047 to the closed
position, the test-in progress light remains on and the depressurization timer
starts
during the depressurization period (5 mins & adjustable) a “BURNER LEAK
restart the test
depressurization period the test has been successful, the test-in-progress lamp
goes off and a “BURNER LEAK TEST CLEAR” lamp illuminates on the local
panel.
SHT 28 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 6.4 PRE - PURGE
Once Pilot Leak Test followed by Main Leak Test has been successful, then Pre-
purge of the Firebox is carried out. Pre-purge or ventilation of the firebox chamber
and downstream flue gas passages will be a manually regulated operation using air
from FD fans for a period of 15 minutes. The Fans should not be stopped once
started for purging i.e. Fans shall be kept in running condition during Pilot Ignition.
A Field operator will confirm that the pre-purge is complete by checking that the
chamber is free from combustibles using a portable device using the Sampling
Connections for the same.
6.5 PILOT IGNITION
 On completion of a successful leak test the operator is permitted by the BMS to
switch the pilot double block and bleed valves to the open and closed position
respectively by pressing a push button 010-HZS-3102 on the local panel to
“OPEN PILOT BLOCK VALVES”. A lamp on the panel will indicate “PILOT
BLOCK VALVES OPEN” 010-XZL-3007.
 The Burner pilots can now be ignited manually. One operator will insert the
igniter and initiate the spark while another opens the individual pilot automatic
isolation valve by pressing a PILOT #1 push button on the local panel. Ignition
of the first pilot should be taken up within 10 minutes of opening the Pilot
Block valves & closing the Bleed Valves. The Local Panel operator opens the
pilot isolation valve. The valve shall remain open for 10 seconds (adjustable). If
the pilot flame rod senses the presence of a flame during this time the isolation
valve remains open, otherwise it closes. More than three consecutive attempts
of Pilot ignition should not be attempted.
 Lamps on the local panel indicate whether the monitoring system detects
PILOT # 1 ON or PILOT #1 OFF
 When the first pilot is alight the other pilots can each be ignited in the same
manner as the first
 If the BMS does not detect the first pilot flame within 10 mins (adjustable) of
opening the Pilot Block valves & closing the Bleed Valves, it will switch the
pilot double block and bleed valves to the closed & open position respectively
& a new leak test must be performed.
 When the BMS confirms that all configured Burner pilots are alight it will
permit the burner ignition to be started
6.6 MAIN BURNER IGNITION
 The Main Burner shall be ignited using Fuel Gas (in case sufficient refinery
Fuel Gas or LPG is available) as the fuel and only after then should the Burner
be taken on Fuel Oil firing.
 The system shall include automatic double block and bleed valves to shut off
the main fuel gas supply to the heater, and a downstream manual isolation valve
local to each burner.
SHT 29 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  The BMS shall not permit the fuel gas double block and bleed valves to be
switched to the open position until a successful leak test has been carried out to
confirm that the burner isolation valves are closed and all configured pilots are
lit. This is permissive to open FG double block valves.
 The operator can switch the fuel gas double block and bleed valves to the open
position by pressing a push button 010-HZS-3104 on the local panel to “OPEN
FUEL GAS BLOCK VALVES”. A lamp on the panel 010-XZL-3032 will
indicate “FUEL GAS BLOCK VALVES OPEN”.
 The burners can now be ignited manually. The burner isolation valves shall be
quarter turn type ball valve or similar, and each shall be located adjacent to a
peep door so that the burner it controls can be clearly viewed whilst operating
the valve. Under no circumstances shall the burner isolation valves be located
so that personnel need to be underneath the heater when operating them.
 The operator will slowly open the burner isolation valve whilst observing the
flame.
 If a flame is not established within 3 seconds of the valve being fully open the
operator shall quickly close it again. Further ignition attempts must not be made
for at least five minutes.
 Once a stable flame is observed the operator may light other burners using the
procedure described above.
 Operator can then take each Burner on Fuel Oil as required after opening the
individual FO/atomizing steam valves 010-XZV-3044/3059 A to T using push
buttons 010-HZS-9033 A to T in the local panel 010-LP-002.
SHT 30 OF 71
NEW DELHI O1
NEW DELHI
SECTION - VII
MANUAL FOR VACUUM

PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 31 OF 71
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - VII
7.1 NORMAL START-UP OPERATION
The most hazardous periods in the operation of a Heater are during start-up and
shut down. Explosions, for example, will occur if a source of ignition is introduced
into a firebox containing a flammable mixture of fuel and air. It is therefore, vital
that no source of ignition is introduced until the firebox has been purged and
checked to be gas free. The following procedures are designed to avoid this and
other dangerous situations. They should be studied closely and the reasoning
behind each successive step fully understood. It is most important that two-way
communication is maintained at all times between the field operator (at Heater/
WHB/ APH site) and the control room.
When lighting up, shutting down or working on an operating Heater always wear
helmet, gloves and face- shield.
7.2 START-UP PROCEDURE
For the purpose of this manual, it has been assumed that the Heater has been
mechanically completed in all aspects, that the process pressure tests have been
carried out and that the set points for all the alarms and minimum stop positions
have been established according to the design requirements.
All fire and safety equipment must be in place.
7.2.1 Preparation of Heater
 Check Heater isolation, i.e. all blanks are in place.
 Carry out an external and internal inspection of the Heater, checking that all
auxiliary equipment is in place and that there is no oil or extraneous material in
the firebox.
 Check that the Heater Dampers operate freely over their full travel range. Make
sure that the Damper indicators correspond to the actual position of the
Dampers.
 Check the Burners for correct positioning and the gaskets are fitted and in good
conditions.
 Check that all Burner air registers move freely.
 Make sure that purge, snuffing steam and instrument tapping openings are free
and are not covered by refractory or choked with brick dust or rust.
 Brick up access openings and box up the Heater.
 Leave Header box doors open.
 Check that pilot gas, fuel gas and fuel oil systems have no open ends and that
all vents and drains are plugged or capped.
SHT 32 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Check that all fuel valves and cocks nearest to the Burners are shut.
 Check that all instrumentation is complete and provided.
 Check that ignitors are available and tested in a safe condition.
 De-blank and test snuffing and atomising steam systems.
7.2.2 Testing of Fuel Lines
Testing of various Fuel lines alongwith leak test shall be in accordance with
Section VI of this document. For Fuel oil lines & Treated vent gas lines, testing
shall be as mentioned below:
 Connect a nitrogen supply down-stream of the main block valve and isolating
blank in fuel oil line & Treated vent gas lines to the Heaters.
 Nitrogen purge through the Fuel Oil lines, Treated vent gas lines and each
individual Burner in turn.
 Pressurize each fuel system with nitrogen up to the last Burner valve and test
for leaks. Test pressure is 2.5 kg/cm2g.
 De-pressurize to a slight positive pressure (0.3 kg/cm2g) when leak free.
7.3 FD FAN & ID FAN
7.3.1 Fans start-up and stopping
Following procedure should be followed for the starting and stopping of FD fans &
ID fans:
 Prepare sufficient quantity of the right grade of lubricating oil as specified by
the Vendor and supply to the right level. Prepare hydraulic oil and supply it,
when it is needed for auxiliary machines.
 Supply the cooling water, when the water-cooled type bearing box is used.
 In principle, the fan should be started after suction or the delivery damper is
closed completely.
 Confirm the indication of starting conditions completed.
 Rotate the machine in a twinkle to confirm the rotating direction and observe
how the machine stops and confirm that there is no unusual noise.
7.3.2 Operation of fan
 Start the fan.
 If any unusual vibration or noise occurs during starting, stop immediately and
trace its cause.
 Open the suction or delivery dampers gradually after the speed comes up to
normal. It is prohibited to run with the damper closed for a long time, because it
increases the inner temperature of the fan and may result in damage to the fan
or some accident.
SHT 33 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Select such expansion joints that respond to the fan movement and ensure that
their reaction force to the fan is minimum, when they are set on the suction and
the delivery flange.
 The gas temperature should be increased gradually for the high temperature fan.
 In case of extra high temperature fan, confirm the situation of thermal
expansion, because its axis is decided. (see the installation drawing).
a) Axial : The rotor expands to the plane bearing

Expansion from the thrust bearing. The casing
expands from axial expansion axis.
b) Horizontal : The casing expands from the horizontal
Expansion expansion axis.
c) Vertical : The casing expands from the casing
Expansion foundation
7.3.3 Caution during operation

 Record the pressure, capacity, motor current, bearing temperature etc., at certain
regular interval.
 During operation, patrol around the fan at certain regular interval, and check,
measure and record all the parameters, mentioned above and make adjustments,
if needed.
 Inspect the lube oil and hydraulic oil (where applicable) at certain regular
interval, and replace deteriorated oil.
 Pay attention to any abnormal situation in vibration, noise, and temperature rise
of bearing.
7.3.4 Stoppage of Fan
 Switch off the motor of the fan after preventing the blow-back of gas by closing
the suction or delivery damper gradually.
 In case of emergency stop, accident, etc., switch off the mains and close the
valve quickly.
This is only a general guideline for FD & ID Fan operation. Fan vendor’s
Operating manual should be read carefully before starting these equipments. If
there is any deviation in operating procedures as indicated in the foregoing
paragraphs and Vendors manual then later should hold good.
7.4 COMMISSIONING OF THE HEATER/ WHB / APH SYSTEM
7.4.1 Establishing flows through tubes and purging the Heater
 Establish good flows through the Heater tubes in accordance with data sheet.
SHT 34 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Check frequently that instrument flow readings are correct. Water may be swept
forward from various parts of the plant if steaming out or pressure testing have
been previously carried out. Instrument lead lines may be partially filled with
water giving false readings.
 Open the stack or flue gas damper fully.
 Re-check that all the pilot gas burner valves are tightly shut. Commission steam
tracing on fuel gas lines to the Heater and check that the fuel gas knock-out
drum is free of liquid.
 Open snuffing steam to the firebox or run FD fans and purge the Heater for 15
minutes (minimum) or until fire box become free of any hydrocarbons.
 Test the firebox at representative points for the presence of inflammable gas/
vapour. Use inspection ports.
7.4.2 Gas freeing
Before the fuel line blinds are turned to the open position, the Heater must be tested
and declared "gas free". It is essential to air purge the firebox on all occasions
before lighting any Burner (or re-lighting Burners, for instance after an emergency
shutdown). The air purge should continue for 15 minutes, followed by a gas free
test. When a gas free certificate has been issued, proceed without delay to start the
fuel lines and lighting the Burners. If there is a delay between the gas free test and
lighting of the Burners, the firebox must be re-purged and re-tested. The gas free
certificates should specifically state the length of this delay.
7.4.3 Lighting Pilot Burners
 Refer 6.5 for pilot ignition.
 Do not attempt to light pilot Burners from an adjacent pilot Burner or hot
firebrick work.
 After all the pilots are alight check that the pilots cannot be blown out by
increasing the opening of air registers to the maximum possible. After the test,
reset the air registers to the normal main Burner start-up position.
 At least one pilot burner must be stable and burning satisfactorily before
charging the main fuel gas/ fuel oil line to Burners.
7.4.4 Lighting Fuel Gas Burners from pilot Burners
 Refer 6.6 for burner ignition
 Under no circumstances should gas Burners be lit off from adjacent Burners or
hot brickwork
 Adjust combustion air flow
 Gradually open the Burner gas valve until the Burner ignites from the pilot.
Continue opening the valve until a stable flame is obtained. If at first burner
fails to ignite within five seconds, shut the valve and wait five minutes before
SHT 35 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they making a further attempt. (Initial failure of the gas to ignite may be due to
residual nitrogen in the system). Adjust air registers for proper flame shape
 Light additional gas Burners as required in the same manner described above
 The fuel gas pressure at the Burner (i.e. downstream of the individual isolating
valves) must be maintained above the manufacturer's specified minimum
required pressure at all times. Failure to observe this may result in flame
instability, the liberation of unburnt gas and a resultant explosion
 Inspect Burner flames frequently and certainly after each increase in fuel gas
flow. Should a Burner flame go out, shut off the gas to that Burner and establish
the cause of flame failure before attempting to relight. Adjust air damper of
burner if necessary, to maintain a bluish coloured flame with a slightly yellow
tip
 When the demand for gas comes within the control range of the fuel gas
controller, gradually open the Burner isolating valves fully, simultaneously
adjusting gas flow to maintain constant heat input. Place the fuel gas pressure
controller on automatic control and maintain Burner light up pressure. Continue
lighting further Burners as dictated by the required rate of warm up until all are
operating at minimum light up pressure. Thereafter increase fuel gas pressure as
required to continue the warm up. Place fuel gas pressure control on automatic
from the control room.
 Wherever possible modern practice is to set air rates at light up to sustain
combustion throughout the warm up period without any further adjustment. The
large initial quantities of excess air provide for better temperature control and
more even temperature distribution. Once the Heater is at operating conditions,
fine adjustments are made to obtain efficient combustion.
7.4.5 Lighting Fuel Oil Burner
 Under no circumstances should attempts be made to light oil Burners from an
adjacent Burner or from hot brickwork
 Check that the correct type of Burner guns have been installed and are properly
positioned within the assembly. Where fitted, set the Burner interlocks to the
fire position.
 Re-check that all individual Burner valves and main supply/ return block valves
are shut and that all drains and vents are plugged or capped.
 Deblank the fuel oil supply/ return lines.
 The fuel oil must be circulating steadily at the required temperature, pressure
and at a sufficient rate of flow. Check that the steam/ electric tracing on the
Heater fuel oil supply system is commissioned and operating satisfactorily.
 Commission the atomizing steam supply to all Burners, then adjust the desired
light up pressure.
SHT 36 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Re-check that the individual Burner oil valves are closed, and that all pilot
Burners are alight and stable.
 For forced draught Burners, open Burner isolating Damper, adjust the stack
damper to obtain the recommended Heater draft through the Heater and set the
fan to provide specified flow.
 Slowly open the main fuel oil supply valve, reset the shut-down valve and
pressurise the system up to the Burner valves and check for leaks, if any. Adjust
the main fuel oil supply valve (such that) to give the recommended fuel oil
pressure at the Burner.
 Open the individual Burner purge steam valve and purge the gun barrel. Close
the purge valve.
 Gradually open the Burner oil valve until the oil spray ignites from the pilot
flame. Continue opening oil to the gun until a stable flame is obtained. Adjust
air registers for proper flame shape.
 Light additional oil Burners as necessary to achieve the specified rate of warm
up. This may require further manual adjustment of the fuel oil control valve. At
the first opportunity open individual Burner valves fully and place the fuel oil
on automatic control. Make final adjustments to the atomising steam supply
pressure and place on pressure controller.
 Inspect the flames frequently. If any one of them is unsatisfactory or goes out,
shut off the fuel, replace the oil gun with a clean one, and re-ignite
7.4.6 Raising Heater outlet temperature
On start up, each Burner, whether it is firing fuel oil or fuel gas may have to be
individually controlled until the flow is sufficient to bring the fuel controller within
its control range (usually greater than 10% of the full scale reading).
The Burner flame must be fully supervised until the individual Burner valves are
fully open and the low fuel pressure alarms are out.
The rate of increase of Heater outlet temperature is usually not greater than 25°C
per hour and the fuel pressure should not be allowed to fall below the minimum
allowable pressure for the type of Burner in use. Other points to be observed are:
 Increase the Heater outlet temperature in small steps and avoid big temperature
peaks.
 Commissioning of additional Burners should be spaced out in such a manner, as
to give an even heat distribution in the firebox.
 Inspect the firing conditions frequently. Check that all instrumentation is
working correctly.
 Check each Heater pass outlet temperature after every increase in temperature
or flow through the tubes. All process outlet thermocouples must show a steady,
even increase in temperature.
SHT 37 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  If no increase in temperature is evident on all or any one pass, shut-off all main
Burners until the reason for the condition is understood and rectified.
 If firing fuel oil, it may be necessary to adjust the atomising steam pressure to
maintain the specified pressure.
 Continue to increase Heater outlet temperature by adjusting the fuel header
pressure and lighting more Burners. Individual Burner valves should be fully
open unless there is some good reason for pinching down these valves, e.g.
flame impingement. If the Burner valve is pinched, care must be taken that the
fuel header pressure is reduced.
 When the fuel pressure controller is well within its control range, the Heater
outlet temperature control can be taken up by manual operation of the Heater
coil outlet TIC. All temperature increase must be coordinated between the
Heater field operator and the control room operator so that burners can be
adjusted or additional burners lit to hold the fuel header pressure within range
and maintain good firing conditions.
 Switch the coil outlet TIC to automatic once process conditions are reasonably
steady and the instrument is working within its control range.
 During the warming up period frequent checks for leaks from headers, flanges,
etc must be made. The header box doors must not be closed until the heater
outlet temperature reaches the normal outlet temperature.
SHT 38 OF 71
NEW DELHI O1
NEW DELHI
SECTION - VIII
MANUAL FOR VACUUM

HEATER SHUTDOWN
PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 39 OF 71
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - VIII
HEATER SHUTDOWN
This procedure is to be followed for shutdown of the Heater.
8.1 GENERAL
During shutdown it is again important to realise that operation should be
maintained on manual control. Therefore, automatic coil outlet temperature
control should not be used during this cycle. Normally, the firing rate on the
Burners is decreased under manual control lowering the process outlet
temperature at a rate of 25°C per hour until the point of approximately 150°C
arch temperature is reached.
At this point, Burners may be turned off, but process circulation continued until
there is no possibility of potential damage to process equipment or tubes. When
all Burners are turned off, spade main fuel gas and fuel oil lines immediately.
Depending on process requirements, keep the process fluid circulating in the
Heater for cooling down to ambient temperature.
On shutdown resulting from an emergency in equipment other than the Heater,
the procedure is to shut off Burners and flow immediately and continue to steam
out. Local instructions usually cover such occurrences and these must be
followed.
On Heater emergency shutdown resulting from such case as tube rupture, closing
the Damper for example, will cause flames to emerge from the Burner and peep
hole openings, thus causing personnel injury and/ or equipment damage.
8.2 NORMAL SHUTDOWN
8.2.1 Detailed Procedure for Normal Shutdown
All pilot gas Burners must be kept in commission until all main fuel gas and fuel
oil Burners are shutdown and the main fuel systems purged. All Burners must be
steam purged. All oil Burner guns must be removed.
Take the Heater coil outlet TIC out of service and place the fuel on manual
pressure control. As the feed rate to the unit associated with the Heater is reduced
to the specified level, reduce the number of main Burners in service so that the
desired temperature is maintained and fuel supply pressure does not fall below
flame stability limits. The shutdown of Burners should be staggered so that the
remaining Burners are spaced to give even firing and heat distribution throughout
the firebox.
The Heater must not be left un-attended during this period and checks must
be made frequently to ensure that pilot Burners remain alight and Burner
firing conditions are satisfactory.
 If the WHB/ APH are in line, gradually open the APH air bypass damper to
avoid exit flue gas being cooled below its dew point in the APH
SHT 40 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  At 400°C Arch temperature or when the Heater duty nears 50% of Design,
both the WHB/ APH are to be completely bypassed and allow flue gases to go
directly to the Stack
 The flow rates through the Heater passes must be maintained above the
minimum specified in the data sheet until all fires including pilot Burners are
shut off.
 When all the main Burners are shut off, close the main fuel gas supply valve
to the Heater. This assumes that the fuel oil supply has been shut down,
purged and guns removed earlier.
 Open all intermediate valves between the main fuel gas supply to the Heater
and the individual Burner block valves.
 Check again that all pilot Burners are still burning satisfactorily, then slowly
open one main gas Burner block valve and burn off gas to depressurise the
system.
 Close the Burner block valve when the flame goes out. Do not leave the
Burner unattended during this operation.
 Check again that all pilots remain alight and burning satisfactorily. Then
slowly open one gas Burner at the farthest end of the fuel gas header until it
ignites and burns all the fuel gas purged out of the system. Take care not to
blow out the pilot Burner and do not leave the Burner unattended during this
operation
 As soon as the flame goes out shut off the Burner supply valve
 Continue purging all lines to individual Burners one at a time until each
becomes free of gas
 When all the main Burners have been purged, shut off the purge and
depressurise the system
 Blank off the fuel gas supply to the Heater
 Shutdown all pilot gas Burners except one at the farthest end of the pilot gas
header
 When only one pilot gas Burner remains lit, shut the main pilot gas supply,
allow the single Burner to go out and close its valves
 When the above has been completed the pilot gas system to the Heater should
be isolated and blanked off.
At this stage the following checks should be carried out to ensure that:
 All the flames are extinguished
 The main fuel gas system to the Heater is free of gas and isolated with
spectacle blind.
SHT 41 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  The fuel oil system to the Heater is purged clear of oil, isolated with spectacle
blind and the Burner guns are removed from the Heater.
 The pilot gas system is free of gas and isolated with spectacle blind.
 In case of a major Shutdown when Heater Tubes need to worked upon, then
ensure that the Heater tubes have been oil or gas freed.
8.3 EMERGENCY PROCEDURE
8.3.1 Total Flame Failure
Shut off immediately all fuels supplied to the Heater by either tripping all
automatic safety tight shut off fuel valves or closing a main block valve in each
fuel supply line. Fuels supplied include fuel gas, fuel oil and pilot gas (and any
off-gas, if applicable).
 Open up the steam purge to the firebox and header box.
 Complete the valve isolation of the fuel to the Heater by closing the main
block valves and then all the individual Burner valves in each fuel supply
system.
 Continue steam purge for at least 30 minutes then shut off all steam and allow
it to clear from the Heater.
 Where forced draft fan is used for purging instead of steam, operate the fans
for the specified time.
 Inspect the Heater floor for oil and arrange for a gas test to be carried out on
the firebox, through inspection doors, at high and low locations.
If the gas test shows the presence of an explosive mixture, the purging must be
repeated and gas tests carried out. If further gas tests show the continued presence
of combustibles, the cause must be found and rectified immediately.
When the firebox is certified gas free, the Heater can be recommissioned. All
individual Burner valves must be checked to be closed before resetting the shut
down valves in the fuel system.
8.3.2 Flame failure where pilot Burners remain alight
 Trip the automatic main fuel shut off valves or close the main fuel supply
block valves.
 Close all the individual valves to main Burners.
 Where automatic safety shut off valves in the fuel lines to the Heater have
tripped shut, they may now be reset open. (Never attempt to reset safety shut
off valves until all individual Burner isolating valves have been shut, and the
cause of the trip rectified).
 Check that all pilot Burners are burning satisfactorily.
 Re-light main Burners from pilot Burners in the approved manner and as
process conditions permit.
SHT 42 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 8.3.3 Failure of individual Burners
 Close the fuel supply valve to the Burner affected.
 Check and rectify the cause of the failure.
 Check the pilot Burner to the failed main Burner and if burning satisfactorily,
relight the main Burner from the pilot in the approved manner.
 Should both the individual pilot and main Burner flame be out, both the pilot
and main Burner valves must be closed immediately.
 Relight the pilot Burner using an igniter in the approved manner and when the
pilot is burning satisfactorily, re-light the main Burner.
 Where ignitors are not fitted, the Burner should be relit using an ignitor
designed for that application.
8.3.4 Failure of Pilot Burner Gas Supply
 Close the pilot gas supply main block valve.
 Close all individual pilot Burner valves.
 Establish the cause of failure and rectify.
 Re-open the main pilot gas supply valve after following the proper Start-up
procedure.
 Relight pilots using the approved igniter.
While the pilot Burners are off, the main Burners must be closely supervised
by the operator.
8.3.5 Liquid carry over into the Firebox
Flammable liquid can inadvertently enter the firebox from the fuel gas systems or
due to a faulty fuel oil Burner.
A substantial carry-over will cause a large uncontrolled fire in the firebox that
may spread outside and underneath the Heater.
In this event this happening immediately shut off all these fuel sources from a
safe distance, but leave the pilot Burners in operation if the pilot gas system is
free of liquid. Immediately establish the cause of the carry-over, e.g. high level in
knock out drums or separators and rectify at once.
Consider whether other Heater are likely to be affected if the liquid carry-over is
from a common fuel gas main and take immediate preventive action.
The choice of whether to continue fuel oil firing or not will largely depend on the
extent of the carry-over, the temperature generated within the Heater by the
burning liquid carry over, the possible external damage to Burner assemblies,
control cabling and instruments in the vicinity. Do not continue oil firing if
combustion is occurring within the windbox or Burner chambers.
SHT 43 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they Once the emergency has passed, and before resuming fuel gas firing, ensure that
all liquid is thoroughly drained from the affected lines (draining must be to a safe
system and location; do not run off to surface drains in the vicinity of the Heater).
A large uncontrolled fire in a firebox may be due to either a ruptured tube or
liquid carry over, action should be taken appropriately.
8.3.6 Heater Tube Failure
In general, when tube failure occurs, the following actions should be carried out
immediately:
 Open snuffing steam to headers and firebox.
 Shut off all fuels including gas.
Prior knowledge of the fuel system and location of various isolation valves is
very essential to handle this type of emergency because the intensity of the
fire may be such that isolation of the Heater becomes necessary through the
isolation valves on fuel lines located at a safe distance.
 Stop the FD fan.
 Shut the air registers to the system to isolate the combustible. Do not close the
Damper in stack.
The manner in which the leakage from the tubes into the firebox is dealt with will
depend on the process, the location of the leak and the isolation and blow
through/ blow down facilities provided. Effort must be directed to reduce air, stop
the flammable material feeding the fire by isolation, depressurising the tube side,
pumping out associated equipment or blowing through tubes.
8.3.7 Failure of operating FD / ID Fan
FD/ ID fan failure can occur due to any of the following reasons:
 Failure of coupling
 Failure of electric power
 Failure of fan motor
 Failure of capacity/pressure control
 Failure of any other mechanical part
Failure of FD fan capacity/pressure control will make fan control inoperable,
which must be detected by regular monitoring of operating parameters. Alarms
should sound when any of the parameter exceeds safe value.
8.3.8 Low Flow in Heater Coil / High Temperature of the Process Fluid at outlet
In case of low flow of process fluid through heater coil or high process fluid
temperature at Heater outlet, fuel supply to Heater cuts off automatically.
8.3.9 Low pressure in fuel supply line
In case of low pressure in fuel supply line, fuel supply cuts off automatically as
per the set point of low pressure switch of individual fuel.
SHT 44 OF 71
NEW DELHI O1
NEW DELHI
SECTION - IX
MANUAL FOR VACUUM

PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 45 OF 71
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - IX
9.1 GENERAL
Proper operation of any Heater is important since poor operating techniques can
result in injury to operating personnel, pose a danger to the adjacent equipment
and endanger the life and limbs of the other staff or visitors in the neighborhood.
It can also result in unnecessary shutdown and reduction in life of the equipment.
If the Heater run is ended at an unscheduled time, the loss of production can
result in a substantial financial loss.
In addition, improper operation of the Heater/ WHB/ APH System can result in
reduction in the life of fundamental parts of the Heater and excessive wear on
Heater tubes can give rise to a dangerous situation. If a few basic simple rules of
operation are observed, Heater should give long and satisfactory service.
Of course, many variables including the service of the Heater play important roles
in the operation and life of the Heater. Coking or cracking service or other similar
high temperature and sensitive operating conditions will limit both the life and
run-length of the Heater.
However, with proper operation, the on-stream time (run length) and the
equipment life will be kept to a maximum. The conditions below should be
followed as closely as possible.
9.2 FIRING CONDITIONS
The Heater should be fired so that at no time flames impinge on the tubes. The
Burners should be operated to provide flames, which are as uniform in length and
size as can be obtained. It is normally desirable to fire all Burners even when
running at reduced capacity to ensure a uniform heat distribution to all tubes.
Excess air required for satisfactory combustion of fuel is normally 20% for fuel
oil and 15% for fuel gas firing in case of balanced/ forced draft burners. The
amount of excess air should be measured at the bridge wall or where the flue
gases enter the convection section.
It is possible to operate the Heater at excess air below 15-20% as specified and it
may, in fact, be desirable since this will increase the efficiency of the Heater.
However, a gas analysis of the flue gas should indicate that no carbon monoxide
is present (for cross checking).
If a gas analysis does indicate carbon monoxide, the excess air must be increased
to ensure complete combustion. With carbon monoxide, harmful after-burning
may result which would be indicated by a rapid increase in stack temperature.
Immediate steps should be taken to correct this, since its continuation can result
in severe damage to the stack metal and upper structural members. This may be
done by first reducing the firing rate, then increasing the air rate and then
increasing the firing rate to the desired amount. If this does not improve the
SHT 46 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they situation, the rate of firing should be cut back substantially until after-burning
ceases before the rate is increased.
If a total fuel gas failure occurs, the gas pilots and gas Burners should be
shutdown and the Heater purged for 15 minutes with steam/ running of FD fan
before the firebox is checked as gas free and the pilots and Burners are relit.
Repeat the procedure if the gas test shows presence of an explosive mixture.
9.3 DRAFT
The Burners require sufficient draft to meet the heat liberation requirements of
the Heater and only sufficient excess air quantity to optimise efficiency.
To minimise air leakage in the firebox minimum draft (negative pressure) is to be
maintained. Draft is measured at the arch of the radiant chamber and should under
normal circumstances be kept at 2.5 mm WC. This is necessary to ensure that in case
of a leak cool ambient air flows into the Heater, rather than hot flue gases coming out.
There should never be a case when a positive pressure exists at the arch. In the
case of an emergency when the arch pressure tends towards positive value, the
stack Damper should be opened immediately through winch and cable, if it fails
to open through safety interlocks.
9.4 FLOW
Maintenance of adequate flow through Heater tubes is important to prevent tube
damage. However, total Heater flow is not the only criterion. Extreme care must
be exercised to be certain that equal flow distribution is established to all passes
throughout the life of it.
Many operators will adjust flow to one or more passes by means of flow
controllers in order to maintain the same pass outlet temperature. This can be a
very dangerous procedure unless certain precautions are taken. Before any
adjustment in the flow to each pass is made, all Burners must be first trimmed to
ensure identical firing rates. If adjustment of Burners does not result in even pass
outlet temperature, some variation in process flow to each coil can be tolerated.
However, as a general rule, no more than 5% variation between the flow in each
of the passes should be allowed. Flow through the tubes should not be allowed to
fall below the minimum required as per design.
9.5 PEEP DOORS
The peep doors should be tightly closed to prevent air ingress which will result in
a decrease in the system thermal efficiency. In addition, uneven distribution of air
infiltration will result in more cooling of one area than the other areas. Thus a
variation or imbalance of heat transfer to different coils will result.
9.6 BURNER OPERATION
When the firebox is clear and does not have a smoky appearance, Burner flames
are steady and well shaped. This indicates that air supply to the Heater is properly
controlled.
SHT 47 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they In forced draft gas Burners, it is better to use more primary air and minimise the
use of secondary air to get shorter and more compact flames. A rapidly pulsating
Burner can be cured by increasing primary air and for oil firing, flame lift can be
overcome by reducing differential pressure between oil and steam slightly.
Clinker formation on Burner guards is due to impingement of flame on unburnt
oil droplets and will interfere with flame pattern. Therefore, it must be removed
otherwise firing conditions will deteriorate even further. The impingement
normally may run down the Burner block and collect in the Burner. The best way
to remove the clinker is to burn-off by firing the Burner on gas and
commissioning atomising steam only through the oil gun.
Burners should be checked regularly for any signs of blockage or unusual flame
conditions. If there is any doubt about the quality of flame from oil Burner, shut
off that particular Burner and clean/ replace tips before putting it back in
operation.
If desired turndown is not achievable with all Burners firing, some Burners may
be turned off so that firing Burners have a stable flame and operate satisfactorily.
However, it must be ensured that Burners be shut off judiciously ensuring that
heat distribution remains uniform throughout the firebox.
All the Burners should be in operation even during Heater operation at lower
than normal loads to avoid uneven heat distribution in firebox.
Pilot Burners should be kept running all the times as these are essential part
of the Heater safety system.
Some indication of faulty Burner operation and their probable causes and
corrective actions are as follows:
INDICATIONS PROBABLE CAUSE CORRECTIVE ACTION
Bad flame * Overfiring, insufficient air * Increase combustion air flow and
appearance, * Fouled or damaged burners avoid substoichiometric
smoky stack * Incorrectly set air registers combustion
* Too low steam pressure * Check Burner tip for correct
* Too low fuel temp. location, damaged condition
* Incorrect Burner tip location * Check fuel pressure and temp. to
ensure fuel oil viscosity of 25
cSt at Burner tip
* Check steam pressure
Flames lift * Combustion air flow too high * Reduce combustion air
* Atomizing steam flow too high * Maintain fuel oil viscosity
* Oil temperature too high below 25 cSt (max) at Burner
tip.
SHT 48 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they Clinker/ hard * Incorrect oil gun location * Reset Burner tip/gun
coke build-up on * Fuel oil temperature low * Correct Burner tip location
quarl, primary * Atomising steam flow too low * Increase fuel oil temp.
block fuel gun * Wet atomising steam * Increase atomising steam flow
and temperature
20°C superheat
* Atomising steam quantity
0.20-0.4 Kg/kg fuel
Sparklers in the * Atomising steam temperature * Increase steam pressure
oil flame low * Increase fuel oil temperature
* Steam pressure too low * Increase atomising steam
* Oil temperature too low temp. to get min 20°C
* Wet atomising steam superheat
20°C superheat
* Maintain fuel oil viscisity
below 25 cSt
*Organize a structured
maintenance schedule for
cleaning burner oil tip,
oil/steam filter
Airpreheater * Firing of heavy & dirty fuel * Improved water washing
fouling * Inadequate washing arrangement implemented in
new design
* Proper washing frequency
Instrumentation * Improper maintenance of * Periodic calibration and better
instruments/ controls and house keeping
analysers
9.7 ROUTINE INSPECTION
The Heater must be inspected at regular intervals. Inspection of firebox must be
carried out carefully utilising all inspection/ peep doors to enable a complete
examination of Heater tubes and Burner flames. Particular attention must be paid
to the following points:
 Individual pass flow
 Heater pass outlet temperature and skin temperature
 Heater firebox temperature
 Burner flame appearance and size
 Heater tube appearance and movement
 Free movement of vertical Heater tube guides through the Heater floor.
 Condition of refractory and tube hangers. Any abnormality should be reported
immediately to the proper authority.
 Airpreheater inlet and outlet temperature
SHT 49 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 9.8 ROUTINE TESTING
All emergency shutdown and alarm systems must be checked at regular intervals.
When the plant is shutdown, the Heater emergency systems should be checked,
the fuel shutdown valves checked for tightness and the results recorded.
Regular testing of all burners should be carried out to ensure that the flame
stability has not deteriorated due to natural wear and tear of the equipment, and
that fuel pressure alarm settings are correct for the type of Burner used.
Following procedure is to be followed:
Ensure a draft of (-) 2.5 mmWC at Arch. Slowly close the individual Burner
isolation valve until the flame becomes unstable and note the fuel pressure
downstream of the isolation valve (i.e. pressure at the Burner). This pressure
should be lower than the low pressure alarm set point. If the oil Burners are on
differential steam/ oil pressure control then individual Burner steam pressure can
be turned down to suit the oil pressure.
The following points must be observed:
 The tests should be carried out under strict supervision ensuring that all pilot
Burners are firing correctly.
 Burners must be tested one at a time and a test pressure gauge installed at the
burner.
 Faulty Burners must be removed from service, repaired and retested.
 The tests should only be carried out when the heater load is at least 60% of
normal operating load.
 As soon as the Burner shows sign of instability, the isolation valve must be
slowly reopened.
 The fuel low pressure alarm set point should be set above the instability
pressure.
 A record should be kept of all tests undertaken.
When possible the gas Burner tests should be carried out when fuel is at different
values of the molecular weight range, and in all cases the tests must be related to
the analysis of the fuel.
SHT 50 OF 71
NEW DELHI O1
NEW DELHI
SECTION - X
MANUAL FOR VACUUM

PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 51 OF 71
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - X
These instructions are based on the assumption that air and flue gas are uniformly
distributed at the inlet flanges and throughout the Airpreheater.
10.1 Design Data
Design data specifying the performance of the Cast/ Glass Tube Airpreheater at
Design conditions shall be as per the equipment datasheet.
10.2 General Description of Cast Tube Airpreheater
The cast tube air preheater is an assembly of rectangular cast tubes. The heat
exchange surface is made up of hot end and cold end sections. The cast iron tubes
in hot end have integral fins on both internal and external surfaces. Tubes in cold
end have integral fins only on the outside surfaces.
The entire tube assembly is built inside a steel frame made by beams and fully
insulated casings. Flue gas and air terminal connections are made of rectangular
flanges formed from rolled steel sections and forms an integral part of the air
preheater frame. The entire Airpreheater assembly can be considered as part of
the ducting system because of its general arrangement.
The tube is made up of two half sections, cast independently and then bolted
together. To prevent air leakage in the longitudinal direction ceramic ropes are
placed on the tube flange before bolting. The flanges provide the necessary gap
for the flue gas passage. The flanges also have peripheral grooves on all four
sides to accommodate asbestos rope to ensure all tightness between adjacent
tubes.
The cold end bank is placed at the cold end of the APH as the lowermost rows/
pass of the Cast iron tubes. All the modules of the APH are connected with air
return headers to make the APH multi-pass on the air side. The APH thus behaves
as a true cross-current flow heat exchanger.
Flue gas enters at the top of the hot end and flows vertically down over the
outside of tubes and leaves the Air preheater at the bottom of the cold end. Air
enters the Air preheater at the side of the cold end and flows first through the cold
end tubes. On leaving the cold end the air is turned through 180° and flows
horizontally through the hot end tubes of the Air preheater. The flue gas in is a
single pass, which flows vertically down from top to bottom and the air is on
single or multiple passes, as the case may be.
10.3 General Description of Glass Tube Airpreheater
The glass tube air preheater is an assembly of round temperature resistant boro
silicate tubes. The heat exchange surface is made up of these bare tubes which are
fixed inside tubesheets using appropriate Teflon/ PTFE bushes. These bushes
permit sealing of the tube to tubesheet gap so that minimum leakage of air occurs
into the flue gas side.
SHT 52 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they The tubesheets are themselves lined with Teflon to avoid acid dew point
corrosion. The glass tube bank is placed below the cast tube bank (with flue gas
flowing downwards and air flowing sideways from the glass bank to the cast tube
bank).
Normally only one pass of the glass bank is adequate to permit low level heat
recovery while ensuring that the tube metal temperature in the cast tube bank is
still maintained above the minimum metal temperature specified for the type of
fuel/ excess air being used in the Heater.
Commissioning procedure for an Airpreheater has to be formulated considering
the process Heater it is going to serve and the overall system conditions. The
instructions mentioned here for commissioning assistance are meant for the
general safety of the Airpreheater equipment alone.
To avoid fouling and corrosion of the heat exchange surface it is recommended
that the heat load be brought upto design conditions as early as possible. This
procedure is aimed at rapidly elevating the cast iron tube wall temperature above
the acid dew point to minimise acid condensation on the cast APH tube surfaces.
It is to be noted that the air bypass may be necessary during winter/ turndown
conditions. The user shall review the actual quantity to be bypassed considering
the other equipment in the system like Dampers, Heater etc.
However, it is recommended that under no circumstances the flue gas exit
temperatures be allowed to go below the recommended values and the air bypass
may need to be adjusted accordingly to avoid acid condensation under all
operating conditions and special care need to be taken when the Airpreheater is
taken on line. The tube skin temperature on the last row of tubes in the cast APH
section should be monitored closely and should be kept atleast 10°C above the
dew point of the flue gases.
Due to the tubular construction of the cast fin air preheater there are neither
extensive flat surfaces, nor small ducts or no flow zones. The whole working
surface is swept by the flow of flue gases thus preventing soot deposit.
Since the flue gas is only cooled in cast Airpreheater to a point where the
minimum tube wall temperature is still safely above the acid dew point, there is
no condensation on the flue gas side surfaces and hence no sticky deposits. No
frequent cleaning of the tubes is therefore required during normal operation.
However some soot deposition does take place due to abnormally poor
combustion in the heater and for the safe operation, it is recommended to monitor
the flue gas pressure drop and when this approaches the limit of ID Fans capacity,
the Airpreheater should be taken out of line and washed.
SHT 53 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 10.6 Washing Procedure
Washing of Airpreheater has to be done by taking it off line. Vendor’s
instructions for carrying out the washing of the APH should be followed
thoroughly. A separate washing arrangement is provided for the Cast tube &
Glass tube banks of the APH.
Commissioning, Maintenance and Washing Instructions above are general only
and vendor’s instructions with regard to above must be followed thoroughly. In
case of any contradiction, vendor’s instructions shall overrule these general
guidelines.
SHT 54 OF 71
NEW DELHI O1
NEW DELHI
SECTION - XI
MANUAL FOR VACUUM

WASTE HEAT BOILER & STEAM DRUM
PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 55 OF 71
REV.
SECTION - XI
WASTE HEAT BOILER & STEAM DRUM OPERATING INSTRUCTIONS
These instructions are based on the assumption that boiler feed water supply to steam
drum is un-interrupted and the flue gases are uniformly distributed at the inlet flanges
and throughout the Waste heat boiler.
11.1 Design Data
Design data specifying the performance of the Waste Heat Boiler / Steam Drum
at Design conditions shall be as per the equipment datasheets. The Waste heat
Boiler package includes the following:
 Boiler section (Evaporator)
 Steam drum & Safety relief valves
 Instrumentation & Controls
 Boiler piping which includes risers & down comers, blow down valves etc
 Other Valves & fitting
 Common Phosphate dosing package for CDU & VDU Heater
 Soot Blowers for Waste Heat Boiler
11.2 General Description of Waste Heat Boiler
The Waste Heat Boiler (WHB) is an assembly of carbon steel tubes with inlet and
outlet headers also of carbon steel. These carbon steel tubes have integral fins.
The entire assembly is built inside a steel frame made by beams and fully
insulated casings with Header boxes for return bends. Flue gas terminal
connections are made of rectangular flanges formed from steel sections which
form an integral part of the WHB. The entire WHB assembly can be considered
as part of the ducting system because of its general arrangement. Two down-
comers from the Steam drum are connected to the inlet header of the WHB and
three risers from outlet Header of WHB are connected to the Steam drum. The
WHB is of water tube type with natural thermo-syphon water circulation.
The Flue gas is a single pass which enters at the top of the hot end and flows
vertically down over the outside of finned tubes and leaves the WHB at the
bottom of the cold end. Water from Steam drum through down-comer pipes
enters in the inlet Header of WHB at the side of the cold end and flows first
through the cold end multiple pass tubes. On leaving the cold end the steam-water
mixture is turned through 180° and then it flows horizontally through the hot end
tubes and enters in the outlet Header of the Waste Heat Boiler. Steam-water
mixture from the outlet Header through riser pipes enters in the Steam Drum. 3
Nos. of Soot Blowers have been provided for outside cleaning of finned tubes.
Soot Blowers are electrically operated retractable type. Soot Blower Instruction
manual is comprehensive and should be referred to by the operating and
SHT 56 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they maintenance personnel. Requisite Dampers/ SOBs have been provided at the inlet
and outlet of the WHB for isolation as and when required.
11.3 General Description of Steam Drum
The Steam Drum is fabricated from boiler quality plate and is mounted
horizontally on a supporting structure having platforming all around for ease of
operation/ maintenance. Hemispherical dished ends alongwith Manway have
been provided at each end of Steam drum. The Steam drum has a Design Pressure
of 19 kg/cm²(g), Design Temperature 350°C and Steam flow rate of 9.7 TPH. 2
Nos. of Pressure Safety valves with set pressures of 18.5 kg/cm²(g) &
19kg/cm²(g) have been provided on the Steam drum. The Steam drum internals
consist of a vortex breakers, demister pad etc.
The Steam drum has been provided with the following nozzles:
 Feed water Inlet
 Riser
 Down comer
 Chemical feed
 Continuous Blow down & Intermittent Blow down
 Steam Outlet
 Vent
 Instrumentation nozzles
Commissioning procedure for WHB has to be formulated considering the
operating cycle that the main Heater is going to serve and the overall system
conditions. The instructions mentioned here for commissioning assistance are
meant for the general safety of the WHB alone.
To avoid fouling and corrosion of the heat exchange surface, it is recommended
that the heat load be brought upto design conditions as quickly as possible.
The Steam drum level should be maintained at the center-line of the Steam drum.
Some soot deposition does take place on the heat transfer surface of the Boiler.
Regular soot blowing operation should be carried out to remove the deposited
soot on the heat transfer surface.
Apart from continuous blow down from the Steam drum to maintain the quality
of water being re-circulated in the WHB tubes, intermittent blow down operation
should be carried out regularly to drain out the slug/ sediment from the steam
drum to avoid build-up of impurities in the Steam drum.
SHT 57 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 11.6 Chemical Dosing Procedure
The desired pH value of the steam produced in Steam drum is ensured by
chemical/ Phosphate dosing system. The Phosphate Dosing system includes a
dosing tank with a capacity of 860 liters, 3 Nos. Metering pumps with motors out
of which two are running and one standby. Necessary instrumentation/ valves
have been provided to ensure proper operation of the Dosing system. Vendor’s
instructions for carrying out the chemical dosing should be followed thoroughly.
Commissioning, maintenance and chemical dosing Instructions above are general
only and vendor’s instructions with regard to above must be followed thoroughly.
In case of any contradiction, vendor’s instructions shall overrule these general
guidelines.
SHT 58 OF 71
NEW DELHI O1
NEW DELHI
AND
SECTION - XII
MANUAL FOR VACUUM

ISOLATION FOR SAFE ENTRY
PROCEDURE FOR GAS FREEING
PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 59 OF 71
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - XII
PROCEDURE FOR GAS FREEING & ISOLATION FOR SAFE ENTRY
When it be necessary to enter a Heater firebox for inspection or repair, the
following steps must be carried out after completion of normal shutdown
procedure:
 Open wide the stack Damper and all primary and secondary air registers.
 Open snuffing steam to the firebox and purge or use forced draught fans for
specified period. Carry out gas test to ensure proper purging.
Isolation by spectacle blinds on the firebox side of the Heater must include:
 Fuel oil lines
 Fuel gas lines
 Pilot gas lines
 Treated vent gas lines
 Atomising steam lines
 Snuffing steam lines
Check that all purge connections to fuel gas headers have been disconnected.
Where the Heater shares a common stack with other Heater, close the Damper in
the flue ducting. In this case open the inspection/ entry doors in the upper section
of the Heater to provide continued ventilation.
Following complete isolation permission may be given to enter the Heater
provided that:
 The Heater is adequately ventilated
 The Heater is tested and certified gas free and tested for oxygen deficiency
 The Heater has cooled sufficiently to allow personnel to enter
The procedure does not cover the gas freeing and isolation of the tube side of the
Heater which will form part of the associated unit shut down procedure
Instructions given above are general in nature and procedures/ instructions of the
Safety Department of the operating refinery should be adhered to in letter and
spirit.
SHT 60 OF 71
NEW DELHI O1
NEW DELHI
SECTION - XIII
MANUAL FOR VACUUM

PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 61 OF 71
REV.
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they SECTION - XIII
13.1 GENERAL
Preventive maintenance of Heater/ WHB/ APH System should be carried out
regularly and as per a fixed program. This should be a result of regular inspection
during operation at which time the extent of general damage and deterioration
may be visually determined. It is important to have a regularly scheduled
shutdown to make a detailed mechanical inspection and to repair or replace any
auxiliary equipment that does not meet the minimum requirements.
If equipment breaks down during normal run time, unnecessary delays due to
unavoidable maintenance as well as possible dangerous conditions may result.
The very nature of the service required of a Heater makes proper maintenance of
the component parts essential.
Visual inspection of Heater should be performed on a frequent schedule and
particular emphasis placed upon the tubes, fittings and setting. It is these three
items that are generally considered to receive the greatest amount of wear during
the normal operation of the Heater. Any flame impingement and hot spots should
be noted and the exact location recorded. In addition, any indication of tube
bowing or refractory surface cracks should be recorded.
Operating instruments should be checked to assure proper functioning. The
thermocouples in particular should be carefully checked. Any improperly
operating piece of equipment should be reported and repairs be carried out
immediately.
The operating data of the Heater for the inspection period should be assembled
and compared. The flow and temperature information on the Heater charge
should be available for calculation of the Heater duty. The temperatures for each
pass in the Heater should also be obtained. In addition, the firebox and flue gas
temperatures, the fluid and fuel pressures and the draft in all sections of the
Heater should be measured. An Orsat analysis should be made of the flue gas
composition to find out the amount of excess air. Any unusual changes in
operating loads should be checked by means of the Heater log sheets.
The entire record including operating, inspection and maintenance results should
be summarized in a report for each inspection period. This may result in
unexpected problems and indications of unusual, significant changes from
previous inspection reports.
The Heater operational information should then be checked with the design
condition of the Heater to determine the cause of these results and immediate
corrections then made if the reports suggest faulty or dangerous operation.
SHT 62 OF 71
NEW DELHI O1
follows:
1. Positive pressure at * Stack Damper excessively * Open stack damper to maintain
top of firebox (Arch) closed (-) 2.5 mmWC pressure at Arch
* Excessive firing rates * Reduce firing rate and rectify air
* Excessive fouling or leakage points
blockage of convection * Carry out 'ON-LINE' tube cleaning
section * Water wash Airpreheater
* Problem in ID fan * Check ID fan operation/capacity
2. High/ Uneven tube * Overfiring; flame * Trim Burners to achieve uniform
skin temperature impingement firing rates
* Unbalanced Low process * Adjust process fluid flow
fluid flow * Reduce fuel firing rate
* Excessive firing * Decoke Heater coils
* Coking in side Tubes * Check skin thermocouple
* Wrong/ detached
thermocouple
3. Excessive * Overfiring * Check process fluid inlet temperature
temperature in * Excess air too high * Analyse fuel composition
firebox/ leaving the * After burning * Check burner tips/ burner design for
Heater * Heat release too high fuel fired
* Reduce fuel firing
4. High fuel * Incorrect combustion air * Limit excess air to: Fuel gas: 5-15%,
consumption Flow Fuel oil: 10-20%
* Dirty or blocked Burners. Remember every 5% increase in
* High Excess Air excess air reduces Heater efficiency
* Fouling of Tubes by 0.4%
* Plug leakage through peep hole and
reduce combustion air flow through fan
* Ensure uniform combustion air flow
through each Burner
* Carry out flow modeling of air duct,
if required
* Organise structured maintenance
schedule for cleaning Burners & tubes
5. Variation in outlet * Unequal flow distribution * Reduce fuel firing rate
temperature of * Uneven firing * Adjust process flow through each
multipass Heater * Uneven firing pass to ensure variation in flow is
within 5%
* Avoid two phase flow at Heater
inlet
6. High pressure drop * Coke build-up * Decoke Heater coil
through tubes * High flow-rate * Reduce process flow rate
* High vaporization rate/ * Check feed composition
excessive fouling
SHT 63 OF 71
NEW DELHI O1
follows:
7. Low pressure drop * Low flow rate * Increase process flow rate
through tubes * Change in Heater inlet/ * Check feed composition
outlet conditions
8. High flue gas * External fouling of * Decoke the Heater periodically
temperature ex- Convection tubes Remember every 20°C increase in
convection bank * Coking / fouling of inside flue gas temperature reduces
of radiant tubes Heater efficiency by 1%
9. Corrosion in Heater * Fuel ash & acid dew point * Check fuel oil composition for
tubes, support corrosion sodium, vanadium and sulphur
castings
The mechanical inspection of the Heater should be generally performed in the
sequence that results in the inspection of the most critical items first.
13.2 REFRACTORY SETTING
The refractory setting provides the enclosure for containing the heat liberated in
the Heater and must protect the exterior structural members that support the coil
tube supports of the Heater. The setting is also important in that the amount of
heat which passes through these walls will affect the thermal efficiency of the
equipment. The prime factors causing deterioration of the Heater settings are
climatic conditions, operating temperature and products of combustion. Damp,
humid atmosphere in the vicinity of the Heater resulting either from geographic
location or location within the plant itself can result in deterioration of the
refractory and insulation. Cracks or openings in the external housing of the
Heater can allow rain or moisture to attack this material particularly when the
Heater is not in operation. The operating temperature and manner in which the
Heater is fired is a major cause of the deterioration of the Heater refractory. At
high temperatures the refractories will deteriorate by spalling as a result of long
time exposure, failure of binding material, melting and loss of mechanical
strength. The products of combustion very often contain sulphur and vanadium. If
cracks or openings are present in the refractory lining, these gases can reach the metal
and the formation of sulphurous acid could result and cause harmful deterioration. In
addition when these ash products and the refractory are in contact at high
temperature, a fluxing action may occur producing a slag that may be
more or less fluid. Vanadium pentoxide is such a fluxing agent, and can result
in the decrease in the refractory thickness and thus the heat insulation with
ultimate result of high temperature of supporting steel structures
The insulating concrete and expansion joints should be carefully checked for
damage from heat, distortion, debris or open joints. The inspection should include
check for breakage, slag formation, crumbling or open joints, any of which, if
allowed to go un-checked can result in damage to the supporting steel from high
metal temperature oxidation and corrosion. The supporting steel for the roof
should be thoroughly inspected and any supports that indicate excessive damage
should be replaced.
SHT 64 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they If cracks have occurred and are more than a hairline separation, they should be
cleaned for the full thickness of the material so that the faces of each side of the
opening are parallel to one another for the entire thickness before inserting repair
material. If spalling has occurred, the entire area affected should be replaced.
In the case of castable material care must be exercised to use reinforcing material
tied back to the casing and it is necessary to place one layer of castable on
another. This is important since layers of castable material should be mixed in the
exact proportions and quantities recommended. After initial set they should be
cured for approximately 24 hours by keeping the surface moist or until the time
when the finger can be drawn across the refractory without picking up any moist
material. Without this procedure the surface may crack and become trouble-some.
Occasionally a split tube or firing without charge will result in overheating of the
refractory. The refractory surface becomes plastic and begins to flow. The surface
upon cooling solidifies and forms a hard glazed surface. This is not normally
repaired since this condition does not seriously affect the setting performance.
In the case of mechanical damage to the setting, the refractory affected should be
replaced.
13.3 STRUCTURAL SUPPORTS
A visual inspection should be made of all load carrying structural steel members,
such as, columns, supporting structures, stairways, walkways and roof. If this
inspection indicates any unusual conditions such as deflection or bending in any
members or corrosion, which might result in substantial weakening of the
support, the cause of the trouble should be immediately determined.
Bending or deflection may result from over-loading, over-heating or forces due to
expansion of some element in the Heater. Once the cause of the problem has been
determined, it should be relatively simple to either protect or reinforce the
member so that the condition resulting in the bending or deflection can no longer
affect it.
On members that have corroded, the remaining metal area should be determined
and a check should be made to determine the suitability of the member to perform
its function. If not satisfactory, corrective measures should immediately be taken.
The connection between columns, beams and girders should be checked to see
that bolts are tight and not broken. This should be done particularly where
corrosion is a problem.
13.4 BURNERS
Burners should be checked visually during operation and any changes required
should be made at this time. If mechanical repairs are required, the Burner should
be removed and replaced by a spare Burner (if available) immediately to ensure
proper and uniform firing conditions. A more detailed examination for erosion,
corrosion and oxidation should be made when the unit is shutdown.
SHT 65 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 13.5 CLEANING OF BURNER
Ideally there should be tailor-made burner stripping bench and solvent bath
available for Burner cleaning.
13.5.1 Fuel Oil Burners
Normally fuel oil Burners are cleaned by using steam as a cleaning medium on
the Burner cleaning bench. Even after cleaning by using steam, if the
performance of the Burner is not found to be upto the mark, gun should be
dismantled to allow cleaning of the oil and steam orifices. Burner vendor's
instruction for this purpose must be available to the operating and maintenance
personnel.
If steam/ air blowing is in-adequate, use soft copper and bronze wire brush for
cleaning out the holes or removal of carbon from surfaces. Wash all parts in a
suitable solvent. Both steam and oil orifice dimensions should be checked, if
wear is suspected. During re-assembling, proper gasket or O-ring should be used.
Do not allow parts of Burners for some other Heater to get mixed. Also check
gaskets or O-ring on the burner block while putting back the gun again
13.5.2 Fuel Gas Burners
Normally fuel gas Burners require less often cleaning than oil guns. For proper
flame envelope and good combustion, during annual turn-around the spud, central
gas guns and rings must be cleaned. While cleaning gas Burners care should be
taken so that holes are not enlarged. If tips are found to be with oversized holes,
then the tips must be changed / replaced after consultation with Burner vendor.
13.5.3 Pilot Gas Burners
Correctly positioned pilots with a proper flame are one of the most vital safety
devices in a Heater.
During shutdown or turn-around, pilot tips, tip retention jets or orifice holes are to
be cleaned. Any blockage of the tip retention jets may cause flame instability.
Care should be taken so that orifice holes are not enlarged during cleaning.
13.6 BREECHING/ DUCTS/ DAMPERS
Breeching may be visually inspected externally while in operation. The
inspection should give an indication of external oxidation that may be a result of
overheating of the metal after refractory lining has failed. The indication of
overheating and oxidation may mean failure of some part of this lining. The
lining should then be carefully inspected on shutdown.
Bolts and welds should be checked to ensure that they are in good condition. If
the ducts or breechings are painted and flaking or other failure is indicated, the
area affected should be cleaned and re-painted.
An internal inspection should be made on shutdown to determine any damaged
area. If the breeching or duct is un-lined, the metal thickness can be checked for
thinned area by means of the hammer test.
The Dampers should be checked for corrosion and operability with particular
emphasis made around the shaft and linkages of the operating mechanism.
SHT 66 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they 13.7 STEAM AIR DECOKING OF PROCESS COILS
Ideally Heater should be decoked periodically (during Heater shutdown) to ensure
that there is no fouling/ coking inside the Heater process coils. Need for taking
the Heater for de-coking can be reviewed based on increased tube metal
temperature, increase in process fluid pressure drop, need for over-firing to obtain
process duty.
Due to the nature of the Crudes proposed to be processed and in order to have
flexibility in operation, there is a need felt to have a forward as well as reverse
steam-air de-coking during a planned plant maintenance shut-down. Steam-Air
De-coking Systems for the Vacuum Heater have the provision of being Steam-air
de-coked pass by pass or all passes together – whether in the forward or in the
reverse de-coking mode.
The following are the steps for decoking the Heater process coils:
 Once Heater is shutdown completely ensure that there is no process fluid
inside the process coils
 Using the swing elbows disconnect the Heater coils from the process inlet &
outlet piping and connect Heater coils to decoking headers
 Open the MP steam valve to allow de-coking steam to pass through Heater
coils. The globe valve along with Flow element 010-FE-3045A to L provided
on the MP steam line can be used to set the flow through each pass.
 After ensuring MP Steam is flowing through the tubes, start a few Burners to
heat the firebox to at least 500°C.
 Open the Plant air valve to allow Plant air to pass through Heater coils. The
globe valve along with Flow element 010-FE-3046 provided on the Plant air
line can be used to set the flow. Rotameters are provided on each pass of
Plant Air for decoking.
 Now gradually increase the Firebox temperature. During initial decoking keep
the air flow at minimum so that the temperature rise due to the burning of the
coke does not lead to overheating of the tube. Then gradually increase the air
quantity to the specified figure for proper decoking of the tubes.
 During De-coking operation, firebox temperature & Skin Thermocouples
readings should be carefully monitored to avoid over-heating of the tubes.
 Once decoking is started, simultaneously open the service water for
quenching of effluents entering into Decoking drum. Ensure sufficient water
is supplied to the Drum using the globe valve on service water line and
Temperature gauge 010-TG-3197 (close to the Decoking drum) on decoking
line to decoking drum
 Also ensure water supply to the spraying arrangement provided inside the
Decoking drum
 During decoking the gaseous waste from the decoking drum shall be vented
to the Stack and unwanted liquid shall be drained out to OWS
SHT 67 OF 71
NEW DELHI O1
This document and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agreement that they  Once the decoking is complete, stop the Plant air to the Heater. Then
gradually start reducing the firing and finally stop all the Burners. Once the
Firebox reaches 400°C, cut off the MP steam supply to Heater coils. Also
close quench water/ spray water to the Drum
 Allow the Heater and connected piping to cool. Then connect the swing
elbows to Process inlet & outlet piping.
 On completion of decoking the removable quick opening type flange at the
bottom of the decoking drum can be used to remove any slug from the drum
 The total MP Steam, Plant Air and Service Water required for Decoking
operation are 120000 kg/hr, 11920 kg/hr and 57000 kg/hr respectively.
 During Decoking operation the followings shall be Set Points of the
Instruments.
P&ID: PECL/C-908/1145/AVU/C-4011
TIC – 3002 A to L High 650°C (Adj.)
Outlet Temperature
Tube Skin
temperature
Tube Skin
temperature
Tube Skin
temperature
Individual HC Feed
PAH – 3003 A to L High 6 kg/cm2g (Adj.)
Inlet Pressure
SHT 68 OF 71
NEW DELHI O1
NEW DELHI
ENCLOSURES
SECTION - XIV
MANUAL FOR VACUUM

PECL/C-908/
1145/AVU/C-150
DOCUMENT NO.
O1
SHT 69 OF 71
REV.
NO. OF
SHEETS
API Datasheet for Vacuum Charge Heater 010-F-
1. PECL/C-908/1145/AVU/C-013
002
12
Burner Data sheet for Vacuum Charge Heater

2. PECL/C-908/1145/AVU/C-018
010-F-002
5
3.
APH Data sheet for Vacuum Charge Heater 010-
4. PECL/C-908/1145/AVU/C-021
F-002
6
FD Fans Data sheet for Vacuum Charge Heater

5. PECL/C-908/1145/AVU/C-028
010-F-002
7
Motor Data sheet for FD Fans for Vacuum

6. PECL/C-908/1145/AVU/C-029
Charge Heater 010-F-002
3
ID Fans Data sheet for Vacuum Charge Heater

7. PECL/C-908/1145/AVU/C-031
010-F-002
7
Motor Data sheet for ID Fans for Vacuum Charge

8. PECL/C-908/1145/AVU/C-032
Heater 010-F-002
3
SAPH Data sheet for Vacuum Charge Heater

9. PECL/C-908/1145/AVU/C-035
010-F-002
3
WHB Data sheet for Vacuum Charge Heater 010-

10. PECL/C-908/1145/AVU/C-037
F-002
4
WHB Steam Drum Data sheet for Vacuum

11. PECL/C-908/1145/AVU/C-039
5
Soot Blower Data sheet for Vacuum Charge

12. PECL/C-908/1145/AVU/C-042
Heater 010-F-002
6
Motor Data sheet for Soot Blower for Vacuum

13. PECL/C-908/1145/AVU/C-043
3
Decoking Drum Data sheet for Vacuum Charge

14. PECL/C-908/1145/AVU/C-045
Heater 010-F-002
4
Damper/ SOB Data sheet for Vacuum Charge

15. PECL/C-908/1145/AVU/C-047
Heater 010-F-002
15
Data sheet for Expansion Joints for Vacuum

16. PECL/C-908/1145/AVU/C-049
4
Data sheet for De-Superheater for Vacuum

17. PECL/C-908/1145/AVU/C-203
5
Data sheet for Silencer for Vacuum Charge

18. PECL/C-908/1145/AVU/C-207
Heater 010-F-002
4
Soot Blower Data sheet for WHB for Vacuum

19. PECL/C-908/1145/AVU/C-212
6
Motor Data sheet for Soot Blower for Vacuum

20. PECL/C-908/1145/AVU/C-213
3
P&ID for Process Section for Vacuum Charge

21. PECL/C-908/1145/AVU/C-4011
Heater 010-F-002
1
P&ID for Heater Casing for Vacuum Charge

22. PECL/C-908/1145/AVU/C-4012
Heater 010-F-002
1
SHT 70 OF 71
NEW DELHI O1
NO. OF
SHEETS
23. PECL/C-908/1145/AVU/C-4013 Superheating for Vacuum Charge Heater 010-F- 1
002
P&ID for Firing Section Heater for Vacuum
24. PECL/C-908/1145/AVU/C-4014
1
P&ID for FD Fans & SAPH for Vacuum Charge

25. PECL/C-908/1145/AVU/C-4015
Heater 010-F-002
1
P&ID for Air Preheating System for Vacuum

26. PECL/C-908/1145/AVU/C-4016
1
P&ID for WHB & Steam Drum for Vacuum

27. PECL/C-908/1145/AVU/C-4017
1
P&ID for Decoking Facility for Vacuum Charge

28. PECL/C-908/1145/AVU/C-4018
Heater 010-F-002
1

29. PECL/C-908/1145/AVU/C-4020
for Vacuum Charge Heater 010-F-002
1
Cause & Effect Table for Vacuum Charge Heater

30. PECL/C-908/1145/AVU/C-4021
010-F-002
3
PECL/C-908/1145/AVU/C-4051- GA Cross Section & Longitudinal Section for

31. 4052 Vacuum Charge Heater 010-F-002
2
PECL/C-908/1145/AVU/C-4061-
32. 4068
GA Plans for Vacuum Charge Heater 010-F-002 8

33. PECL/C-908/1145/AVU/C-4071 Connections for Vacuum Charge Heater 010-F- 1
002
PECL/C-908/1145/AVU/C-5011- APH GA Plans for Vacuum Charge Heater 010-
34. 5013 F-002
3
PECL/C-908/1145/AVU/C-5021- APH GA Elevations for Vacuum Charge Heater

35. 5022 010-F-002
2
PECL/C-908/1145/AVU/C-5031- Miscellaneous Details & Notes for APH System

36. 5032 for Vacuum Charge Heater 010-F-002
2
PECL/C-908/1145/AVU/C-5041- GA for Ground Mounted Stack for Vacuum

37. 5042 Charge Heater 010-F-002
2
Data sheet for Flue Gas Analyzer for Vacuum

38. PECL/C-908/1145/AVU/C-8221
19
Data sheet for Skin Thermocouples for Vacuum

39. PECL/C-908/1145/AVU/C-8681
11
Control & Shutdown Narrative for Vacuum

40. PECL/C-908/1145/AVU/C-8871
30
SHT 71 OF 71
NEW DELHI O1

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OPERATING MANUAL

INDIAN OIL CORPORATION LIMITED

INDIAN OIL CORPORATION LIMITED

MANUAL NUMBER: PN/AVU/OM/U- COPY NO.

(Debbrata Mondal) (Manish Kumar) (Shashikant Kumar)

Revision No. Revision Date Details of Revision Approved By

Revision-01 April 2016 CPNM

(a) Process scheme description of “NEW CAUSTIC DOSING

Chapter No. 12:

Chapter No. 13:

Chapter No. 22:

Revision-04 January Chapter No. 3:

Chapter No. 010:

Chapter No. 01 &03:

Revision-06 January Chapter No. 22:

Revision-07 January Chapter No. 03:

Prepared By: Checked By: Approved By:

(Debbrata Mondal) (Manish Kumar) (Shashikant Kumar)

Copy No: Issued To: Department

Copy 1 of 6 Engineering Assistants Production

Copy 2 of 6 Panel Officers Production

Copy 3 of 6 Shift in Charge Production

Copy 4 of 6 Unit in Charge Production

Copy 5 of 6 HOD Production

Copy 6 of 6 Emergency Control Room HSE

INDIAN OIL CORPORATION LIMITED

(Debbrata Mondal) (Manish Kumar) (Shashikant Kumar)

Erstwhile CHAPTER -22 has been removed and maintained as

Prepared By: Checked By: Approved By:

1.0 GENERAL DESCRIPTION:

Prepared By: Checked By: Approved By:

Prepared By: Checked By: Approved By:

Prepared By: Checked By: Approved By:

2.0 DESIGN BASIS

3.1 DESIGN OBJECTIVE

3.2 UNIT SECTION & CAPACITIES

2.3.1 CDU SECTION

Prepared By: Checked By: Approved By:

2.3.2 VDU SECTION

2.3.3 NSU SECTION

Prepared By: Checked By: Approved By:

2.3.4 OFF GAS TREATMENT SECTION

2.3.5 SOUR / VDU VENT GAS TREATMENT SECTION

3.3 DESIGN FEED

Prepared By: Checked By: Approved By:

3.4 DESIGN PRODUCT SPECIFICATIONS

2.3.1 PRODUCT CUT POINTS

2.3.2 PRODUCT SPECIFICATION

Prepared By: Checked By: Approved By:

C4 in Naphtha 1.0 % vol

2.3.3 FEED STOCK CONTAMINANTS (VGO)

Prepared By: Checked By: Approved By:

3.5 FEED & PRODUCT BATTERY LIMIT CONDITIONS

Prepared By: Checked By: Approved By:

3.6 FEED & PRODUCT STORAGE FACILITIES & STREAM CONDITIONS

Prepared By: Checked By: Approved By:

3.7 MATERIAL BALANCE

Prepared By: Checked By: Approved By:

VGO 481.8 26.73 434 24.1

3.8 OUTSIDE BATTERY LIMIT ROUTING OPTIONS OF DIFFERENT STREAMS IN AVU

Prepared By: Checked By: Approved By:

Prepared By: Checked By: Approved By:

3.10 DISTILLATE STRIPPING