AVU-II Skill Development (2008-09).pdf
Short Description
AVU-II Skill Development...
Description
CENTRIFUGAL PUMP Start Up & Shutdown Date: - 05.09.08
Faculty Name
: Sh. K.K. Raman
Participant’s Name:
1. Sh. T.S. Anandan 2. Sh. Suresh Sumani 3. Sh. Dilawar Singh 4. Sh. Dheeraj Arora
START UP PROCEDURE: Following to be checked before start up: 1. CW line up 2. Oil cup and bearing house oil level 3. Quenching steam 4. FLO (Seal FLO) 5. Warm-up to be closed (in case of hot pumps) 6. Energized condition of motor. 7. Shaft free rotation. 8. Seal pot oil level. 9. Motor earthing. 10. Casing vent & drain to be closed. 11. Suction i/v open and discharge i/v close. 12. Seal pot line up to flare. 13. Motor/pump bare bolt condition. Procedure: - Start the motor (pump). Open the discharge i/v slowly after sufficient discharge press is attained. Discharge i/v to be opened, keeping in watch with the (ampere) current of the motor. Confirm the panel officer for sufficient flow. Shutdown Procedure: - close discharge i/v. stop the pump (motor). 1. FLO to be closed. 2. Bearing CW to be pinched (To reduce CW consumption) 3. To be put on warm-up. 4. Quenching steam (just puffing). Suggestion: - Stand by pump FLO to be kept in line to avoid line congealing.
EXCHANGER HAND OVER AND TAKE OVER PROCEDURE Date: - 06.09.08
Faculty Name
:
Sh. R.N. Patel
Participant’s Name:
1. Sh. T.S. Anandan 2. Sh. P. Mariappan 3. Sh. Deeraj Arora 4. Sh. Sujeet Kumar
Isolation procedure: 1. Hot fluid to be by passed. 2. Cold fluid to be by passed. By passing procedure: 1. Gradually open the by-pass i/v With Co-ordination of panel officer. 2. Gradually close the inlet i/v. 3. close the outlet i/v 4. Before starting isolation FLO and CBD drain i/v’s hpv & ipd de-blinding to be checked. If not, it should be done. Draining and material:1. CBD to be lined up and depressurization to be done. 2. After depressurization exchanger to be flushed with FLO. 3. Ensure CBD draining (i) by touching the line and (ii) by visual observation in OWS (in case of cold material) (iii) confirmation with panel officer by CBD level. 4. Completion of FLO to be confirmed by sample checking from OWS. FLO draining procedure: 1. Close the FLO i/v’s (both). 2. Open hpv i/v and continue CBD draining. 3. Ensure completion of draining and close CBD drain i/v’s. 4. After FLO draining completed, steaming to be done. Reason for steaming: - To make the exchanger HC free. Steaming Procedure: • Steam hose to be connected at the hpv. Condensate draining to be done at OWS. Check periodically the condensate draining. After steaming CBD, FLO, exchanger main I/L and O/L i/v’s to be blinded and hand over to maintenance. Take over procedure Checking the following things: 1. Check for sort bolting. 2. I/L & O/L i/v’s de-blinding. Rated gaskets provided or not. 3. De-blinding of CBD, FLO, hpv. Note: - Inform panel officer before taking the exchanger online. Take cold fluid in line and then hot fluid.
Procedure to take material in exchanger: 1. Fill FLO and expel air through hpv. 2. After air removal expelling exchanger to be taken on line. Procedure: 1. Cold and hot side filled with FLO. 2. Replace FLO with the cold fluid by opening the O/L i/v and simultaneously closing the by-pass and I/L I/V to be opened gradually.. 3. FLO in the hjot side to be draining immediately before the exchanger is pressurized. 4. Then hot fluid to be taken on line and after FLO replacement CBD to be closed. Key point: 1. Flow and temperature of both the hot and cold sides to be confirmed by coordination with panel officer. 2. Observe for nay leakage or abnormality periodically.
PUMP H/O & TAKE OVER FROM MAINTENANCE Date: - 08.09.08
Faculty Name
:
Sh. R.N. Patel
Participant’s Name:
1. Sh. Dilawar Singh 2. Sh. Lavneet Madaan 3. Sh. T.S. Anandan 4. Sh. Dheeraj Arora
Venue
AVU-II POC.
:
Pump Handover Procedure: 1. Pump c/o and then isolation of pump by closing discharge i/v. 2. Close FLO i/v to seal, then close suction i/v. 3. Steam quenching i/v also to be closed & BCS i/v also to be closed. 4. Thrust balancing i/v also to be closed in special cases. 5. Ensure CBD line was deblinded then start draining of pump & ensure draining. 6. After draining flush with FLO in case of viscous liquid. 7. Confirm draining of liquid by opening OWS i/v. 8. If draining completed them pump can h/o to mechanical maintenance by putting blind in suction & discharge line. 9. Denergigid the motor. Pump take over from Maintenance procedure: 1. Check pump fitting & then check deblinding of suction & discharge i/v. 2. Check all draining point / vent point should be closed. 3. Air removal done by FLO filling in case of hot pump. 4. Replace FLO by process fluid by changing to CBD. 5. Line up all utility such as quench system, BCS & seal FLO. 6. Open suction i/v fully then pump to be put on warm up mode by slowly. 7. Give clearance to m/m for alignment & coupling. 8. Get pump motor energiged after completing m/m job. 9. Thrust balancing i/v should be opened in special cases. Routine checks 1. Seal pot level should be ok. 2. Seal pot vent to flare should be lined up. 3. Seal pot cooler water should be lined up. 4. Seal pot drain should be blinded. 5. Coupling guard should be there. 6. Oil cup level should be there.
HOT PUMP WARM UP PROCEDURE Date: - 13.09.08
Faculty Name
:
Sh. K.K.Raman
Participant’s Name
:
1. Sh. Punit Kumar 2. Sh. L. Madan 3. Sh. Dilawar singh 4. Sh. Uday Bhan
Venue
:
AVU-II POC.
Warm Up Procedure: 1. 2. 3. 4. 5. 6. 7.
Check drains. All drains must be closed. Open 5-6 threads of suction valve. Check for any leakage If there is no leakage open further suction valve. Line up seal pot vent to flare if closed. Line up all utilities. Keep close water for half an hour or until pump in at process lamp then increase rate (warm up).
SAND FILTER DRAINING PROCEDURE Date: - 15.09.08
Faculty Name
:
Sh. K.K.Raman
Participant’s Name :
1. Sh. Punit Kumar 2. Sh. T.S.Anandan 3. Sh. Mari 4. Sh. Uday Bhan
Venue
AVU-II
:
Procedure: 1. Confirm level with panel of sand filter. 2. Check level / confirm level of 73-V-23 (spent caustic tank) if ok, then start draining of sand filter by opening IInd i/v (globe valve)slowly, by following open 1st I/v (gate valve) by 5-6 threads. 3. Confirm level from panel for decreasing trend & rise in level of 73-V-23. 4. Completion of draining confirmed by opening local drain to OWS except LPG sand filter. 5. In case of LPG sand filter confirm by touching drain line, it should be cold. Of draining completed then close 1st i/v first and then close IInd i/v simultaneously.
DESLUDGING OF DESALTER PROCEDURE Date: - 06.10.08
Faculty Name
:
Sh. K.K.Raman
Participant’s Name :
1. Sh. Punit Kumar 2. Sh. DVP Rao 3. Sh. Dilawar Singh 4. Sh. Dheeraj Arora
Venue
AVU-II POC.
:
De-sludging of desalter: De sludging of 73-V01 and V02 1. Open valve (globe) below desalter. 2. Observe flow rate and adjust according to interruption by panel officer. 3. In case of V01 through outlet desalting water flow to 73-V-02. 4. Check brine colour periodically and repeatedly after 20 minutes. 5. While brine colour is improved, stop desludging and normalize flow of desalting in case of 73-V-01.
COOLER BACKFLUSHING Date: - 11.10.08
Faculty Name
:
Sh. K.K.Raman
Participant’s Name:
1. Sh. Uday Bhan 2. Sh. DVP Rao 3. Sh. Lavneet Madaan 4. Sh. Manto Yogesh Pannu
Venue
AVU-II POC.
:
Cooler Backflushing: 1. Firstly ask the temperature before starting the Backflushing from panel. 2. Then, open the drain & slowly close i/l, i/v. 3. For confirmation of the backflushing, wait for clear material to come out and observe the line by physical touching it become hot or not. 4. After confirmation, inform to the panel to stop backflushing. 1st open i/l, i/v and then close drum. 5. After stopping the backflushing again as the temperature from panel whether it comes down or not.
PUMPS ROUTINE CHECKS Date: - 11.10.08
Faculty Name
:
Sh. K.K.Raman
Participant’s Name:
1. Sh. Uday Bhan 2. Sh. DVP Rao 3. Sh. Lavneet Madaan 4. Sh. Manto Yogesh Pannu
Venue
AVU-II POC.
:
Pumps Routine Checks: 1. Firstly observe the proper supply of utility like (BCW, FLO). 2. Check the sound and vibration of the pump. If any abnormal, inform the Incharge. 3. Check the seal of the pump for any leakage. 4. Observe the bearing temperature & sound by physical touching & hearing. 5. Observe the seal pot level. 6. Check the isolation valves for any leakage. 7. Check the oil cup level and oil in bearing house. 8. Check for the proper amperage & pressure. 9. Check all the stand by hot pumps whether they are in warm up position or not. 10. Check the base bolts and earthing of the pumps.
LUBE OIL USED IN PUMPS / FD/ ID FANS Date: - 11.10.08
Faculty Name
:
Sh. K.K.Raman
Participant’s Name:
1. Sh. Uday Bhan 2. Sh. DVP Rao 3. Sh. Lavneet Madaan 4. Sh. Manto Yogesh Pannu
Venue
AVU-II POC.
:
1. Lube oil grade servo-46, for all centrifugal pumps, oil pumps and FD/ID fan bearings. 2. Check oil cups & oil viscosity. If any, suspended particulars change the oil. 3. Oil cup filled up to 50% of oil cup. 4. If pump under maintenance, totally oil changed & new oil filled in bearing. 5. FD, ID fan lube oil console ‘Servo 100’ used. Maximum operatable level. 6. Always post filters in lube oil console P gauge. It indicates lube oil pressure, filter cholkage. 7. Lube oil supply / return temperature observed. Its difference not more than 10150C. 8. Ensure FD/ID fan, fluid coupling gauge glass. Level was full, normal used (Servo prime 46) used. 9. Bearing Lube oil – SP 46 10. Screw Pump – S220 11. ID/FD fan bearing – Servo Press-100 12. FD/ID fluid coupling – Servo prime 46 13. Reciprocating pump – SP 220, SP-150 14. Centrifugal Pump – SP 320
HEATER ROUTINE CHECKUP Date: - 14.10.08
Faculty Name
:
Sh. K.K.Raman
Participant’s Name:
1. Sh. Uday Bhan 2. Sh. DVP Rao 3. Sh. Lavneet Madaan 4. Sh. Vrindawan
Venue
AVU-II POC.
:
Heater Routine Checkup: 1. Leakage of fuel oil at burners & detect the fuel gas smell. 2. Leakage of process crude from gland etc. in pass flow valve. 3. Check fuel gas pressure & drain KOD twice in shift. 4. Check fuel oil pressure, atomizing steam temperature & pressure. 5. Noted pressure of individual passes of heaters (I/L & O/L) 6. Check flame pattern of each cell. 7. Check coke formation & red hot spots (if any). 8. Check velocity steam flow (VDU Heater). 9. Check furnace flue gas O/L damper and combustion air dampers. 10. Check primary, secondary & tertary air adjustment of indusual burner & flame pattern. 11. Close contact with panel officer for skin, ARC box temperature and outlet temperature of each pass. 12. Check coil hangers, coil supports, convection zone coils. 13. Check pressure of off gas at flame arrester. 14. Check atomizing steam header drain trap in line. 15. Hand over / take over to oil gun / gas gun maintenance / cleaning jobs.
UTILITIES IN UNIT Date: - 16.10.08
Faculty Name
:
Sh. K.K.Raman
Participant’s Name:
1. Sh. Uday Bhan 2. Sh. DVP Rao 3. Sh. Lavneet Madaan 4. Sh. Sanjeev 5. Sh. Chandrajeet Singh 6. Sh. Vrindavan
Venue
AVU-II POC.
:
Points: 1. LP Steam 2. Process Water 3. Plant air & inst. Air 4. N2 (inert gas) 5. HP Steam 6. MP Steam 7. Cooling water 8. DM Water 9. BFW 10. T/Water 11. LP Steam 1. LP Steam
For using vessel flushing, any hot pumps gland leaks, flange leaking LP steam lancw fitting. Heavy oil (VR) leaks. Cleaning purpose.
2. Process water
Cleaning of flow, pumps platforms. Vessel platforms, sample points cleaning.
3. Plant Air
Chemical dosing air pumps, vessel cleaning leak checking.
4. N2 (Inert gas)
Purging purpose, vessel, purging …………. Of air / O2 for hot work jobs. VDU flushing handover to M/M for M/ inspection.
VDU CLOSE CIRCULATION Date: - 16.10.08
Faculty Name
:
Participant’s Name:
1. 2. 3. 4.
Sh. Yogesh Pannu 1. Sh. K. Kumar 2. Sh. Lavneet Madaan 3. Sh. A.K. Dash 4. Sh. Vrindavan
Close the RCD MOV FLO replacement & min. circulation isolation valve should be in closed condition. HVGO i/v & VR given in RCO manifold should be in closed condition. VR R/D i/v of manifold should be closed, VDU bottom circulation MOV & its upstream i/v should be in opened condition. 5. Take FLO in VDU column through tapping given in pump suction (74-P-6A/B/C) 6. Start the pump 74-P-6 after coming proper level in column and start circulation. 7. During circulation pilot burners should be in line & main FG & FO burners will come into line as per temperature conditions.
OWS SYSTEM Date: - 17.10.08 Faculty Name
:
Participant’s Name:
Sh. K.K.Raman 1. Sh. P. Mariappan 2. Sh. Suresh Somani 3. Sh. Uday Bhan 4. Sh. Dheeraj Arora
1. OWS system is provided in connection with CBD drain. OWS i/v operated to check whether the system is fully drained to CBD header. To check that fully close CBD 2nd i/v and open the OWS i/v. 2. Keeping open the CBD 2nd i/v and OWS i/v will result in the gas back from CBD header. So, during OWS draining CBD 2nd i/v should kept in close condition. 3. During hot work, nearby OWS funnels should be kept blocked and funnels should be washed with running water to remove hydrocarbon. 4. During exchanger handover time, check the OWS whether the material got diluted during steaming condensate draining.
CRWS (Contaminated Rain Water System) Date: - …4/02/09………….
Faculty Name
:
Participant’s Name:
Sh. K.K.Raman 1. Sh. Uday Bhan 2. Sh. P. Mariappan 3. Sh. Suresh Somani 4. Sh. L. Madan 5. Sh. Puneet/Ajay
During exchanger blinding / pump blinding, a little quantity of oil is spilled. This spilled oil is washed with water and sent to the CRWS through the plant inside channel.
In the CRWS, oil catcher is provided. In this oil catcher, oil and water get separated. This separated oil goes to OWS system. The separated water goes to oil skimmer where CRWS from HCU/HGU/ DHDT to mixed. In this oil skimmer, oil gets separated and goes to OWS, water gets separated and routes to the open channel of the site. Check the open channel for the contamination of water with oil.
HEATER TRIP Date: - 07/02/09…………
Faculty Name
:
Sh. K.K.Raman
Participant’s Name:
1. Sh. Uday Bhan 2. Sh. S. Somani 3. Sh. Sanjeev 4. Sh. Marappan
1. Confirm all UV (Fuel oil, fuel gas, off gas) should be closed. 2. Pilot FG should be opened. 3. ID & FD should be stopped condition. 4. MSD should be open condition. Check from field & i/f to panel. 5. combustion air damper should be closed.
Following actions should be taken: -
1. Fuel oil, Fuel gas, Off gas atomizing steam should be closed (individual br.) 2. Furnace draft confirms should be negative. 3. Open view glass & observe the pilot flame condition. If all pilot flame in condition, no box purging required. 4. If all pilot put off condition then isolate all individual pilot burner i/v. before pilot light up box purging required.
IFO PUMP FAILURE Date: - 23.01.09
Faculty Name
:
Participant’s Name:
Sh. K.K.Raman 1. Sh. S. Somani 2. Sh. DVP Rao 3. Sh. Chandrajeet Singh 4. Sh. Vrindavan
1. IFO pumps 73-P-811 A/B/C. normally running two pumps, one pump standby. 2. Both running pumps trip due to proper dip informed to panel officer and S/I (if interlocks taken by passed. 3. Furnace operation. Take action all FO burners isolated and steam flushed. 4. In the same way, all main FG burners taken in line. 5. CDU/VDU heaters taken heat load on gas burners 6. Close the FO return spill back c/v open 7. When resume the power P-811A/B one by one pump started. 8. All FO, supply / return ROV’s normalized. (Ring headers) established. 9. slowly FO burners taken in line one by one.
FIRE MANUAL CALL POINTS IN UNIT Date: - 02.02.09
Faculty Name
:
Participant’s Name:
Sh. K.K.Raman 1. Sh. S. Somani 2. Sh. Lavneet Madaam 3. Sh. Uday Bhan 4. Sh. Mariappan 5. Sh. Puneet 6. Sh. Ajay 7. Sh. Sanjeev
1. Fire call point on the road in front of the POC. 2. Near POC 3. Near Cooling water supply to ejector platform 4. Near NSCC fan platform stairs 5. Near Neutralizing Amine Vessel. 6. Near Stack 7. Near FD Fan 8. Near 73-P-5A (Reflux pump) 9. Near 73-E-21 C/D at TS-3B 10. On pillar No. 16 11. In front of 73-E-14 A/B at TS-3A 12. On pillar 01 (in front of 73-P-41) 13. Near 73-P-44 (BCW pump) at B/L 14. Near Sample point.
FIRE MONITORS IN UNIT Date: - 03.02.09
Faculty Name
:
Participant’s Name:
•
Sh. K.K.Raman 1. Sh. Dvp Rao 2. Sh. Lavneet Madaam 3. Sh. A K Dash 4. Sh. Varindavan 5. Sh. Sanjeev
Three fire monitors are located near ejector platform, near CDU furnace and VDU furnace. There monitors can be operated automatically. These monitors can be adjusted to any desired direction by adjusting the knob in the control panel.
BURNER LIGHT UP PROCEDURE Date: - 03.02.09
Faculty Name
:
Participant’s Name:
Sh. K.K.Raman 1. Sh. Lavneet Madaam 2. Sh. A K Dash 3. Sh. Varindavan 4. Sh. Sanjeev
1. After box purging of the heater. 2. Ensure the pilot gas to burner i/v closed position. 3. Latch the pilot gas u/v. 4. Line up the pilot gas to burner. 5. Open the pilot gas i/v at burner and simultaneously visit the spark igniter. 6. Pilot burner ignites, after that as per requirement take oil or gas firing, keeping on mind that FD should be in load position.
IFO BURNERS HANDOVER / TAKEOVER Date: - 03.02.09
Faculty Name
:
Participant’s Name:
Sh. K.K.Raman 1. Sh. DVP Rao 2. Sh. Lavneet Madaan 3. Sh. A K Dash 4. Sh. Varindavan 5. Sh. Sanjeev
IN CDU HEATERS: - HANDOVER TO OIL GUN: 1. B No. 7 and 10, both oil burners smoky and impengment to tubes. Suspected to the burner tip choke formed, cleaning required. 2. BNO.7 and 10 taken to main gas firing. 3. F. Oil valve closed and flushing steaming started. 4. BNO. 7 and 10 after 10 min. steam flushing done, atomizing steam and flushing steam, oil valve closed unsurely. 5. Safety “DO NOT OPERATE TAG” provide in oil burner, oil valve. 6. Informed to M/M person for oil gun removal. TAKE OVER TO OIL GUN FROM M/M: 1. After M/M fitted the oil gun. Please check the proper fitted or not. Confirm to the M/M 2. Oil gun open the flushing steam, atomizing steam open taken warm up atleast 20 min. 3. Informed to panel as requirement of panel slowly taken to oil gun. First flushing steam closed and oil valve open slowly. 4. See oil burner flame length, flame pattern. Colour and main gas closed.
HEATER SOOT BLOWING Date: -10.02.09
Faculty Name
:
Participant’s Name:
Sh. K.K.Raman 1. Sh. Chanderjeet 2. Sh. Lavneet Madaam 3. Sh. A K Dash 4. Sh. Varindavan
1. For better heat transfer, soot blowing is required to remove soot deposited on the surface of heater coil. 2. Soot blowing steam to be kept is warm up condition by opening the warm up line. 3. Condensate trap to be kept in line. 4. After warm off , inform to C/R. 5. Unload the FD fan. 6. Full open the M.S.D., and soot blowing steam. 7. All condition of heater after normalizing. Put the soot blowing (Panel) in auto mode. 8. Keep on observation of sequence of soot blowing. 9. See the condition of burner by opening the peep door. 10. After sequence completed, stop the soot blowing. 11. Inform to the panel. 12. Close to the panel. 13. Close the i/v of soot blowing steam.
LPG VAPORIZER KOD DRUM V-30 Date: - 11/02/09.
Faculty Name
:
Participant’s Name:
Sh. K.K.Raman 1. Sh. Chanderjeet 2. Sh. Lavneet Madaam 3. Sh. A K Dash 4. Sh. Yogesh
PROCEDURE: -
As there is system gas draining the vessel in flare & OWS and we have to drain in flare except in some condition. For draining V-30 first we have to make communication with panel and should tally level in LT and LG and with the continuous communication. It should be routed to flare.There may lie a chance of LT out . So, we should also confirm by touching the line for temperature change. After getting the level line we have to close the isolation valve to flare ……….. and information should be given to panel.
FG KOD DRAINING V-38 Date: -13.02.09
Faculty Name
:
Participant’s Name:
Sh. K.K.Raman 1. Sh. Dilawar 2. Sh. S. Somani 3. Sh. DVP Rao 4. Sh. Arora
PROCEDURE: FG draining is also having same procedure like LPG vaporizing KOD draining. So, after informing to panel, open the flare isolation valve. Get check the LT and LG level and drain up to minimum. Closed the i/v of flare by wheel key and inform the panel.
CHEMICAL INJECTION TO ATMOSPHERIC AND VACUUM SECTION Date: - 14.03.09
Faculty Name
:
Sh. K.Kumar
Participant’s Name:
1. Sh. Dilawar 2. Sh. Yogesh 3. Sh. D.Arora 4. Sh. A. Diwan
All dosing facilities are skid-mounted system Following chemical dosing facilities have been provided in CDU/VDU:
De-mulsifier Dosing This is injected at Desalters inlet through mixing valve and crude charge pump suction to aid breaking in emulsion of water in crude. Option of adding ahead i.e. in crude pump suction allows good mixing / distribution of de-mulsifier . Air driven pump is used to unload in a pot, mixed with DM water and then dosed with metering pumps.
Neutralizing Amine Dosing This is dosed for pH and chloride control in overheads. As desalting do not completely eliminate salts, the first water droplet condensed in overhead is very acidic and can cause corrosion. Therefore, neutralizing amine is dosed on overheads. Air driven pump is used to unload in a pot, mixed with DM water and then dosed with metering pumps. There are total 6 pumps for three column overheads. Two is common spare. Future pumps have to be installed for future Deethaniser.
Filming Amine Dosing Apart from chloride and pH, filming amine is injected in column overheads as a corrosion inhibitor. This is dissolved in naphtha so that it vaporizes at column top causing a fine dispersion of the inhibitor and thus creating a thin film. It is dosed in crude and in stabilizer column. There are six pumps for three dosing points and have a spare for each pump.
Caustic Dosing
Caustic is used for caustic wash of LPG, Light Naphtha Hy. Naphtha and sour scrubbing the gas internal scrubber caustic make up pump (73-PE014 A/B) supplies the caustic from caustic make up tank 73-T-001.
NORMAL START UP OF THE UNIT Date: - 09.03.09
Faculty Name
:
Participant’s Name:
Sh. K.Kumar 1. Sh. D.Arora 2. Sh. Puneet 3. Sh. Marriappan 4. Sh. Chanderjeet
A.) 1. Inform OM&S to start crude booster pump, inform RSM, TPS, OM&S regarding unit start up. 2. Start 73P1, 73P2, and 73P10A/B and establish cold circulation. 3. Light up pilot Burners in all the four sections of 73-H-001. 4. Gradually increase coil outlet temp. to 120º C @ 30º c/Hr. B.) 1. At 120º C hold the temperature for two hours. 2. Adjust flow in VR; HVGO and LVGO circuit such that 73-P-001 suction temperatures does not increase beyond 70º C. 3. Check system for any leaks. Attend if any. 4. Start tempered water pumps & establish circulation. 5. Maintain system pressure @ 1.0 Kg/Cm2 (g) by taking from fuel gas or flaring ex 73-C-001. 6. Raise the coil outlet temperature to 200º C @ 30º C./hr. At top temperature of 100º C most of the water will get evaporated and come out of the system. 7. Drain water from all the pump casings and low point drains. 8. At top temperature of 100º C, pressure of the column will start increasing. Start four or five overhead air cooler fans and maintain column pressure at 1.7 Kg/Cm2 (g). 9. Line up 73-V-004/5 Boot water to ETP by running 73-P-20. C.) 1. 2. 3. 4. 5. C. 6.
Raise coil outlet temperature to 250º C @ 30º C/hr. Give clearance for hot bolting of flanges. Start additional overhead air coolers to maintain pressure. Drain 73-P-005A/B and 73-P-006A/B suction line from pumps casing. Start 73-P-005A/B at low flow rate and maintain top temperature at 120-130º
Check for any leaks in columns, crude, air coolers, reflux line and bottom circuit and get it attended.. 7. Commission Corrosion inhibitor and filming amine. 8. Switch ‘ON’ both the desalters. 9. Increase COT to 300º C @ 50º C/hr.
COMMISSIONING OF STABILIZER Date: - 09.03.09
Faculty Name
:
Participant’s Name:
Sh. S.K.Kumar 1. Sh. Dilawar 2. Sh. Vrindawan 3. Sh. Ajay Diwan 4. Sh. Uday Bhan
1. Start 73-P-6 (stabilizer feed pump) 2. Take 75% level in 73-C-006. 3. Divert LGO CR partially to 73E-25 (Stabilizer Reboiler) to Raise 73-C-6 temperatures gradually. 4. When level in 73-V-006 appears, take 73-P-15A/B/C in line. 5. Check LPG sample at 73-C-006 top/bottom temp of around 65/180ºC respectively & pressure of 10.kg/cm2 6. Route to normal rundown of LPG to Amine Treatment.
TAKING APH IN LINE Date: - 09.03.09
Faculty Name
:
Participant’s Name:
Sh. R.N.Patel 1. Sh. Ajay Diwan 2. Sh. Yogesh Pannu 3. Sh. DVP Rao 4. Sh. Chanderjeet Singh
1.
Bypass all automatic interlocks/trips except the furnace low feed flow trip.
2.
Maintain combustion airflow by passing APH. Keep the air by pass damper full open and each of the air inlet dampers to individual APH 50% close.
3.
Keep the main stack damper open to route the flue gases directly to stack. With the increase in draft towards APH inlet duct, flue gases would be routed to APH as indicated by rise in APH inlet temp.
4.
At flue gas outlet temperature of 250 C start ID fan.
5.
Close APH air bypass gradually & take APH in line.
START UP OF VACUUM DISTILLATION UNIT Date: - 10.03.09
Faculty Member : Participant’s Name:
1.
Sh. K.k Raman / Sh. K.Kumar 1. Sh. Vrindawan 2. Sh. Puneet 3. Sh. Yogesh Pannu 4. Sh. Chanderjeet Singh
After due pressure & vacuum testing, purge the system with steam & start fuel gas backup.
2.
When system pressure becomes steady, stop gas backing.
3.
Drain condensate under fuel gas pressure from all low points.
4.
Take FLO in 74-C-001 through 73-P-43A/B and build up 50-60% level.
5.
Keep open FLO valve and run the pump.
6.
Take flow through all the passes one by one and establish closed circulation through furnace.
7.
Close FLO make up.
8.
Take FLO through 74-P-001, 002, 003 discharge internal reflux line upto 74-C-1.
9.
Stop circulation.
10.
Allow the system to settle and drain condensate from all the low points.
11.
Establish circulation and light up pilot after that take up one or two main burners.
12.
Increase COT to 120º C @ 15º C and hold for two hrs. Drain condensate from low points.
13.
Increase COT to 150º C @ 30º C and hold for two hrs. Drain condensate from low points.
14.
Give clearance for hot bolting of flanges.
NORMAL SHUTDOWN PROCEDURE Date: - .12/03/09.............
Faculty Name
:
Participant’s Name:
1. Sh. K.K.Raman 2. Sh. R.N.Patel 3. Sh. K.Kumar 4. Sh. S.Kumar 1. Sh. Marriappan 2. Sh. Chanderjeet Singh 3. Sh. D.Arora 4. Sh. Dilawar 5. Sh. DVP Rao 6. Sh. S.Somani
SHUT DOWN SEQUENCE 1. Reduction of feed rate to all units. 2. Decommissioning of NSU 3. Discontinue chemical injection. 4. Putting the VDU on circulation 5. Shut down Vacuum section. 6. Shutdown stabiliser 7. Decommissioning of desalters. 8. Putting the CDU on circulation. 9. Shut down Atmospheric section. 10. Emptying out of the units and purging. 11. Positive isolation. Inform OM&S, TPS, ETP, SRU, RSM regarding shutdown. REDUCTION OF FEED RATE . 1. Reduce crude through put gradually step by step. 2. Reduce RCO through put gradually to turn down flow of normal feed rate. NAPHTHA SPLITTER SHUTDOWN. 1. Inform OM&S to divert naphtha splitter overhead & bottom from H2 feed tanks 2. Reduce the steam flow through reboiler. 3. Stop Light Naphtha withdraw and put the column on total reflux. 4. Continue 59-C-1 reflux to control the top temperature. 5. At 70º C column bottom temp. 6. Open B/V at the Bypass line of Naphtha splitter feed. 7. Close B/V at the feed inlet to Splitter Column. 8. Empty out 59-C-1 by allowing pump 59-P-02 to run till it loses suction & close pump discharge B/v.
DISCONTINUING CHEMICAL INJECTION
1. Stop Demulsifier injection pump 73-P-30 and isolate the valve near crude inlet line to CDU from storage. 2. Stop neutralizing amine pumps and isolate the injection lines. 3. Stop Filming amine pumps.
VDU SHUT DOWN 1. Reduce the T’put of CDU so as to bring down the VDU T’put slowly. Simultaneously reduce crude t’put to maintain CDU column level @ 50-60 %. 2. Inform OM&S to divert HVGO from OHCU feed tank to HPS/ FCCU feed tank etc. 3. Reduce COT @ 30º C/hr to 320º C. 4. Divert products to slop when they go off spec. 5. At 320º C stop feed to 74-H-01 and put VDU on Hot circulation. 6. Stop and isolate ejectors one by one closing 3rd stage ejector and then other stages in descending order. Ensure 74-UV-1702 to be close. 7. Isolate steam to ejectors. 8. Close hot well liquid seal valve and non-condensable return valve along with last stage ejector. 9. Open the gas back up valve & back up gas to the column to keep the column in positive pressure to avoid air ingress. 10. Isolate stripping steam to column. 11. Increase internal refluxes to make the Vacuum column bottom content more light. 12. Discontinue VR quench at column bottom. 13. Continue top reflux and IR/CRs for dilution of material inside column. At 200º C COT, dilute circulation material by taking FLO through 74-P-6. 14. Check the column bottom material for dilution, when it is sufficiently diluted, stop the reflux. 15. Flush Vac slop, VR, HVGO circuit upto rundown tanks with FLO. 16. Empty out the column & line material & do steaming as per standard procedure for hand over to maintenance.
CDU SHUTDOWN 1. Reduce through put @ 50 M3/hr to bring down the throughput to 450 M3/hr. 2. Start reducing COT to 300º C @ 30º C/hr. 3. Isolate Stripping steam to CDU column, HGO & LGO strippers.
4. Reduce HN, KERO, LGO R/D flow and drop the material to dilute bottom circuits. 5. At 300º C, put CDU on circulation by diverting RCO through VR, HVGO, LVGO circuit to 73-P-1 suction. 6. Reduce COT @ 50º C/hr to 200º C. 7. Reduce KERO CR, LGO CR, HGO CR, flows & finally stop these pumps as per column temp. Profile. 8. Continue circulation with 73-P-1, 73-P-2, 73-P-10 to bring down the temp. (Push out RCO & dilute with gas oil 2-3 times). 9. Cut off furnace burners Keep only pilot burners on with box temp 250 C. 10. When COT reaches 150º C stop 73-P-1. 11. Continue to run 73-P-2 till it lose suction. 12. Pump out 73-C-2/3/4/5 to R/D tanks and 73-C-6 to Naphtha tanks. Then stop respective pumps till it loses suction. 13. Flush RCO circuit with FLO. 14. Do the necessary blinding, steaming & handover to maintenance as per standard procedure.
EMERGENCY PROCEDURE Date: - .08/03/09...............
Faculty Name
:
Participant’s Name:
Sh. K.Kumar 1. Sh. Dilawar 2. Sh. Yogesh 3. Sh. Uday Bhan 4. Sh. Puneet 5. Sh. Sanjeev
INTRODUCTION Emergency in the operating plant can occur due to failure of utilities like, Power, Steam, Instrument Air, fuel Oil etc. and failure of equipment. During some of the emergency situations the unit can be operated for a limited duration with appropriate action in time, while in other cases an immediate shut down may be necessary to avoid any damage to the operating personnel and equipment of the unit. During emergencies, actions by operating personnel must be taken quickly & precisely. General guidelines listed below should always be kept in mind while tackling an emergency. 1. Excessive pressure/level and temperature beyond design limits for vessels, columns and furnaces must be avoided. 2. Furnaces coil should never run dry while furnace is ‘ON’. 3. In the ejector, flow of the motive steam must be ensured prior to opening of vent off gas line. Conversely if the steam to ejector is failing, the ejector off gas vent B/V must be closed immediately. close the goose neck valve, noncondensable valve above hot well . 4. Transfer line temperature in furnace coil should never shoot up. Accordingly, fuel oil firing in the furnace to be controlled. 5. Heavy oil circuit such as RCO, vacuum slop, HVGO, LVGO & VR must be diluted with gas oil to avoid congealing of lines during emergency S/D of unit. 6. In case of furnace shut down, fuel oil circulation should be kept ‘ON’ but individual burner B/V must be closed & flushed with steam. 7. Main fuel gas B/V at individual furnace should be closed first before putting off all the gas burners. 8. Steam lines connected to the column must be isolated in case of steam failure to avoid hydrocarbon backing into steam line. 9. Run down B/V must be closed inside unit, to avoid backing of Hydrocarbon from offsite & other units. 10. Keep watch on furnaces & watch for any leakage due to thermal shock.
DDCS POWER SUPPLY FAILURE Dated: 13.03.09 Faculty
:
Participants Name
:
Sh. K.Kumar 1. Sh. D.Arora 2. Sh. Dilawar 3. Sh. Yogesh 4. Uday Bhan
Power supply to DDCS comes from two invertors, which supply 220 volts A/c power. One of the invertors is connected to Distribute Process Control Station (DPCS) and the other invertor is connected to POC and DBS. DPCS requires 24 volts DC which it converts from 220 volt mains by its own power supply unit POC/DBS requires 110 volts AC which is made available after stepping down from 220 volts inside the DDCS room. All the interlocks system for furnaces and APH are fed 110 volts DC from process substation.
In case of any power failure in DDCS, the battery back up through invertors should come inline but in case it also fails, the power supply to DPCS/POC/DBS will fail and no indication will be available at console, neither will any control be possible and all control valves will go to their FAIL SAFE position. If power supply to DPCS is not affected, the DPCS will be kept on holding/controlling the last value. In this condition, if POC/DBS power is not restored with in very short time the unit will have to be brought down under emergency shut down (in such a situation it is possible to monitor the critical parameters of the plant from VSVP’ card of DPCS, with the help of instruments maintenance group while going for shut down).
HEATER TUBE FAILURE Dated: 14.03.09
Faculty Member
:
Participants Name :
A.
Sh. R.N.Patel 1. Sh. D. Arora 2. Sh. Puneet 3. Sh. Marriappan 4. Sh. Uday Bhan
MINOR TUBE LEAK (ATMOSPHEIRC SECTION) WHEN NORMAL SHUT DOWN CAN BE TAKEN GRADUALLY. 1. After identifying leaky portion cut off furnace firing. Charge box purging steam to furnace. Ensure the readiness of emergency steam charge the steam as soon as possible 2. Watch on the pressure of the column. Empty out the column bottom and pump out the strippers to slop. 3. Bring down the vacuum system. Reduce furnace firing and establish close circulation). Close ejector steam MOV noncondensible valves. Start gas back up to VDU column to 200 mmof HG. Flush HVGO/ VR / VACSLOP lines up to r/d tanks 4. Stop all the product pumps when start losing suction. Allow the CR pumps for sometime for cooling the column. 5. Stop desalter water injection and switch off the desalter transformer. 6. Keep two small burners at that affected furnace and cut other affected furnaces completely. 7. Watch on the column pressure, which should not exceed 1.5Kg/cm2. 8. Once it is confirmed that fire or hydrocarbon leak from the affected tube has stopped and only steam is coming out, cut off burners completely and purge the firebox with steam. Prepare the affected furnace for handling over to Maintenance for repair. 9. Close the coil flushing steam close all the burner Put the blind in IFO/ FG/ pilot lines and also put the blinds in the convection i/l and radiation o/l. Hand over the furnace to maintenance. (Before blinding ensure the column to be fully depressurised.)
B.
TUBE RUPTURE OR BIG TUBE LEAK In case of big rupture cut off fire in the furnace completely and introduce snuffing to smother fire and to cool the firebox. Close IFO/FG/PILOT gas control valve isolation at all furnaces. Keep atomising steam ‘ON’. Combustion air may get cut off at high-arch pressure trip. Ensure combustion air cut-off. Emergency steam to be charged to coil gradually and watch the furnace box. If any smoke or any fire is witnessed inside the box then reduce the coil flushing steam and increase the box purging steam. In this case vacuum also to be brought down. The same procedure as stated above to be followed for bringing down the vacuum system.
C.
TUBE LEAK IN VACUUM SECTION In case of a tube failure in Vacuum furnace 74-H-1, proceed to shut down of Vacuum unit sustaining operation of Atmospheric Section on reduced through put, if necessary.
ROUTINE FIELD CHECKS AND JOBS Date: -17/03/09 ...........
Faculty Name
:
Participant’s Name:
Sh. K.Kumar 1. Sh. Lavneet Madaan 2. Sh. Puneet 3. Sh. Mariappan 4. Sh. S.Somani
FURNACE/APH ROUTINE CHECKS Check from the panel- type of crude, pass flows, COT, skin temperature, box temperature, arch temperature, FO & FG pressure, atomising steam DP, ID/FD RPM, furnace draft, excess oxygen etc. Check in the furnace for any burner impingements & adjust the burner firing. If any oil burner coking is observed, isolate oil, take in gas firing, steam flush the oil burner for few minutes & take back the burner in oil firing after coke burning. Check for any leakage from burner assemblies, report to Shift-In-Charge. Note down burner positions w.r.t. FG & FO burners. Check for ingress of air in the furnace due to leak. Check the air registers. Check the hydraulic oil temperature of ID and FD fans, direction of rotation and the amperage of the fans. Do oil top up if required. Check the lube oil pressure of FD and ID turbines. Check the inlet pressures of each pass. Check the FO, FG & atomising steam pressure and control valve opening in field and cross check with panel. ROUTINE JOBS Soot blowing Ask panel to fully open the MSD and unload ID fan. Drain condensate from soot blowing steam header. Start the soot blowing operation from panel in auto mode. Time to time check the operation of soot blowers from the soot blower platform. If any problem is there inform shift in-charge to take corrective action. If there is any problem with any soot blower bypass the above from panel and continue the operation. Observe the steam exhaust from the stack. Burner cleaning Regularly some and pilot burners to be cleaned to maintain healthy furnace condition. Isolate the FO and atomising steam of the burner and flush with flushing steam. Get the burners cleaned by mechanical maintenance in close supervision. Insist for cleaning of the atomising steam port every time. After box up take the burner in line and check the performance of the burner.
FURNACE LIGHT UP PROCEDURE
Date: - 16.03.09
Faculty Name
:
Participant’s Name:
•
Sh. R.N.Patel 1. Sh. Puneet 2. Sh. Marriappan 3. Sh. Uday Bhan 4. Sh. Ajay Diwan
Slowly charge box-purging steam from convection and radiation section. Watch for any hammering in the line. Increase the steam rate and observe steam coming out from the furnace stack. Box purge for about 45 minutes to drive out air.
•
De-blind the pilot gas line and start lighting up pilot gas burners after stopping box purging. Before lighting up of pilots, ensure that pilot gas line is condensate free.
•
After required pilots are lighted up de- blind main gas line, FO supply & return lines.
•
Start FD fan and ask panel to load it.
•
Ask panel to reset FO and FG UVs.
•
Establish FO circulation through the furnace rings.
•
Light up main gas burners. Adjust the registers properly.
•
Light up FO burners as per requirement and adjust air registers properly.
•
Once the flue gas temperature reaches 250 °C start ID fan. Ask panel to load it.
•
Ask panel to close the MSD after stabilization of the furnace.
PUMPS CHECKING Date: - 16.03.09
Faculty Name
:
Participant’s Name:
Sh. S.Kumar 1. Sh. Chanderjeet Singh 2. Sh. Dilawar 3. Sh. Uday Bhan 4. Sh. D. Arora
PUMPS • • • • • • • • •
Check for bearing housing, stuffing box, and motor temperature, report if high. Check the lube oil level in bearing housing- top up if required. Check for proper CW flow, quench steam. Check the discharge pressure and amperage. Check for leakage from seal and flange- report to shift i/c in case of any leakage. Check the FLO going to the seal. The FLO pressure should be (suction pressure + 20% of discharge pressure). All stand by pumps to be in warm up condition and its FLO, steam and water lines to be isolated. Also check the power supply. Check for abnormal vibration. Check pressure for unusual pulsation.
STARTING OF PUMPS • • • • • • • • • •
Ensure bearing housing is topped up with lube oil. Check the free movement of the shaft by hand. In case of 73-P-2 pumps start the forced lubrication pump (AOP) and observe the pressure downstream of the filter Check the flow of seal oil (FLO), quench steam & CW. Check for the closing of disch. Valve, casing drain valve etc. Open suction valve, top vent and close bottom drain. Bleed gas from pump through top vent and in case of hot pump open warm up line for heating. Ensure for power supply and then start the pump after ensuring proper temperature of the pump. Check discharge pressure gauge and if pressure has increased, open the discharge valve slowly. Check the amps of the pump while opening the discharge valve and confirm the flow from the panel. Check for abnormal sound, vibration, and oil losses, bearing temperature.
PUMPS HAND OVER AND TAKE OVER PROCEDURE Date: - 18.03.09
Faculty Name
:
Participant’s Name:
Sh. R. N. Patel 1. Sh. Chanderjeet Singh 2. Sh. Dilawar 3. Sh. S.Somani 4. Sh. D. Arora
HAND OVER PROCEDURE ¾ ¾ ¾ ¾ ¾ ¾ ¾
Isolate the pump by closing the suction and discharge valves. Close the cooling water line, FLO line and steam quench valves. In cold pumps open the vent and drain to CBD/OWS. In hot pumps ensure warm up valve is closed. If the pump is hot then drain the pump after proper cooling. De-energize the pump Ensure that suction & discharge valves are not passing.
TAKE OVER PROCEDURE ¾ ¾ ¾ ¾ ¾
Visually check whether all the nut bolts are properly tightened. The coupling guard to be in position. Open the suction valve by 2-3 threads and check for any leakage. If there is no leak, open the suction valve fully. In case of hot pump put the pump in warm up condition by opening the warm up valve. ¾ Open the water valve. FLO valve, steam quench valve and check for any leakage/ sufficient water passage/ proper FLO pressure. ¾ Check free rotation of the pump by hand. ¾ Start the pump in presence of maintenance and observe for leakage/ vibration.
HEAT EXCHANGER HAND OVER AND TAKE OVER PROCEDURE Date: - 19.03.09
Faculty Name
:
Participant’s Name:
Sh. K.K.Raman/S Kumar 1. Sh. Puneet 2. Sh. Vrindawan 3. Sh. S.Somani 4. Sh. Uday Bhan
HAND OVER PROCEDURE ¾ ¾ ¾ ¾ ¾
Gradually open the bypass valve of hot side. Gradually open the cold side bypass valve. Isolate the inlet and outlet side isolation valves of the exchanger. Allow the exchanger for cooling. De-blind the HPV, CBD drain lines of both shell & tube side. After sufficient cooling, drain the hydrocarbons to CBD. In case of heavy hydrocarbons dilute the material with FLO before draining to CBD. ¾ If required, steaming to be done after thorough dilution. ¾ Offer for blinding of inlet, outlet & CBD lines before handing over to maintenance. TAKE OVER PROCEDURE ¾ De-blind inlet and outlet lines. ¾ Fill up the tube and shell side with FLO. Keep the HPVs open while filling with FLO to bleed out the air. ¾ Open the inlet and outlet valves of cold side first and slowly close the bypass valve. ¾ Once the cold side is commissioned open the inlet and outlet valves of hot side and slowly close the bypass valve. ¾ Check for any leakage from any flange. ¾ If required, do the hot bolting of the flanges.
ROUTINE CHECK UP OF VESSELS Date: - 20.03.09
Faculty Name
:
Participant’s Name:
Sh. R.N. Patel 1. Sh. Chanderjeet Singh 2. Sh. Vrindawan 3. Sh. A.K.Dash 4. Sh. A. Dhiman
¾ Check level in LG/ LT and cross check with panel ¾ Check for leaks from connected flanges ¾ Check PSVs for passing, isolate if passing. ¾ Monitor the pressure in PG.
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