Final CCRU Operation Manual March 2016.Docx[1]

Indian Oil Corporation Limited Mathura Refinery

OPERATING MANUAL CONTINUOUS CATALYTIC REFORMING UNIT (CCRU) UPDATED MARCH 2016

PREPARED BY

REVIEWED BY

APPROVED BY

Sh.BrijeshYadav,

Sh. Suraj Sharma,

Sh. B.S.Pachahara,

DMPN

CPNM

AMPN

FOREWORD The Continuous Catalyst Regeneration type of Reforming Unit (CCRU) commissioned on 18th May 1998 at Mathura Refinery Is a new feather in the cap of Indian Oil Corporation. Its process is based on advanced technology from IFP (France), which allows continuous regeneration of catalyst unlike in earlier semiregenerative type of CRU’ s operating with limited cycle length between two consecutive regenerations.

Installed at the cost of about Rs. 360 crores (inclusive of power plant), the CCRU is serving us to produce high octane reformate (up to 98 RON) from straight run (C5–145 0C cut) naphtha through catalytic reforming process.

Reformate so

produced is a component used to upgrade (by blending with) lower Octane streams up to the desired level of Octane number for production of Euro-III and Premium Grade MS.

Thus, incorporation of CCRU in the process configuration of Mathura Refinery has made it, in real sense, a GREEN Refinery by way of producing eco-friendly (leadfree) motor spirit.

Date: 31.03.2016

Chief Production Manager (B.S.PACHAHARA, CPNM)

ADDENDUM 2016 1.

Provision of routing Penex Net gas scrubber off gas to K-5 for Hydrogen recovery (CRU-02-32*) 2. Dosing of IPA along with C2CL4(CRU-02-10*) 3. 17DR-1 Heater running indication and Heater failure alarm on DCS (CRU-02-17*). 4. Experience Sharing in changeover of Stripper feed/bottom Exchanger (MISC -21- 02) 5. Experience sharing in CCRU short shut down(1.9days) due to Ebara tripping(MISC–21-02)

ADDENDUM 2015 1. 2. 3. 4. 5. 6.

10. 11. 12. 13. 14 15.

Design basis for Side Cut (NSU-01-02) New Addition for Side Cut (NSU-01-02) Distillation and Density Table of NSU (NSU-01-03) Process Modification for Side Cut (NSU-02-03) Process Parameter for Side Cut (NSU-02-03) Operational Philosphy for operating HTU Feed in OMS (NHTU-02-05) 7. Energy saving by stopping 14K-2A/B (NHTU-02-06) 8. 14E-103A/B taken in line due to leak in 14E-3A/B. (NHTU-14-01) 9. Provision of Bypass line in 14-E-2. (NHTU-14-03) Opearting Philospy for maintaining Oil/Gas DP of Ammonia Package (NH3-05-01) New DMDS Scheme for maintaining Sulphur in CCRU feed (CRU-02-01*) Reacceleration Facility for pump 15P-1A/B (CRU-02-01*) Catalyst Properties of 15-DR-1 (CRU-02-14*) New CCR Catalyst CR-601 Properties (CRU-03-08) Ledger of Experience (MISC -21- 02)

ADDENDUM 2014

1. Inclusion of side cut facility.(NSU-01-01) 2. Inclusion of MP BFW for NHTU wash water section. (NHTU-01-01) 3.Replacement Catalyst CR-401 with New Catalyst CR601(CRU-04-01) 4. Inclusion of Clean Pac system for Ebara Compressor. (MISC -09-06) 5. Inclusion of ELCM for EBARA Compressor. (MISC -09-06) 6. Inclusion of New parallel Ammonia Condenser.(NH3-03-01)

INDEX

PART – A:

NAPTHA SPLITTING UNIT (UNIT – 9)

PART – B:

NAPTHA HYDROTREATER UNIT (UNIT – 14)

PART – C:

CATALYTIC REFORMING & CONTINUOUS CATALYST REGENERATION UNIT (UNIT– 15&17)

PART – D:

NITROGEN UNIT (UNIT – 40)

PART – E:

AMMONIA REFRIGERATION SYSTEM (15-X-1)

PART – F:

AIR PREHEATER SYSTEM FOR 09F-1 / 15F-4

PART – G:

OFF-SITE HYDROGEN STORAGE FACILITY

PART – H:

MISCELLANEOUS

PART – A NAPTHA SPLITTING UNIT (UNIT – 9)

S NO

DESCRIPTION

PAGE NO.

1.0

Introduction

NSU-01-01

2.0

Process description

NSU-02-01 NSU-02-01 NSU-02-01 NSU-02-02

2.1 2.2 2.3

3.0

Normal operations 3.1 3.2

4.0

Feed Supply Splitter Section Re-boiling Heater

Operating Parameters Process Variables

Start up procedure 4.1 4.2 4.3

Steam Purging And Oxygen Removal Fuel Gas Back Up Oil In And Final Adjustment

NSU-03-01 NSU-03-01 NSU-03-02 NSU-04-01 NSU-04-01 NSU-04-01 NSU-04-01

5.0

Shut down procedure

NSU-05-01

6.0

Emergency shut down procedure

NSU-06-01 NSU-06-01 NSU-06-01 NSU-06-01 NSU-06-02 NSU-06-02 NSU-06-02 NSU-06-02 NSU-06-02 NSU-06-03 NSU-06-03 NSU-06-03

6.1 6.2 6.3 6.4 6.5

7.0

Stationary equipment list 7.1 7.2

8.0

Loss Of Feed Reflux Pump Failure Splitter Bottom Pump Failure Heater Tube Failure Utilities Failure 6.5.1 Power Failure 6.5.2 Steam Failure 6.5.3 Fuel Oil Failure 6.5.4 Cooling Water Failure 6.5.5 Instrument Air Failure 6.5.6 DCS Failure Stationary Equipment List PSV List

Interlocks

NSU-07-01 NSU-07-01 NSU-07-02 NSU-08-01

PART – B NAPTHA HYDROTREATER UNIT (UNIT – 14) S NO

DESCRIPTION

PAGE NO.

1.0

Introduction

NHTU-01-01

2.0

Process Description

NHTU-02-01 NHTU-02-01 NHTU-02-01

2.1

2.2 2.3 2.4 2.5

3.0

Basis Of Design 3.1 3.2

3.3 3.4

4.0

Duty Of The Unit Feed Specification 3.2. Naphtha Feed 1 3.2. Product Specifications 2 3.2. Yields 3 Battery Limit Conditions 3.3. Description 1 Normal Operating Parameters

Operating Variables 4.1

4.2 4.3

4.4 4.5

5.0

Feed Supply 2.1. Off-Sites 1 2.1. Inside CRU 2 Charge Heater (14F-01) Reaction Section Stripping Section Stripper Reboiler (14F-02)

Reactor Temperature 4.1.1 14-R-2 4.1.2 14-R-1 Space Velocity Hydrogen Partial Pressure And H2/HC Ratio 4.3.1 14R1 4.3.2 14R2 Feed Quality Stripper Bottom Temperature

Chemical Reactions 5.1

14-R-1 Reactions 5.1.1 Hydro-refining Reactions 5.1.1. De-sulfurisation 1 5.1.1. De-nitrification 2 5.1.1. Hydro De-oxygenation 3

NHTU-02-01 NHTU-02-02 NHTU-02-02 NHTU-02-04 NHTU-02-05 NHTU-03-01 NHTU-03-01 NHTU-03-01 NHTU-03-01 NHTU-03-06 NHTU-03-07 NHTU-03-07 NHTU-03-07 NHTU-03-08 NHTU-04-01 NHTU-04-01 NHTU-04-01 NHTU-04-01 NHTU-04-02 NHTU-04-02 NHTU-04-02 NHTU-04-02 NHTU-04-03 NHTU-04-03 NHTU-05-01 NHTU-05-01 NHTU-05-01 NHTU-05-01 NHTU-05-02 NHTU-05-02

5.2

5.1.2 Hydrogenation 5.1.3 Elimination of arsenic and metals 14-R-2 Reactions 5.2.1 Hydrogenation of Di-olefins 5.2.2 Iso Di-olefins 5.2.3 Olefin Hydrogenation

S NO

DESCRIPTION 5.2.4

6.0

Catalyst And Chemicals 6.1

6.2

7.0

Catalyst Contaminants 7.1. Inhibitors 1 7.1. Temporary poisons 2 7.1. Permanent poisons 3

Utility Requirement 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8

9.0

14-R-1 And 14-R-2 Catalysts 6.1. LD 145 14R1 Catalyst 1 6.1. HR 348 14R1 Catalyst 2 6.1. Inert Alumina balls 3 6.1. HR 945 14R2 Catalyst 4 Chemicals 6.2. Corrosion Inhibitor 1 6.2. Polymerisation Inhibitor 2 6.2. Dimethyl di-sulphide 3

Catalyst Characteristics 7.1

8.0

Sulfur reaction

Electric Power Fuel Gas Cooling Water Steam Treated Feed Water Nitrogen Hydrogen Intermittent Steam Requirement

Preliminary Operations 9.1

Initial Leak Test 9.1. General 1 9.1. Feed section 2

NHTU-05-03 NHTU-05-03 NHTU-05-03 NHTU-05-04 NHTU-05-04 NHTU-05-05

PAGE NO NHTU-05-05 NHTU-06-01 NHTU-06-01 NHTU-06-01 NHTU-06-01 NHTU-06-02 NHTU-06-02 NHTU-06-03 NHTU-06-03 NHTU-06-03 NHTU-06-03 NHTU-07-01 NHTU-07-01 NHTU-07-01 NHTU-07-02 NHTU-07-02 NHTU-08-01 NHTU-08-01 NHTU-08-01 NHTU-08-02 NHTU-08-02 NHTU-08-02 NHTU-08-02 NHTU-08-02 NHTU-08-02 NHTU-09-01 NHTU-09-01 NHTU-09-01 NHTU-09-01

9.2

9.3

10.0

9.1. Reaction Section 3 9.1. Stripper Section 4 Drying 9.2. General 1 9.2. Feed section Drying 2 9.2. Reaction section Drying 3 9.2. Stripper section Drying 4 Catalyst Loading 9.3. Preliminary 1 9.3. 14R1 Catalyst Loading 2 9.3. 14R2 Catalyst Loading 3 9.3. Leak Test 4

First Start Up 10.1

Purging And Oxygen Removal 10.1.1 Feed Section 10.1.2 Reaction Section 10.1.3 Stripper Section

10.2 10.3

Oil In And Stripper Circulation Pressurization Of The Reaction Section And Hydrogen Leak Test Reaction Section Oil In Catalyst Sulphiding 10.5.1 Introduction 10.5.2 Operation of 14R1 10.5.3 Notes 10.5.4 Operation for 14R2 Feed Change & Final Adjustment

S NO

DESCRIPTION

10.4 10.5

10.6

11.0

Normal Shut Down 11.1 11.2

12.0

Short Duration Normal Shut Down Long Duration Normal Shut Down

Emergency Procedures 12.1 12.2 12.3 12.4 12.5 12.6 12.7

Introduction General Loss Of Feed Recycle Compressor (14k-1) Failure Hydrogen Rich Gas Make-Up Failure Stripper Reboiler Pump 14-P-4a/B Failure Utilities Failure 12.7.1 Fuel Gas 12.7.2 Cooling Water

NHTU-09-02 NHTU-09-02 NHTU-09-03 NHTU-09-03 NHTU-09-03 NHTU-09-03 NHTU-09-03 NHTU-09-04 NHTU-09-04 NHTU-09-05 NHTU-09-07 NHTU-09-08 NHTU-10-01 NHTU-10-01 NHTU-10-01 NHTU-10-02 NHTU-10-02

PAGE NO NHTU-10-03 NHTU-10-04 NHTU-10-05 NHTU-10-05 NHTU-10-05 NHTU-10-06 NHTU-10-07 NHTU-10-08 NHTU-10-12 NHTU-11-01 NHTU-11-01 NHTU-11-02 NHTU-12-01 NHTU-12-01 NHTU-12-02 NHTU-12-02 NHTU-12-03 NHTU-12-04 NHTU-12-04 NHTU-12-05 NHTU-12-05 NHTU-12-05

12.7.3 12.7.4 12.8

13.0

Restart-Up Of The Unit 13.1 13.2 13.3

14.0

High Delta P In The Reactors Feed/Effluent Or Feed/Bottom Exchanger Leaks Chemical Hydrogen Consumption Increase Presence Of Water Or H2s In Reformer Feed Presence Of Total Sulfur In Reformer Feed

Safety Devices 15.1 15.2 15.3

16.0

Re-Start After Short Duration Shut Down Re-Start Up After Long Duration Shut Down Start Up After, Catalyst, Regen. / Repl.

Troubleshooting 14.1 14.2 14.3 14.4 14.5

15.0

Power Supply Instrument Air And/Or Instrument Power Supply Failure Major Leak Or Fire

Emergency Sequences Alarm List Process Safety Interlock

Catalyst Regeneration 16.1

In-Site Regeneration 16.1.1 Heating The Catalyst Bed 16.1.2 Catalyst Bed Steam Stripping 16.1.3 Pre-Oxidation

S NO

DESCRIPTION 16.1.4 16.1.5

17.0

Catalyst Unloading 17.1 17.2

18.0

Coke Burning Cooling

Used Catalyst Unloading For Disposal Unloading For Reactor Inspection

Stationary Equipment List

NHTU-12-05 NHTU-12-06 NHTU-12-07 NHTU-13-01 NHTU-13-01 NHTU-13-01 NHTU-13-02 NHTU-14-01 NHTU-14-01 NHTU-14-01 NHTU-14-02 NHTU-14-02 NHTU-14-02 NHTU-15-01 NHTU-15-01 NHTU-15-03 NHTU-15-04 NHTU-16-01 NHTU-16-01 NHTU-16-01 NHTU-16-01 NHTU-16-01

PAGE NO NHTU-16-02 NHTU-16-02 NHTU-17-01 NHTU-17-01 NHTU-17-01 NHTU-18-01

PART – C CONTINUOUS CATALYST REGENERATION UNIT 1.O

Introduction 1.1 1.2 1.3

1.4

2.0

Design Capacity Feed Specification 1.2.1 Distillation Product Specifications 1.3.1 C5+ cut 1.3.2 Hydrogen rich gas 1.3.3 Fuel Gas Utilities

Process Description 2.1

Feed Section

CRU-01-01 CRU-01-01 CRU-01-01 CRU-01-03 CRU-01-04 CRU-01-04 CRU-01-04 CRU-01-05 CRU-01-06 CRU-02-01 CRU-02-01

2.2

2.3 2.4 2.5

2.6

2.7 2.8

Reaction Section 2.2.1 Heaters 2.2.2 Burners 2.2.3 Pilot Burners 2.2.4 Reactors Re-contacting Section Debutaniser Section 2.4.1 Stabiliser reboiler Catalyst Regeneration 2.5.1 Coke Burning 2.5.2 Calcination 2.5.3 Oxy-chlorination 2.5.4 Dryer Catalyst circulation 2.6.1 Catalyst level control 2.6.2 Sequence transfer Catalyst Circulation and regeneration 2.7.1 Dryer Catalyst circulation and regeneration 2.8.1 Catalyst flow control 2.8.2 Isolation of reaction section 2.8.3 Regeneration loop 2.8.4 Catalyst regeneration procedure 2.8.5 Nitrogen lift gas system

S NO

DESCRIPTION 2.8.6 2.8.7 2.8.8 2.8.9

3.0

3.2

3.3

4.2

5.0

Promoting Rxn With Hydrogen Production 3.1.1 Dehydrogenation Of Naphthenes 3.1.2 Paraffin De-hydrocyclisation Promoting Reactions Without H2 Production 3.2.1 Isomerization Of Linear Paraffins 3.2.2 Isomerization Of Naphthenes Retarding Reactions 3.3.1 Hydro-cracking 3.3.2 Hydro de-alkylation 3.3.3 Alkylation 3.3.4 Coking

CRU-03-01 CRU-03-02 CRU-03-04 CRU-03-04 CRU-03-04 CRU-03-05 CRU-03-05 CRU-03-06 CRU-03-06 CRU-03-07

Catalyst And Chemicals 4.1

PAGE NO CRU-02-23 CRU-02-24 CRU-02-27 CRU-02-29 CRU-03-01 CRU-03-01

Chemical Reactions 3.1

4.0

Catalyst replacement Procedure for Regenerator Cleaning/Repair Steam Generation System Process Variables

CRU-02-02 CRU-02-02 CRU-02-02 CRU-02-02 CRU-02-03 CRU-02-05 CRU-02-05 CRU-02-06 CRU-02-07 CRU-02-08 CRU-02-09 CRU-02-09 CRU-02-11 CRU-02-11 CRU-02-11 CRU-02-12 CRU-02-14 CRU-02-14 CRU-02-14 CRU-02-14 CRU-02-15 CRU-02-16 CRU-02-18 CRU-02-22

Catalyst (Cr-201) 4.1.1 CR-201 Chemicals (C2Cl4, NaOH, N2) 4.2.1 Per-chloro ethylene 4.2.2 Caustic soda 4.2.3 Nitrogen

Start Up Of The Unit

CRU-04-01 CRU-04-01 CRU-04-01 CRU-04-02 CRU-04-02 CRU-04-02 CRU-04-02 CRU-05-01

5.1 5.2 5.3 5.4 5.5 5.6 5.7

6.0

Shut Down Of The Unit 6.1 6.2 6.3 6.4

7.0

First Start Up Of The Unit Catalyst Circulation And Drying Stabilizer Start Up At Total Reflux Catalyst Heating Up And Reduction Feed Introduction High Severity Operation Regeneration Start Up

Short Duration Normal Shut Down Normal Duration Normal Shut Down Normal Shut Down With Catalyst Unloading Catalyst Circulation And Regeneration Section 6.4.1 Activity Of Partial Shut Down 6.4.2 Activity Of Total Shut Down

Emergency Shut Down Procedure 7.1 7.2

7.3

Introduction Loss Of Feed 7.2.1 Recycle gas compressor 7.2.2 Absorber feed pump failure 7.2.3 Reboiler pumps Utilities Failure 7.3.1

Fuel Gas

7.3.2 7.3.3 7.3.4 7.3.5 7.3.6

Cooling Water Failure Power Supply Instrument Air Major Leak Or Fire Fire

S No

8.0

DESCRIPTION

Restart Of The Unit 8.1 8.2

9.0

Restart Of The Entire Unit (Including Regenerating Section) Restart Of The Regeneration Section Alone 8.2.1 After A Partial Shut Down 8.2.2 After A Total Shut Down

Trouble Shooting 9.1 9.2

9.3

General Unexpected Decrease In Ron (Research Octane Number Leak In The Feed/Effluent Heat Exchanger 9.2.1 Presence Of Nitrogen In Feed 9.2.3 9.2.3 Presence Of Sulfur In The Feed 9.2.4 Presence Of Metals In The Feed 9.2.5 Low Chlorine Content Of The Catalyst 9.2.6 Partial By-Pass Of The Catalyst Loss Of Reformate Yield 9.3.1 Presence Of Sulfur In The Feed 9.3.2 Presence Of Metals In The Feed

CRU-05-01 CRU-05-02 CRU-05-03 CRU-05-04 CRU-05-05 CRU-05-07 CRU-05-07 CRU-06-01 CRU-06-01 CRU-06-02 CRU-06-03 CRU-06-04 CRU-06-04 CRU-06-05 CRU-07-01 CRU-07-01 CRU-07-02 CRU-07-03 CRU-07-04 CRU-07-04 CRU-07-04 CRU-07-04

PAGE NO CRU-07-04 CRU-07-05 CRU-07-06 CRU-07-07 CRU-07-08 CRU-08-01 CRU-08-01 CRU-08-02 CRU-08-02 CRU-08-03 CRU-09-01 CRU-09-01 CRU-09-01 CRU-09-02 CRU-09-02 CRU-09-02 CRU-09-02 CRU-09-02 CRU-09-03 CRU-09-03 CRU-09-03 CRU-09-03

9.4 9.5 9.6

9.7 9.8 9.9 9.10 9.11 9.12

9.13

S No 10.0

Shut Down Of The Refrigeration System

DESCRIPTION Equipment List 10.1 10.2 10.3 10.4 10.5 10.6

11.0

Too High Chlorine Content Of The Catalyst 9.3.3 Unexpected Delta T Reduction The First Catalytic Bed High Hydrocracking Rate And Risk Of Temperature Run Away 9.5.1 Hydrocracking Can Be Caused By High Pressure Drop In The Reactors Or The Regenerator 9.6.1 Reactors 9.6.2 Prevention 9.6.3 Reactor cleaning 9.6.4 Regenerator 9.6.5 Stop catalyst circulation Failure Of Regeneration Failure Of Nitrogen Lift System Failure Of Chlorine Injection Failure Of Catalyst Circulation Washing Suction Default Difficulties In Controlling The Regeneration Temperature 9.12.1 High Temp. Out Of First Combustion Bed 9.12.2 High Temp. Out Of Second Combustion Bed 9.12.3 Low Temp Out Of Second Combustion Bed High Temp In The Oxy-chlorination Or 9.12.4 Calcination Bed 9.12.5 Low Temp. In The Calcination Bed

Vessels / Reactors / Regenerator / Filters / Columns / Furnaces Exchangers Pumps Air Coolers / Electric Heaters Compressor & Blowers Stationary Equipment List

Safety Interlocks 11.1 Unit-15 11.2 Unit-17 11.3 Process safety interlocks (Unit 15&17)

CRU-09-04 CRU-09-04 CRU-09-05 CRU-09-05 CRU-09-06 CRU-09-06 CRU-09-07 CRU-09-07 CRU-09-07 CRU-09-07 CRU-09-08 CRU-09-08 CRU-09-09 CRU-09-09 CRU-09-09 CRU-09-10 CRU-09-10 CRU-09-10 CRU-09-10 CRU-09-10 CRU-09-11 CRU-09-11

PAGE NO CRU-10-01 CRU-10-01 CRU-10-03 CRU-10-04 CRU-10-05 CRU-10-06 CRU-10-06 CRU-11-01 CRU-11-01 CRU-11-02 CRU-11-08

PART – D NITROGEN PLANT S No 1.0

Introduction

DESCRIPTION

N2-01-01

2.0

Design Basis

N2-02-01 N2-02-01 N2-02-01 N2-02-01

2.1 2.2 2.3

Nitrogen Requirement Air Requirement Product Quality

PAGE NO

2.4

Production Pattern

N2-02-01

3.0

Principle Of Operation

N2-03-01

4.0

Process Description

N2-04-01 N2-04-01 N2-04-01 N2-04-02 N2-04-03 N2-04-03 N2-04-03 N2-04-04 N2-04-05 N2-04-05 N2-04-06 N2-04-06 N2-04-07

4.1 4.2 4.3 4.4

4.5

5.0

Regenerations Of Adsorbers 5.1

6.0

Air Compression Section Refrigeration Section Air Purification Section Liquefaction And Fractionation Section 4.4.1 Cold Box 4.4.2 Exchanger (40-E-1) 4.4.3 Fractionating Column & Vaporiser Condenser 4.4.4 Expansion Turbine (40-D-1) Product Storage & Supply 4.5.1 Cold Converters 4.5.2 Atmospheric Vaporiser 4.5.3 Nitrogen Booster Compressor Step Of Regenerations

Air Compressor 6.1 6.2 6.3 6.4

Lubrication System Control System Air Compressor Start-Up Stopping The Air Compressor

6.5

Inter Locks

S No 7.0

8.0

DESCRIPTION Refrigeration Section 7.1 7.2 7.3

Refrigeration Compressor Starting Procedure Stopping Procedure

7.4

Trouble Shooting

Expansion Turbine 8.1 8.2 8.3

9.0

Lube Oil System Seal Gas System Procedures

Start Up Of Plant 9.1 9.2 9.3

9.4 9.5 9.6

Preparation Of Adsorbers Drying Of The Circuits (Cold Box) Putting In Cold (Before Placing The Insulation) 9.3.1 Start Up Of The Unit 9.3.2 Shut Down Of The Plant Tightening Of Nut & Bolts Inside The Cold Box Placing the Insulation Inside The Cold Box Final Start Up 9.6.1 First Stage 9.6.2 Second Stage 9.6.3 Third Stage

N2-05-01 N2-05-01 N2-06-01 N2-06-01 N2-06-03 N2-06-07 N2-06-08

PAGE NO N2-06-09 N2-07-01 N2-07-01 N2-07-04 N2-07-04 N2-07-05 N2-08-01 N2-08-02 N2-08-03 N2-08-03 N2-09-01 N2-09-01 N2-09-01 N2-09-02 N2-09-02 N2-09-03 N2-09-04 N2-09-04 N2-09-04 N2-09-04 N2-09-04 N2-09-05

9.6.4

10.0

Liquid Nitrogen Draw Off

Shut Down Of The Plant 10.1

10.2

Planned Shut Down 10.1.1 Short Time Stoppage 10.1.2 Prolonged Stoppage Emergency Shut Down

N2-09-05 N2-10-01 N2-10-01 N2-10-01 N2-10-01 N2-10-01

11.0

Defrost Of The Plant

N2-11-01

12.0

Danger Of Impurities

N2-12-01 N2-12-01 N2-12-01 N2-12-01

12.1 12.2 12.3

13.0

Dangers Of Acetylene Dangers Of Oxygen Dangers Of Nitrogen

Miscellaneous Information 13.1

13.2

Stationary Equipment List 13.1.1 Water Block end 13.1.2 CRU end 13.1.3 CRU Panel end Stationary equipment list

N2-13-01 N2-13-02 N2-13-02 N2-13-02 N2-13-03 N2-13-03

PART – E AMMONIA REFRIGERATION SYSTEM (15-X-1) S No 1.0

Introduction

DESCRIPTION

PAGE NO NH3-01-01

2.0

Process Description

NH3-02-01

3.0

Operating Parameters

NH3-03-01

4.0

Equipment Description

NH3-04-01

5.0

Starting & Stopping Procedure

6.0

Shut Down Procedure

NH3-05-01 NH3-05-01 NH3-05-02 NH3-06-01

7.0

Control System For Plc Logic

NH3-07-01

8.0

Lube Oil Pumps Logic

NH3-08-01

9.0

Compressor Start / Stop Logics

NH3-09-01

5.1 5.2

Starting Procedure Stopping Procedure

PART – F AIR PREHEATER SYSTEM 09F-1 / 14F-1 / 14F-2 / 15F-4

S No 1.0

DESCRIPTION General Description 1.1 1.2 1.3 1.4 1.5

2.0

Air Pre-heater Instructions 2.1 2.2

3.0

Cast Tube Air Pre-heater Glass Tube Air Pre-heater Commissioning Instructions Maintenance During Operation Washing Procedure

Design Data Process Parameters

Interlock And Alarm Set Point 3.1

3.2

Interlock Scheme 3.1.1 FD fan failure 3.1.2 ID fan failure 3.1.3 High arch pressure 3.1.4 High temperature of ID fan inlet 3.1.5 Low combustion Air flow/pressure 3.1.6 Fuel cut-off to furnace 3.1.7 Stack damper 3.1.8 Turndown operation Set Point

PAGE NO APH-01-01 APH-01-01 APH-01-02 APH-01-02 APH-01-03 APH-01-04 APH-02-01 APH-02-01 APH-02-01 APH-03-01 APH-03-01 APH-03-01 APH-03-02 APH-03-02 APH-03-02 APH-03-03 APH-03-03 APH-03-03 APH-03-03 APH-03-04

PART – G OFF-SITE HYDROGEN STORAGE FACILITY S No 1.0

Introduction

DESCRIPTION

H2-01-01

2.0

Hydrogen Storage Bullets

H2-02-01

3.0

Hydrogen Compressor

H2-03-01 H2-03-01 H2-03-02 H2-03-04 H2-03-05 H2-03-05 H2-03-05

3.1 3.2 3.3 3.4 3.5

Lubrication System Initial Start-Up Procedure Start-Up Procedure Stopping Procedure Emergency Stopping Procedure

3.6

Interlocks

PAGE NO

4.0

Cylinder Unloading Facility

H2-04-01

5.0

Hydrogen Transfer To/From Bullets

H2-05-01

6.0

Hydrogen Gas Properties And Hazards

H2-06-01 H2-06-01 H2-06-02

6.1 6.2

Properties Hazards Involved

PART – H MISCELLANEOUS S No 1.0

DESCRIPTION Utility System (NSU, NHTU, CRU, N2 Plant) 1.1 1.2 1.3

1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11

Instrument Air Drinking Water Steam 1.3. LP Steam 1 1.3. MP Steam 2 1.3. HP Steam 3 Cooling Water Dm Water (De-Mineralised Water Boiler Feed Water Fuel Gas System Nitrogen System Plant Air Service Water Flare System

PAGE NO MISC-01-01 MISC-01-01 MISC-01-01 MISC-01-01 MISC-01-01 MISC-01-02 MISC-01-03 MISC-01-04 MISC-01-05 MISC-01-05 MISC-01-05 MISC-01-07 MISC-01-09 MISC-01-09 MISC-01-10

2.0

Standing Instructions

MISC-02-01

3.0

Work Permit System

MISC-03-01 MISC-03-01 MISC-03-01

3.1 3.2

Introduction Scope

3.3

Types Of Work Permit

S No

DESCRIPTION 3.3.1 Definitions General Requirement Responsibilities 3.5.1 Issuing Authority 3.5.2 Executing Authority Procedures 3.6.1 Issue Of Permit 3.6.2 Explanatory Notes To Permit Forms 3.6.3 Explanatory Notes To Permit At Height 3.6.4 Surveillance And Permit Withdrawal 3.6.5 Surrendering The Permit 3.6.6 Training And Awareness

MISC-03-02

PAGE NO

4.0

Unit House Keeping

MISC-03-02 MISC-03-02 MISC-03-04 MISC-03-04 MISC-03-04 MISC-03-05 MISC-03-06 MISC-03-07 MISC-03-11 MISC-03-13 MISC-03-13 MISC-03-14 MISC-04-01

5.0

Roles And Responsibilities

MISC-05-01

6.0

List Of Various OISD Standards

MISC-06-01

7.0

List Of Safety Interlocks & Trip Set Points

MISC-07-01

8.0

Cause And Effect Diagrams

MISC-08-01 MISC-08-01 MISC-08-06 MISC-09-01 MISC-09-01 MISC-09-01 MISC-09-02 MISC-09-04 MISC-09-04 MISC-09-05 MISC-09-05 MISC-09-06 MISC-09-06 MISC-09-06 MISC-09-07 MISC-09-08 MISC-09-08 MISC-09-10 MISC-09-10 MISC-09-10 MISC-09-12 MISC-09-14 MISC-10-01 MISC-10-01 MISC-10-02 MISC-10-03 MISC-10-04 MISC-11-01 MISC-11-01

3.4 3.5

3.6

8.1 8.2

9.0

Recycle Gas Compressor 9.1 9.2 9.3 9.4

9.5

9.6 9.7 9.8 9.9

10.0

Introduction Operating principle Compressor Compressor shaft and sealing system 9.4.1 Seal related data 9.4.2 Gas filter system 9.4.3 Leakage gas system 9.4.4 Separation gas system Turbine 9.5.1 Turbine operating data 9.5.2 Trip & throttle valve 9.5.3 Turbine gland seal system 9.5.4 Lube oil system 9.5.5 Lube oil specifications Turbine governor Compressor anti-surge control Guidelines for start-up Guidelines for shutdown

Handing Over and Taking Over Procedures 10.1 10.2 10.3 10.4

11.0

Compressors Furnaces

Pumps Heat exchangers Vessels Columns

Check Lists 11.1

Initial furnace start-up

Furnace light-up

11.3

Critical equipments handing over/Taking over check list 11.3.1 Compressor handing over check list 11.3.2 Compressor taking over check list 11.3.3 Pump handing over check list 11.3.4 Pump taking over check list 11.3.5 Furnace handing over check list 11.3.6 Furnace taking over check list Start up / Shut down check list 11.4.1 Shut Down check list 11.4.2 Start up check list

S No

DESCRIPTION

11.4

12.0

Material Safety Data sheet (MSDS) 12.1 12.2 12.3 12.4 12.5 12.6 12.7

13.0 14.0

15.0 16.0 17.0 18.0 19.0 20.0

MISC-11-03

11.2

AHURULAN (Corrosion Inhibitor) Ammonia Per-chloro ethylene (C2Cl4) Dimethyl di sulphide (DMDS) Trisodium Phosphate Hydrogen Anti-polymerisation agent

PAGE NO MISC-11-05 MISC-11-05 MISC-11-06 MISC-11-08 MISC-11-08 MISC-11-10 MISC-11-11 MISC-11-12 MISC-11-12 MISC-11-16 MISC-12-01 MISC-12-01 MISC-12-06 MISC-12-10 MISC-12-14 MISC-12-17 MISC-12-21 MISC-12-25

Alarm List

MISC-13-01

Accident / Incident Reporting, Investigation & Analysis 14.1 Introduction 14.2 Scope 14.3 Responsibility 14.4 Definition 14.5 Reporting Procedure 14.6 Guideline for Conducting Investigation 14.7 Cost Analysis 14.8 Corrective and Preventive Action 14.9 Collecting Information on Near miss 14.10 Motivating Personnel to Report Accident / Incidents 14.11 Coordination with External Agency 14.12 Circulation of Lesson learned report 14.13 Major Accident / Incident announcement 14.14 Major Accident / Incident review 14.15 Training on Accident / Incident investigation 14.16 Accident / Incident Analysis 14.17 Problem Solving Project Teams 14.18 Accident Reporting Process Map 14.19 Accident / Incident Reporting Process Map Sampling Schedule Inventory levels of hazardous chemicals maintained in field Standard Blind List Handing Over Schedules for man Entry Charge handing over and Taking over Procedures Emergency Procedures for CRU block 20.1 Cooling water Failure 20.2 Total Power Failure 20.3 Instrument air Failure

MISC-14-01 MISC-14-01 MISC-14-01 MISC-14-01 MISC-14-03 MISC-14-06 MISC-14-09 MISC-14-12 MISC-14-13 MISC-14-13 MISC-14-13 MISC-14-14 MISC-14-14 MISC-14-14 MISC-14-14 MISC-14-14 MISC-14-15 MISC-14-18 MISC-14-18 MISC-14-19 MISC-15-01 MISC-16-01 MISC-17-01 MISC-18-01 MISC-19-01 MISC-20-01 MISC-20-01 MISC-20-01 MISC-20-01

21.0 22.0

20.4 DCS/PLC Failure 20.5 CRU IFP heater tripping 20.6 BFW Failure 20.7 Screen damage in Reactor 20.8 Screen damage in Regenerator 20.9 Runaway Temperature in Regenerator 20.10 Network Hydrogen Failure 20.11 Condensate in FG Header 20.12 Nitrogen Leak 20.13 Ammonia Leak 20.14 Hydrogen Sulphide Leak 20.15 Hydrogen Leak 20.16 14E3A/B tube leak 20.17 Critical pump seal leak 20.18 CRU separator bottom pump Failure 20.19 NHTU Reactor Furnace 14F1 trip 20.20 Stripper reboiler furnace 14F2 trip 20.21 Oil back-up from OW&S 20.22 Nitrogen plant air compressor Failure 20.23 Freon refrigeration Compressor Failure 20.24 Chemical Leakage List Of Critical Equipments in CRU Unit NSU, NHTU and CRU Equipment Process Data Sheets

MISC-20-03 MISC-20-03 MISC-20-03 MISC-20-03 MISC-20-04 MISC-20-04 MISC-20-04 MISC-20-05 MISC-20-05 MISC-20-05 MISC-20-05 MISC-20-05 MISC-20-06 MISC-20-06 MISC-20-06 MISC-20-06 MISC-20-06 MISC-20-06 MISC-20-07 MISC-20-07 MISC-20-07 MISC-21-01

NAPTHA SPLITTING UNIT (UNIT –9) 1.0

INTRODUCTION: Naphtha splitting unit produces feed of required TBP range for the reforming unit by splitting wide cut naphtha from CDU. The selected cut is then Hydrotreated before feeding to the Reforming Unit. This unit has been designed to split SR naphtha (144 MT/hr for BH or 95 MT/hr for AM) to C5-80 oC and 80-115 oC cut. Due to the restriction on Benzene content in the final product (motor spirit), the IBP of the heavier cut is raised to approximately 105 oC. The present operating cut range of NSU for light naphtha is C5-105 oC and for heavy naphtha is 105-160 oC. NSU can be operated with naphtha directly from AVU (hot feed) and from OM&S (Cold feed), it can also be operated using both the feed simultaneously. Light naphtha stream can be routed from splitter to R/D naphtha tanks through AVU, directly to HGU feed tanks, directly to R/D naphtha tanks through slop header. The heavier cut is routed to Hydrotreating unit as hot feed and balance to hydrotreater feed tanks. The off spec naphtha is routed to R/D naphtha tanks using slop header. Naphtha Splitting Unit (designed by EIL) comprises of a single column with on-stream factor of 8000 hours and has an operating flexibility of 50% of the design capacity. Naphtha Splitting Unit was commissioned on 08.03.98. Subsequently Naphtha splitter was revamped during July 2010. Again Naphtha splitter revamped for inclusion of Side cut facility during Nov. 2013. Light naphtha is used as feedstock for penex unit and heavy naphtha for PXPTA and CCRU.For current crude processing capacity of 8.5 – 9 MMPTA, NSU needs to be operated at more than design capacity that in turn affects product qualities.Henceforth, NSU capacity augmentation from 144MT/hr to

200MT/hr in BH case was carried out to maintain product quality and also to avoid naphtha spillover in AVU. CCRU OPERATING MANUAL

NSU- 01- 01

PART-A

Design Basis for Side Cut: At 200 Mt/hr feed rate desired C7+(9%max) for Penex feed and Benzene and Benzene Precursors 7kg/cm 2g (if required adjust service air header pr.) 4. CRU air header pr. To be maintained >7 kg/cm 2g during normal running by adjusting service air header pr.) 5.

In case of any emergency contact CRU control room immediately.

13.1.2 CRU END 1. Line up battery limit b/v (make sure vent is closed at b/l.) 2. After opening compressor discharge b/v (for water block) slowly drain all condensate from final stage knock out drum drain point (other low pt drains may also be used.) Make sure b/v is fully opened. 3. Check pr on knock out drum > 7 kg/cm2g 4. Check mist separator downstream of the Freon chiller drain free of condensate. 5. Coordinate with panel operator and unload running comp. 6. Open compressor Discharge B/v (N2 plant) slowly to fully opened condition while watching header pr. (if required coordinate with water block). Simultaneously close compressor discharge valve (every care should be taken to avoid surging of comp.) CCRU OPERATING MANUAL

N2- 13 - 02

PART-D

7. If every thing found normal stop comp. 8. Check for condensate and header pressure

13.1.3 CRU PANEL END 1. Stop/reduce liquid Nitrogen production to LIN. 40C1 bottom level to be maintained slightly on higher side (to make up any liquid loss during change over) 2. L.P column pr to be maintained >3 kg/cm 2g during changeover (if required. Gaseous Nitrogen flow may be minimized. 3. Coordinate with water block for 40C1 pr >=6.5 kg/cm 2g 4. In case of any abnormality stop liquid Nitrogen draw & gaseous Nitrogen to be diverted to vent.

13.2 STATIONARY EQUIPMENT LIST S. EQUIPMENT NO. DESCRIPTION NO. 1. 2. 3.

40 C 1 40 CB 1 40 E 1

4. 5.

40 E 10 40 E 101

6.

40 E 102

7.

40 E 103

8.

40 E 104

9. 10.

40 E 11 40 E 110

SET PRESSURE Kg/cm2 g)

COLUMN OF COLD BOX-1 COLD BOX-1 PLATE TYPE EXCHANGER OF COLD BOX-1 ATMOSPHERIC VAPORISER ATMOSPHERIC VAPORISER UNDER LIN-1 ATMOSPHERIC VAPORISER UNDER LIN-2 ATMOSPHERIC VAPORISER UNDER LIN-3 ATMOSPHERIC VAPORISER UNDER LIN-4 ATMOSPHERIC VAPORISER EVAPORATOR

CCRU OPERATING MANUAL PART-D

N2- 13 - 03

TYPE

11. 12. 13. 14. 15. 16. 17. 18. 19 20. 21.

40 40 40 40 40 40 40 40 40 40 40

E 111 E 112 E 113 E 12 E 17 E 20 E 21 E 4 EH 16 EH 18 G 1

22.

40 G 2

23.

40 G 3A

24.

40 G 3B

25.

40 IC 1A

26.

40 IC 1B

27.

40 IC 2A

28.

40 IC 2B

29.

40 IC 3A

30.

40 IC 3B

31.

40 IC 4A

32.

40 IC 4B

33.

40 IC 5A

EVAPORATOR EVAPORATOR EVAPORATOR EVAPORATOR DERIMING HEATER DOUBLE TUBE EXCHANGER FREON CONDENSER VAPORISER OF COLD BOX-1 REGENERATION HEATER ELECTRICAL TRIM HEATER OIL SEPERATOR OF FREON COMPRESSOR-1 OIL SEPERATOR OF FREON COMPRESSOR-2 AIR FILTER OF COLD BOX U/S AIR FILTER OF COLD BOX U/S 1ST STAGE INTER COOLER OF AIR COMPRESSOR-A 1ST STAGE INTER COOLER OF AIR COMPRESSOR-B 2ND STAGE INTER COOLER OF AIR COMPRESSOR-A 2ND STAGE INTER COOLER OF AIR COMPRESSOR-B 3RDSTAGE INTER COOLER OF AIR COMPRESSOR-A 3RDSTAGE INTER COOLER OF AIR COMPRESSOR-B LUBE OIL COOLER OF AIR COMPRESSOR-A LUBE OIL COOLER OF AIR COMPRESSOR-B LUBE OIL COOLER OF AIR COMPRESSOR-A

CCRU OPERATING MANUAL PART-D

N2- 13 - 04

34.

40 IC 5B

35. 36. 37. 38. 39. 40. 41. 42. 43.

40 40 40 40 40 40 40 40 40

PSV PSV PSV PSV PSV PSV PSV PSV PSV

44. 45. 46. 47. 48. 49. 50. 51. 52. 53.

40 40 40 40 40 40 40 40 40 40

PSV 2281 PSV 3308 PSV 3309 PSV 3318 PSV 3319 PSV 3320 PSV 4410 RX 1 RX 2 V 1

54. 55. 56.

40 V 101 40 V 102 40 V 103

2203 2206 2211 2212 2230 2231 2247 2249 2257

LUBE OIL COOLER OF AIR COMPRESSOR-B ON 40-V-1 ON 40V-1 O/L LINE ON 40-E-16 ON INST. AIR LINE ON 40-RX-1 ON 40-RX-2 ON 40-C-1 ON 40-E-4 ON 40-D-1(EXPANSION TURBINE) ON 40-E-17 ON 40-V-2 ON40-V-2 ON LINE TO LIN 1&2 ON 40-E-10,11 I/L LINE ON 40E-10,11 O/L LINE ON 40-E-21 ADSORBER REACTOR ADSORBER REACTOR K.O. DRUM AFTER REFRIGERATION LIN-1 LIN-2 LIN-3

CCRU OPERATING MANUAL PART-D

8.8 1.0 8.0 1.29 1.29 1.29 4.0 1.0

CONV CONV CONV CONV CONV CONV CONV CONV

2.0

CONV

7.70 7.70 7.70

CONV CONV CONV

N2- 13 - 05

57. 58. 59.

40 V 104 40 V 2 40 V 3A

60.

40 V 3B

LIN-4 GASEOUS NITROGEN TANK DISCHARGE K.O. DRUM OF AIR COMPRESSOR-A DISCHARGE K.O. DRUM OF AIR COMPRESSOR-B

CCRU OPERATING MANUAL PART-D

N2- 13 - 06

AMMONIA REFRIGERATION SYSTEM (15-X-1) 1.0 INTRODUCTION: The purpose of the plant is to increase the purity of hydrogen in recycle gas by eliminating condensable hydrocarbon like propane, butane at low temperature of -10 oC (pressure 4.8 Kg./cm2 g). To achieve this, Refrigeration plant of capacity 424 TR. has been installed which is supplied as a package unit by M/s KIRLOSKAR. The plant will be handed over to IOC after its commissioning and stabilization by M/s KIRLOSKAR. The condensing temperature of NH3 is 43 oC at 15.3 Kg./cm2 g and liquid to gas evaporation starts at -15 oC at 2.4 Kg./cm2 g. This principle has been applied in Ammonia Refrigeration plant where gaseous NH3 is compressed by a screw type compressor and then after condensation in a condenser by cooling water, the liquid NH3 is again allowed to evaporate by taking latent heat from the system which lowers the temperature upto -15 oC. The gas is compressed again by compressor and a continuos cycle continues.

CCRU OPERATING MANUAL PART-E

NH3- 01 - 01

2.0 PROCESS DESCRIPTION: Ammonia gas is drawn by the compressor through a non-return valve and strainer fitted directly on the inlet flange and discharged into an oil tank separator. The non return valve is necessary to prevent the compressor being "motored" in reverse direction when it is stopped with high gas pressure at the outlet. The suction pressure remains 1.4 Kg./cm 2 g. After compressor, discharge gas mixed with oil comes to oil separator at a pressure of 15.5 Kg./cm 2 g where primary separation takes place. Secondary separation takes place in a wire mesh separator placed close to the outlet. Separated oil from the separator is drawn by the oil pump, cooled in a cooler and filtered in microfilm filter. The cooled and filtered oil at a pressure of 17.5 Kg./cm2 g (Pressure should be 2.0 Kg./cm 2 more than the comp. discharge pressure) is supplied to a manifold from where it is fed to the bearings, balance piston, shaft seal, compression chamber & hydraulic actuator. A pressure relief valve at the oil pump discharge maintains the system oil pressure. Initial pressure adjustment is done with circulation valve provided at the oil pumps common discharge to the oil separator. Compressed NH3 gas from the top of the oil separator (at pressure of 15.5 Kg./cm 2 g) is cooled and condensed in a condenser. Ammonia condensation takes place from gas to liquid phase and the liquid ammonia (at temp. of 41 oC) goes to receiver. This liquid NH3 is further cooled to a temp. of 0.5 oC in superfeed vessel. Superfeed vessel is a shell & tube exchanger where the liquid ammonia stream enters into its tube side. A part of the liquid ammonia stream is fed into the shell side of this exchanger, which evaporates. The shell side achieves a temperature of -5.5 oC on evaporation of liquid ammonia. Liquid ammonia stream is further cooled in the coil of Knock out drum by flashing a part of the Superfeed outlet stream. This cooled liquid ammonia is fed to the kettle type reboiler under its level control LIC 5003 (LIC-1504 as per EIL drawing) and is allowed to evaporate at 2.41 Kg./cm 2 g in the kettle and thereby cooling its temperature to -15 oC. This cools the process stream of hydrocarbon from 19oC to -10oC. The part of the liquid ammonia stream fed to the compressor knock out vessel under level control of LIC 5001 is to cool down the comp. suction gas also to a temp. of -10 oC.

CCRU OPERATING MANUAL PART-E

NH3- 02 - 01

To maintain constant cooling water flow through condenser and oil cooler one package type cooling tower has been installed. Also new Cooling water circuit has been installed directly from the refinery Cooling Water header in case of non availability of cooling tower. Additional Ammonia condenser installed in parallel of old Ammonia Condenser on November 2013. In case of Ammonia Condenser high DP in Tube side due to Chockage. One can be isolated for cleaning and other can be taken in line without stopping Refrigeration system.

3.0 OPERATING PARAMETERS: Following are the main operating parameters for the unit: Sr. No.

DESCRIPTION

FLOW KG/HR

TEMP. oC

PRESS. KG/CM2g

1

COMP. MAIN SUCTION

4,441

-15

2.41

2

COMP. SUCTION FROM SUPERFEED

822.5

-5.5

3.54

3

COMP. DISCHAREG

77.9

15.3

4

OIL PUMP DISCHARGE

428 LPM

77.9

19

5

OIL COOLER OUTLET

428 LPM

45

17.5

6

OIL FILTER OUTLET

428 LPM

45

17.2

7

CONDENSER INLET

77.9

15.3

8

RECEIVER OUTLET

41

15.3

9

SUPERFEED OUTLET TUBE SIDE

0.5

7.9

10

SUPERFEED OUTLET SHELL SIDE

-5.5

2.54

11

SUPERFEED O/L TO CHILLER DIRECT

12

SUPERFEED TO CHILLER VIA KO COIL

13

CHILLER INLET TOTAL

14

CHILLER OUTLET

15

SUPERFEED FLASHING IN KO

16

COOLING WATER TO OIL COOLER

65 M3/HR.

33/37

17

COOLING WATER TO CONDENSER

395M3/HR

33/37

CCRU OPERATING MANUAL PART-E

NH3- 03 - 01

Modification in suction line and connecting discharge line of Ammonia CW pump to new condenser Ammonia condenser Cooling water pump(15XP2A/B) discharge line was connected to only old condenser and new condenser takes suction from cooling water header directly. New 8’ line provided for suction and pump discharge connected to both condensers. Above modification resulted in lowering the temperature of Hydrocarbon to subzero degree, thus increasing the purity of rich gas. Now both condenser are in line and performance of Refrigeration section has been improved.

CCRU OPERATING MANUAL PART-E

NH3- 03 – 01*

4.0 EQUIPMENTS DESCRIPTION: COMPRESSOR: It is an oil injected screw compressor supplied by M/s KIRLOSKAR (Manufactured by M/s Howden of UK). 560 kW 6.6 kV motor of BHEL make is directly coupled to the compressor. The compressor has a capacity control mechanism and is an oil flooded rotary machine. Compression is achieved by the meshing of two helical rotors on parallel shafts housed in a casing. The accurately machined helical rotors are called Male and Female. The Male (driving) rotor has four lobes, which mesh with six flutes in a female (driven) rotor, both rotors having the same outside diameter. Each rotor is supported by two white metal thick walled journal bearings fitted adjacent to the compressor chamber. The lubricating oil is at gas discharge pressure plus 2kg/cm2 for standard range compressor. Rotor end thrust is balanced by balance pistons and angular contact ball bearings. One side of the balance piston is subject to oil pressure (gas outlet pressure plus 2 Kg./cm2 ). The other side is at suction pressure and therefore the balance Piston opposes the normal rotor end thrust and the angular contact bearings are lightly loaded and have a long life. As the rotors continue to rotate the intermeshing of the lobes on the discharge side of the compressor progressively reduces the space occupied by the gas causing compression. Compression continues until the inter lobe space becomes exposed to the outlet port in the casing and the gas is discharged. Capacity control is achieved by means of a slide valve in the casing operated by a piston in a hydraulic cylinder mounted on the compressor. The piston is actuated by lubricating oil, fed from the compressor lubricating oil manifold to one or other side of the piston, moving the slide valve altering the point in the rotor length at which compression begins. This allows internal gas re-circulation, thus controlling the capacity from 100% down to 10% with approx. proportionate saving of power. The main operating parameters are: CCRU OPERATING MANUAL

NH3- 04 - 01

PART-E

Suction / Disch. pressure :

1.4 / 15.29 Kg./cm2 g

Suction / Disch. temp.

:

-15 / 77.8 Oc

Flow

:

4441 kg/hr,

Power required

:

506 kW

Speed

:

2950 RPM

OIL TANK SEPARATOR: It is a vertical vessel of 762mm OD X 1775 mm height. For proper oil separation wire mesh element separator is positioned close to the tank outlet. Operating / Design pressure

: 15.51 / 20 Kg./cm2 g

Operating / Design temp.

: 77.9 / - 177 oC

OIL COOLER: There are two oil coolers for two sets of compressors: Kg./cm2 g

Operating Pressure

: 19

Operating temp. (L.O) IN / OUT

: 78/45 oC

Operating temp. (Water) IN/OUT : 33/37 oC

OIL PUMPS: Each set of compressor is equipped with two oil pumps. The pumps are David Brown UK make with capacity of 450 liters/min. with 9.3 kW motor. CONDENSER: It is horizontal exchanger of Dia 812mm, Length 6000mm with 848 tubes of 3/4"OD. Operating temp. ammonia IN/OUT

: 78 / 41OC

Cooling water IN/OUT

: 33 / 37oC

NEW CONDENSER Operating Pressure

: 16.3 kg/cm2

Operating temperature

: 78/ 41 oC

Cooling water IN/OUT

: 33 / 37oC

CCRU OPERATING MANUAL PART-E

NH3- 04 - 02

RECEIVER: It is horizontal type vessel of volume 7.2m3 Operating pressure : 15.29 Kg./cm2 g : 41oC

Operating temp.

SUPERFEED VESSEL: It is horizontal flooded type exchanger of 457 mm OD and 3000mm length having 200 nos. 3/4" tubes. It is designed for flow of 822 kg/hr in tube side. Shell side operating pressure and temp. are 2.54 Kg./cm 2 g and -5.5oC. Tube side-operating temp. is 0.5oC. SURGE DRUM: Volume

= 0.24 m3

Operating pressure = 1.359 Kg./cm2 g = -10oC

Operating temp. KNOCK OUT POT:

It is vertical vessel of volume 1.7m3 capacity (OD=860mm H=3000mm) Operating pressure = 1.41 Kg./cm2 g = -15oC

Operating temp.

AMMONIA RECOVERY TANK It is a vertical vessel having vol. 0.3m3. = -10oC (minimum)

Operating temp. COOLING TOWER:

Paharpur make Model No. 23101, Cooling Tower Capacity

= 455 m3/hr,

Cooling water Pump Capacity

= 460m3/hr. at 25M head,

Cooling water pump motor

= 45 kW (KEC make)

Cooler tower fan motor

= 15 kW (KEC make)

FRP MAKE UP TANK capacity

= 2500 liters (vertical).

CCRU OPERATING MANUAL PART-E

NH3- 04 - 03

5.0 STARTING & STOPPING PROCEDURE: 5.1

STARTING PROCEDURE: Ensure cooling water flow through condenser and oil cooler. Check and ensure that all the valves in the oil circuit are open, with one oil filter and one oil pump in line. Check and ensure that the following valves in the refrigerant circuit are open: Oil Tank Separator (OTS) outlet valves. Condenser inlet/outlet valves. Receiver outlet valves. All liquid line valves except hand expansion valve and liquid line strainer. All superfeed vessel valves feeding ammonia to tube and shell side. Superfeed suction valve. Vapour line valves leading to and from KO. drum. Compressor main suction valve. Isolation valve for superfeed stand pipe. Check the oil level in OTS. This should be between the top most U-clamp bolt of the level gauge glass and the glass top. Start the oil pump. Ensure that differential oil pressure is minimum 2.1 Kg./cm2 and maximum 4 Kg./cm2. This can be controlled by adjusting the by-pass valve on by pass line. Diff. oil pressure = (Oil Pump Disc. pressure) - (Comp. Discharge. pressure). Operating Philosophy for maintaining Oil/Gas DP of Ammonia Package: Initially open 50% bypass valve(Oil Pump discharge to Oil separator) of Oil Pump. After starting Compressor maintain differential pressure with compressor load by adjusting bypass valve. New Oil gas DP Interlock has been revised from 1.0Kg./cm 2 to 0.8 Kg./cm2. So minimum differential oil pressure to be maintained upto 1.5Kg./cm 2. Below this pump performance to be checked by M/M. Never allow differential oil pressure more than 4 Kg./cm2. It may overload the pump.

CCRU OPERATING MANUAL ART-E

NH3- 05 - 01

Check the compressor is fully unloaded and the 10% load limit switch is actuated. If all the safety requirement are satisfied then compressor ready to start lamp will glow indicating that the compressor can be started. Keep the system in manual mode by selecting the same through the Auto/Manual selection switch. Start the compressor. After the compressor attains full speed, check the following: Discharge pressure is less than 18 Kg./cm 2 g. Suction pressure is around 3 Kg./cm2 g. Oil differential pressure is more than 2.1 Kg./cm 2. Once the compressor is started, its capacity can be controlled either manually (with the help of loading/unloading push buttons) or automatically with the help of capacity controller. Load the compressor by pressing the "Raise" push button. Care should be taken to ensure that in each installment the compressor is not loaded to more than 10% of the earlier loading value. This is to ensure that the other system parameters are not disturbed due to abrupt loading of the machine. The percentage loading of the compressor can be seen on the indicator at the back of the compressors. Compressor loading can also be done manually by the valves facing opposite each other on the load side and can be unload by the valves facing opposite to each other on unload side. For reducing the compressor capacity the same can be accomplished by pressing the lower push button. The same care as mentioned in previous para should be taken while unloading the machine.

5.2

STOPPING PROCEDURE: Stop the compressor by pressing the compressor stop push button. Close the oil bleeder line valve. Keep the oil pump running for some time till the compressor is fully unloaded. Stop the oil pump. Isolate the CW of lube oil cooler and drain it. (This is done due to the past experience of tube leaks) An emergency stop push button has been placed behind the field panel to stop the compressor in case of emergency.

CCRU OPERATING MANUAL

NH3- 05 - 02

PART-E

6.0 SHUTDOWN PROCEDURE: For long period shutdown the following procedure to be adopted: The compressor suction shut off valve should be back-seated (full close) The gauge port plug should be removed and a compound pressure gauge to be installed in the suction shut off valve. Close the liquid valve on the receiver or condenser to retain all the liquid refrigerant in the shell. The solenoid valve (stop valve) should be manually open or the thermostat should be set to hold the valve open so that all the liquid can be withdrawn from the liquid line. The condensing water supplies to be on. The compressor will then draw refrigerant out of the liquid line, cooling coil and suction line and discharges it into the condenser or receiver The compressor should be operated until the gauge on the compressor suction shut-off valve shows a pressure of 0.14 Kg./cm 2 g. To reach the low pressure it may be necessary to hold the contacts of the low pressure switch in the closed position. Do not let the compressor be operated in the vacuum. When the compound gauges shows 0.14 Kg./cm 2g pressure, stop the compressor and close the compressor discharges valve immediately. Then the compressor suction valve should be back seated, the compound gauge removed and the plug replaced in the back seat part of the suction valve. The system should never be pumped out below 0.1 Kg./cm 2 g. A slight positive pressure should always be left in the system. This prevents air being drawn in through very minor leaks and on un-moving seal. After the system is pumped out and all the valves are closed, the part of the system containing the charge on the refrigerant should be thoroughly checked for refrigerant leak. It is necessary, as a large amount of refrigerant may be lost during the shut down period. The condenser water supply valve should be shut-off. If the system is subjected to freezing temperature, the condenser water tubes, the water regulating valve and piping should be drained thoroughly, If draining is not possible then water should be blown out with compressed air.

CCRU OPERATING MANUAL PART-E

NH3- 06 - 01

7.0 CONTROL SYSTEM FOR PLC LOGIC: Control scheme is designed for safe and continuous operation of the plant taking into consideration all safety interlocks and ease for operation and maintenance. One compressor will be running all the time while other will act as STAND BY. The duty of each compressor can be selected using selector switch (Main/Standby) provided on control panel. Each compressor is safe guarded against following safety interlocks.

Sr. no

ALARM DESCRIPTION

1 Comp. Suct. pressure ( KG/CM2 g ) 2 Comp. Disch. pr. (KG/CM2 g ) 3 Comp. Disch. temp. (oC) 4 K.O drum

COMP-1 COMP-2 TAG.NO TAG.NO. . 15 PSL 15 PSL 5001 5005

TRIP SET. COMP-1 COMP-2 POINT

SET. POINT

TAG.NO. TAG.NO. 0.0

15 PSLL 5002

15PSLL 5006

-0.2

15 PSH 5003

15 PSH 5007

17

15 PSHH 15 PSHH 5004 5008

18

15 TSH 5001

15 TSH 5003

85

15TSHH 5002

90

15LSH 5003

15LSHH 5005 15LSL 5001

5 Oil tank separator

15TSHH 5004

15LSL 5002

15LSH 5003

6 Receiver 7 Condenser water DP NORMAL OPERAING DP IS 1.0 KG/CM2 ( KG/CM2)

15DPSL 5001

8 Oil cooler water flow ( KG/CM2) 9 OIL - GAS DP. ( KG/CM2)

15DPSL 5002

15DPSL 5003

0.5

DPSL 5004

DPSL 5005

1.0

NORMAL OPERAING DP IS 1.0 KG/CM2 DPSL DPSL 1.5 5004 5005

0.5

THE VALUES FOR ALARM AND TRIP SETTING HAVE BEEN TAKEN FROM INSTRUMENTS TEST CERTIFICATES. ACTUAL SET POINTS TO BE CONFIRMED. PRESSURE SETTINGS TO BE CHECKED FOR ABS. OR GAUGE.

CCRU OPERATING MANUAL PART-E

NH3- 07 - 01

8.0

LUBE OIL PUMPS LOGIC: 1) Select duty of two oil pumps (main/standby) using selector switch on control panel. Say oil pump 1 (LOP-1) is selected as MAIN. 2) Press 'START' push button. LOP-1 start command will be on and the oil pump STARTS. This closes starter field contact and LOP-1Run lamp glows. 3) If LOP-1 command is ON and even then after pre-set time (0-30 sec. adjustable) the LOP-1 starter field contact do not closes (indicating there is some fault related to starter) then the LOP-1 fail indicating lamp will glow. If LOP-1 fails i.e. there is some fault with LOP-1 starter, a START command for oil pump LOP-2 (standby in this case) will be given automatically by the logics provided. Logic similar to LOP-1 is provided for LOP-2 also. 4) If LOP-1 start command is given and there is no problem with its starter, then LOP-1 starts. If oil/Gas differential pressure do not builds up within PRE-SET TIME (0 to 3 minutes adjustable) then oil/gas DIFF. PRESSURE TRIP indicating lamp will glow. Simultaneously START command will be given automatically by the logic provided for oil pump-2 (LOP2) and LOP2 starts if there is no problem with starter as explained earlier. Once LOP-2 starts after PRE-SET TIME (0-3 minutes adjustable) first oil pump (which was not able to develop oil pressure) LOP-1 STOP command will be given by the logic. 5) Note that for short duration (depending upon present time) both oil pumps are running. This is because for a screw compressor at least one oil pump should run continuously. Therefore both oil pumps are kept running and after confirming that the 2nd oil pump (standby) has started and running OK, then only the first oil pump will stop running. 6) As explained earlier once the stand by oil pump STARTS and even then the oil/gas differential pressure do not builds up within PRE-SET TIME (03 minutes adjustable) for the stand by oil pump also stop command will be given. The stand by oil pumps STOPS running. At this time since both oil pumps are not running "Both OIL PUMPS FAIL' indicating lamp will glow. 7) The indicating lamp "BOTH OIL PUMPS FAIL" will glow even when starter held contact for both oil pumps do not closes within PRE-SET TIME (0-20 Sec) as explained. CCRU OPERATING MANUAL PART-E

NH3- 08 - 01

8) If any of the oil pump (main or stand by) is running, the indicating lamp "OIL PUMP FOR COMPRESSOR RUNNING" will glow.

9.0 COMPRESSOR START/STOP LOGICS: 1) If all the safety interlocks are OK, trip reset push button is pressed, any of the oil pump for compressor is running and the 10% limit switch is closed (ensuring compressor at minimum load during starting) the indication lamp "COMPRESSOR READY TO START" will glow. 2) If compressor ready to start lamp glows, the operator has to push COMPRESSOR START push button. Then start command for selected (main) compressor becomes on. 3) If compressor start command is on and field contact of compressor starter do not closes within PRE-SET TIME (0-30 sec. adjustable) then indication lamp "COMPRESSOR STARTER FAIL" will glow. 4) If compressor start command is ON and there is no problem with compressor starter, compressor motor becomes on and the indication lamp "COMPRESSOR ON" glows. 5) If compressor motor is not running, the indication lamp "COMPRESSOR OFF" glows. 6) As soon as compressor becomes ON indicating lamp "COMPRESSOR READY TO START " becomes off. Similarly the inter lock at 10% load limit switch (as explained earlier) is during starting only (to ensure compressor starting on unload) and as soon as compressor becomes ON, the 10% limit interlock is not required as the compressor can be loaded (either manually or automatically). Reference: Documents supplied by M/s KIRLOSKAR i)

Operating & Maintenance manual for Ammonia Refrigeration System.

ii)

Auto folder No. 3407/97

iii)

Calculation Sheets and P&ID.

CCRU OPERATING MANUAL PART-E

NH3- 09 - 01

AIR PREHEATER SYSTEM FOR 09F-1/14F-1/14F-2/15F-4 1.0

GENERAL DESCRIPTION Combustion air required for Naptha splitter reboiler (09 F-01) and Stabilizer reboiler (015-F-04) is fed by the two forced draft fans 15K-02A/B, and the air is pre heated in glass tube air preheater and then in the Cast air pre heater combined flue gas of all four heaters (09F-01, 14F-01, 14F-02, 15F-04) after the convection section enters Cast air preheater then glass air pre heater, enters ID Fan 15K-03 finally leave through a stack, which is common for all heaters. However 14F-01, 14F-02 are provided with natural draft burners.

1.1

CAST TUBE AIR PREHEATER The cast tube air preheaters 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 old internal and external surfaces. Tubes in cold end have integral tins only on the outside surfaces. The entire tube assembly is built inside a steel frame made by beams and full 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 air preheater 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 two grooves have been provided on the flanges on either side.

Asbestos ropes are

placed in the grooves 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.

CCRU OPERATING MANUAL PART-F

APH- 01 - 01

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 bottom of the cold end. Air enters the air preheater at the side of the cold end flows first through the cold end tubes. On leaving the cold end the air is turned through 180 degrees 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 three passes.

1.2

GLASS TUBE AIR PREHEATER Glass tine APH is a rectangular box containing Glass Tubes held by tube sheets on both ends. The two sides of box are blanked with metal cover while the remaining two sides are used as inlet/outlet for flue gas. The combustion air flows through the Glass Tubes whereas the flue gas flows on the shell side across the tube banks. The tubes in the Air preheater are made from borosilicate glass while the other components of the air preheater coming on contact with the flue gases are suitably lined. Both the Cast Tubes and Glass Tube Air preheaters are provided with separate static wash water systems for cleaning above the top row of tubes.

1.3

COMMISSIONING INSTRUCTIONS Commissioning procedure for an air preheater has to be formulated considering the furnace/process heater to which it is going to be hooked into and the overall system conditions. The instructions mentioned here for commissioning assistance are meant for the general safety of the air preheater equipment alone.

CCRU OPERATING MANUAL

APH- 01 - 02

PART-F

The 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 and diminish the fouling on glass tubes. The glass

tube Airpreheater should be taken in line only after flue gas

temperature at glass APH inlet is below 240 0C. Air preheater performance has also been checked under turndown conditions. It is to be noted that the air bypass is necessary during winter. The user shall review the actual quantity to be bypassed considering the other equipment in the system like dampers, furnaces etc. However, it is recommended that under no circumstances the flue gas exit temperatures are 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 air preheater 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 100C above the dew point of the flue gases.

1.4

MAINTENANCE DURING OPERATION Due to the tubular construction of the cast fin air preheater there are neither extensive flat surfaces, not 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 air preheater 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.

CCRU OPERATING MANUAL PART-F

APH- 01 - 03

However, for the safe operation, it is recommended to monitor the flue gas pressure drop and when this approaches the limit of ID Fan capacity, the air preheater should be taken out of line and washed. This could probably be because of soot deposition due to abnormally poor combustion in the furnace.

1.5

WASHING PROCEDURE Washing of air preheater has to be done by taking it off line.

Vendor’s

instructions for carrying out the washing of the APH should be followed thoroughly. NOTE: Commissioning, Maintenance and Washing Instructions above are general only and vendor’s instructions in the above regard must be followed thoroughly.

In case of any contradiction

vendor’s instructions shall over rule.

CCRU OPERATING MANUAL PART-F

APH- 01 - 04

2.0 AIR PREHEATER OPERATING INSTRUCTIONS 2.1

DESIGN DATA Note : These instructions are established on the assumption that air and flue gas are uniformly distributed at the inlet flanges and through the air preheater.

2.2

PROCESS PARAMETERS Table 1 & 2 specifies the performance of the cast tube and glass tube air preheaters respectively at design conditions: TABLE – 1 (FOR CAPH) 1.

Air temperature in 0C

119

2.

Air temperature out 0C

287

3.

Air flow Kg/hr

50833

4.

Flue gas temp. in 0C

310

5.

Flue gas temp out 0C

210

6.

Flue gas flow rate, Kg/hr

75306

7.

Heat exch., MMK cal/hr

2.08

8.

Allowable press. Drop

80/55

(Flue gas/Air) mmWC TABLE – 2 (FOR GAPH) 1.

Air temperature in 0C

35

2.

Air temperature out 0C

119

3.

Air flow Kg/hr

50833

4.

Flue gas temp. in 0C

210

5.

Flue gas temp out 0C

160

6.

Flue gas flow rate, Kg/hr

75306

7.

Heat exch., MMK cal/hr

1.04

8.

Allowable press. Drop

60/60

(Flue gas/Air) mmWC

CCRU OPERATING MANUAL PART-F

APH- 02 - 01

3.0 INTERLOCK AND ALARM SET POINT GENERAL This chapter has been prepared with the intention of providing the fired 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 furnaces in the event of failure of any operating equipment or any abnormality in the process condition. 3.1.1 FD FAN FAILURE Failure of FD fans can be sensed by a)

Motor Contact XL-3101/XL-3102

b)

Extra Low flow switch FSLL 3103

c)

Low flow switch FSL 3104/3105

During normal operation both the FD fans will run at 50% process load. In the event of failure of one of the fans as sensed by XL-3101/XL-3102 or FSL-3104/FSL-3105 the working fan will go to 100% process load and the tripped Fan will be isolated automatically through the pneumatic actuator of the

discharge

damper,

HV-3107/HV-3108

(As

the

case

may

Simultaneously tripped fan will get decoupled through hydraulic coupling.

CCRU OPERATING MANUAL PART-F

APH- 03 - 01

be)

In the event of failure of both the FD Fans as sensed by FSKK-3103 or XL 3111 and XL-3114 together, or FSL-3104 and FSL-3104 and FSL-3105 together, fuel to both the furnaces 09-F-01 & 15-F-04 will be cut off. 3.1.2 ID Fan Failure Failure of ID fan can be sensed by a)

Motor Contact XL-3115.

b)

High pressure switch PSHH-3107 at ID fan suction.

In the event of ID fan failure, dampers HV-3101, HV03102, HV3103, HV3104 and HV-3105 shall be automatically opened, IF HV-3101 or HV-3102 or HV3103 or HV-3104 fails to open within 0.20 sec., fuel supply to the respective furnaces shall be cut off. If the stack damper HV-3105 fails to open within 0.20 sec., fuel to all the furnaces will be cut off. 3.1.3 High Arch Pressure In the event of high Arch pressure as sensed by two of the three PSH3103A/B/C for NSU heater and PSH-3101/3102/3104 for HDT Charge heater, HDT-Stripper Reboiler Heater and Stabilizer Reboiler Heater respectively, damper HV-3103/3101/3102/3104 (as the case may be) and HV-3105 shall open automatically within 10 sec (full close to full open), If PAH-3103/3101/3102/3104 persists for 0.20 sec, fuel to the respective furnaces will cut off through a time delay of 0.30 sec. 3.1.4 High temperature of ID Fan inlet In the event of extra high temperature of ID fan inlet as sensed by TSHH3134 or extra high temperature at glass APH inlet as sensed by TSHH-3132, damper HV-3101, HV-3102, HV-3103, HV3104, and HV3105 will open automatically and ID fan will trip after a time delay of 0.20 secs. If the dampers fail to open within 0.20 sec., fuel supply to all the furnaces will be cut off.

CCRU OPERATING MANUAL PART-F

APH- 03 - 02

3.1.5 Low combustion Air Pressure/Flow In the event of combustion air extra low pressure to the furnace as sensed by PSLL-3110/3111 or combustion air extra low flow as sensed by FSLL3101/3102, fuel flow to the NSU Heater (09-F-01) /Stabilizer Reboiler Heater (15-F-04) (as applicable) will cut off and the corresponding HV-3103/3104 shall open along with HV-3105.

3.1.6 Fuel cut off to Furnace In the event of fuel cut off to any of the furnaces the following sequential action will take place: a)

Dampers HV-3101, HV-3102, HV-3103, HV-3104 and HV-3105 shall be opened.

b)

ID Fan shall trip within 0.30 secs.

c)

Respective dampers FV-3101/3102 as applicable will close and respective AY-3107/3108 as applicable will be cut off.

3.1.7 Stack Damper HV-3105 shall not be closed unless ID Fan is running. 3.1.8 During turndown operation only one fan will operate and in the event of failure of working fan as sensed by XL-3111/3114 or FSL3104/3105, standby fan shall start automatically.

Fan discharge

damper HV-3107/3108 of the tripped fan will close and that of standby fan will open simultaneously. During this fan switch over operation, fuel supply to the furnace shall attain minimum flow for a time period of 0.30 seconds. 3.1.9 Each interlock shall have individual by pass option (except interlocks specified in 3.1.3 & 3.1.4) available at main control panel with lamp indication.

CCRU OPERATING MANUAL PART-F

APH- 03 - 03

3.1.10 Emergency Emergency stop push bottom has provided on the main control panel on pressing which all drives will trip, dampers HV-3101, HV-3102, HV3103, HV3104 and HV-3105 will open even if interlocks are in bypass mode and simultaneously fuel supply to all the furnaces will be cut off. An additional local emergency push button shall be provided 15 m away from the heater in “Break Glass” enclosure.

3.2

Set Point

TAG NO. TAH 3101 TAH 3108 TAH 3115 TAH 3122 TAH 3129 TAH 3132

SERVICE/LOCATION Fuel gas at Convection Outlet of 014-F-1 Fuel gas at Convection Outlet of 014-F-2 Fuel gas at Convection Outlet of 09-F-01 Fuel gas at Convection Outlet of 015-F-04 Fuel gas at Cast APH ( 015-FP-01) inlet Fuel gas at duct upstream of Glass APH

SET POINT 345 0C 335 0C 230 0C 325 0C 280 0C 230 0C

TAHH 3132

(015-FP-02) inlet Fuel gas at duct upstream of Glass APH

240 0C

TAG NO. TAH 3133

(015-FP-02) inlet SERVICE/LOCATION Fuel gas at duct downstream of Glass APH

TAL3133 TAHH 3134

( 015-FP-02) inlet Fuel gas at ID Fan suction

SET POINT 185 0C 155 0C 195 0C

TALL 3134 150 0C Following are the indicative values of set points of alarms and trips for different instruments. These may require tuning during actual plant operation and assessing the performance.

CCRU OPERATING MANUAL

APH- 03 - 04

PART-F

TAH 3136 TAH 3137 TAH 3141 PAH 3101 PAH 3102 PAH 3103

Hot Air to Burners of 015-F-04 Hot Air to Burners of 09-F-01 Fuel Gas at Stack Fuel Gas at Furnace Arch 014-F-1 Fuel Gas at Furnace Arch 014-F-2 Fuel Gas at Furnace Arch 09-F-1

235 0C 235 0C 180 0C +2mmWC +2mmWC +2mmWC

PAHH 3103 PAH 3104 PAHH 3104 PAHH 3107

Fuel Gas at Furnace Arch 015-F-04 Inlet to ID fan

+5mm WC +2mmWC +5mm WC (-) 40mmWC

Combined hot air to burners of 09-F-01

[Adj:0 to(-)100mmWC] + 20mmWC

PALL 3111

Combined hot air to burners of 015-F-

[Adj:0 to(+)50mmWC*] + 15mmWC

PAH 3112 PAH 3113 PAH 3114 PAH 3115 FALL 3101

04 Flue gas at Furnace Arch 09-F-01 Flue gas at Furnace Arch 015-F-04 Flue gas at Furnace Arch 014-F-01 Flue gas at Furnace Arch 14-F-02 Air to 09-F-01

[Adj:0 to(+)50mmWC*] + 1mmWC + 1mmWC + 2mmWC + 2mmWC 10800

PALL 3110

FALL 3102 FALL 3103

Air to 015-F-04 Burners

[Adj: 8000 to 30000] 4500

Total air flow to heaters 09-F-01 & 015-

[Adj: 4000 to 14000] 15800

F-04

[Adj: 10000 to 45000]

CCRU OPERATING MANUAL

APH- 03 - 05

PART-F

TAG NO. FAL 3104

SERVICE/LOCATION FD an (15-K-02A) suction duct

SET POINT 1200 [Adj: 10000 to 30000]

FAL 3105

FD an (15-K-02B) suction duct

12000 [Adj: 10000 to 30000]

AAH 3107

Oxygen analyser at Arch of 09-F-

6%

#

01

2%

# AAH 3108

Oxygen analyser at Arch of 15-F-

6%

#

04

2%

AAL 3107

AAL 3108 # * Indicates set points are tentatively only and to be adjusted based upon burner performance. # Indicates marked tag nos. are not shown in the APH systemP&ID

CCRU OPERATING MANUAL

APH- 03 – 06

PART-F

Benefit by taking APH in line: In S/D Nov 2013 CAST APH both segment replaced with new one. In October 2014 ID started and APH taken in line. Following is parameter at CAPH bypass fully closed and GAPH bypass fully closed. PARAMETER

FOR CAPH

FOR GAPH

1.

Flue gas temp. in 0C

250

175

2.

Flue gas temp out 0C

175

150

3.

Air temperature in 0C

116

35

4.

Air temperature out 0C

235

116

ID Fan Parameter: 1.

ID Suction temperature :

145 0C

2.

ID Suction Draft :

-170mmWC

3.

RPM@ 14% load :

750

4.

Ampere :

120A

5.

I/B Bearing temperature:

42

6.

O/B Bearing temperature:

48

7.

Oil temperature :

65

8.

Fluid coupling oil flow:

85 LPM

Parameter

Unit

Air inlet temperature Air Outlet Temperature Flue Gas inlet temperature Flue gas ex cast module Flue Gas ex Glass module ID suction temperature ID suction pressure Heat Duty

deg C deg C deg C deg C deg C deg C mmWC Mkcal/hr

Design 35 287 310 200 160 160 -200 3.12

Actual with Old CAPH 35 95-105 210-230 180 105-110 105-110 -300 0.8

Actual with New CAPH 35 235 250 175 150 145 -172 2.10

Calculation Air flow

:

42 Ton/Hr = 42000 Kg/hr

Cp of Air

:

1.06 Kj/KgK = 1.06/4.2 = 0.25Kcal/kgK

Delta T of Air

:

235 – 35 = 200

Heat Duty

:

42000 x 0.25 x 200 = 2100000Kcal/hr = 2.1Mkcal/hr

SRFT

:

1680 SRFT/Yr

1 SRFT

:

46916Rs( last 3 year average)

Total saving

:

1680 x 0.46916 = 788 Lac/Yr = 7.8 Crore

/Yr

(*Calculation are based on utilities price on march 2015.

CCRU OPERATING MANUAL

APH- 03 – 06*

PART-F

OFF-SITE HYDROGEN FACILITY 1.0 INTRODUCTION In Catalytic Reforming Unit, reforming is done in the presence of Hydrogen gas. For the initial start up of the Reforming section, Hydrogen required is procured from outside. Once the reforming section is stabilized, the Hydrogen gas generated in the reforming section is used in the process of CRU and balance is sent to HGU-I where it is compressed using compressor 06K-05 A/B and purified in PSA-140. The pure hydrogen then joins the fresh hydrogen header (20 kg/cm2 g). After recent revamp of NHTU Hydrogen requirement is met from the supply of make up hydrogen from fresh

hydrogen header. The off gas from the PSA-140 is compressed using 06-K04 A/B and sent to fuel gas header. Facility exists for using this off gas in reformer from upstream of compressor. In HGUs the steam reforming of naphtha or natural gas done and reformed gas is purified in PSAs of respective units. The pure hydrogen gas from PSAs is having H2 purity of 99.99 % vol. The pure hydrogen is sent to fresh hydrogen network (20 kg/cm2 g). The fresh hydrogen is utilised in HGU/CCRU/NHTU of CCRU/ DHDT/ OHCU/ MSQ Units/TGTU. An offsite Hydrogen facility to store hydrogen during normal operation and supply hydrogen during start up has been provided. Facility to unload hydrogen cylinder has also been provided to supply hydrogen for the very first start-up of the unit. The offsite hydrogen facility section comprises of the followings: 1. Three Hydrogen gas storage bullets each of capacity 220 m 3 (which were installed along with CRU project) and fourth bullet identical to other three have been installed in DHDT/MSQ Projects. 2. A three stage reciprocating Hydrogen Compressor (42-K-01) to store Hydrogen at a pressure of 40.0 Kg/cm 2g. 3. Unloading of Hydrogen cylinders. 4. A 2" dia. line connects Hydrogen offsite facility with CRU to supply and receive hydrogen gas from CRU.

CCRU OPERATING MANUAL PART-G

H2- 01 - 01

5. A 3” line for supply and to receive pure hydrogen from HGU-I. 6. A 3” line for supply of hydrogen to HGU-II and NHTU (CRU) and to receive pure hydrogen from N-HGU. 7. Inter bullet transfer facility using compressor 42-K-01.

CCRU OPERATING MANUAL PART-G

H2- 01 - 02

2.0 HYDROGEN STORAGE BULLETS: Four bullets (42 VV-001A/B/C/D) each of capacity 220 m3 have been provided to store hydrogen at 40 kg/cm 2g. Each of the bullets is provided with double safety valve with a set pressure of 45 kg/cm 2g, at present the PSVs discharge is given to atmosphere, which will be connected to flare once the new flare network, and new flare is put in operation. A bypass line with double B/V has been provided across one of the Safety valves of each bullet. A temperature gauge, pressure gauge and a sample point have been provided on each bullet. Each of the bullets has been provided with a

pressure indication in field and Control room, which can give process high and low alarms. The 2" inlet/outlet line of the bullet is provided with a Remote Operated Valve's (ROV's) for emergency isolation of the bullets locally (Compressor house). The ROV can be closed from CRU control room also. Minimum residual pressure of 2.0 kg/cm 2g should be maintained in the bullets.

CCRU OPERATING MANUAL

H2- 02 - 01

PART-G

3.0 HYDROGEN COMPRESSOR (42-K-01) It is a three stage non lubricated reciprocating compressor of type 2HSE-3 NL-2 supplied by M/s INGERSOLL RAND (INDIA) LTD. The compressor is driven by 415 volts 100 kW (154 amps) motor supplied by M/s Crompton Greaves. The compressor is designed to handle normal flow of 775 Nm 3/hr (rated for 850 Nm3/hr) with suction and discharge pressures of 4.0 and 41.0 kg/cm 2g respectively. Stage wise design parameters of the compressor are as follows: STAGE I II III

CYLINDER DIAMETER, inch STROKE, inch INTAKE PRESSURE, Kg/cm2g DISCHARGE PRESSURE, Kg/cm2g INTAKE TEMPERATURE, oC DISCHARGE TEMPERATURE, oC PISTON DISPLACEMENT, m3/hr CAPACITY AT INLET, m3/hr SPEED, rpm

3.1

8 9 4 8.8 47 119 293 215.5 330

6 9 8.6 19.4 45 122 151 215.5

4.25 9 19 41 45 124 76 215.5

LUBRICATION SYSTEM The compressor is equipped with a self-contained, force feed lubrication system for the bearing and running surfaces of the compressor frame and running gear. Parts lubricated by the frame lubrication system include the main crankshaft journal bearings, crankpin bearings, crosshead pin bushings, and cross heads. A frame mounted oil pump is a gear type pump with two rotating gears is driven directly off the end of the compressor crankshaft. A motor driven auxiliary pump has been provided for the priming of the main pump and the pre-lubrication of the compressor bearing and running surfaces prior to starting the unit. The oil is drawn from the frame sump through a screen type strainer and into the crankshaft driven gear type oil pump. The pump forces the oil through a cooler and then through a filter (with replaceable cartridge type element).

CCRU OPERATING MANUAL

H2- 03 - 01

PART-G

The cooled and filtered oil then flows under pressure to the main crankshaft journal bearing, located at the oil pump and of the frame and from there through drilled passages in the crankshaft to the crankpin bearings and drive end main bearing. A rifle-drilled hole through each connecting rod conducts the oil from the crankpin to the crosshead pin bushing located in the small (eye) end of the rod. The oil then enters the hollow crosshead pin from where it is distributed to the pin surfaces and the crosshead shoes. After passing through and lubricating the various parts, the oil drains back into the frame sump. Oil from the filter goes to drive end main bearing and to the oil pressure gauge and also to the low oil pressure shut down switch. The spring loaded, ball check type relief valve protects the lubrication system from excessive oil

pressure resulting from (i) low ambient starting temperatures, or (ii) clogging of the oil filter.

Lube Oil Characteristics VISCOSITY at 100 oF, cst (max.) VISCOSITY at 210 oF, cst (min.) FLASH POINT (COC), oC (min.) CCR, %wt (max.) STRONG ACID NUMBER (max.)

168.4 10.2 193 0.45 0

The capacity of the frame oil sump is 26 litres. The operating level of the oil should be maintained at the line on the gauge glass. The oil can be added to the frame sump while the unit is running by removing the breather cap and pouring the oil into the breather tube. The lube oil cooler is designed for an oil inlet / outlet temperature of 71 / 65 o C. Cooling water 11.3 lpm to be supplied at 29 oC.

3.2

INITIAL START-UP PROCEDURE Remove inspection cover from the frame and distance piece to clean and check interiors. Wash out the frame with solvent if necessary and wipe out. Inside of the frame is white painted.

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Fill up the oil sump (capacity 26 litres). Pour oil over all the bearings and running surfaces that can be reached through the inspection opening. Just prior to placing the compressor in operation, Remove closures from cylinder intake and discharge passages and remove the bags containing VPI crystal, connect process piping. Pull the distance pieces inspection covers and remove the VPI crystal bags and the VPI paper wrapping from the piston rod. Install packing rings if they were removed. Any crystal remaining inside the cylinder bore will vaporise when machine is started. Check that temporary filter has been installed in the process gas in-take to the compressor (filter screen of 0.0045" dia wire, 100 mesh, and 140 micron opening.

Check that all blinds have been removed, PSVs installed. Each cylinder can be completely unloaded by removing one or more inlet valves. Re-install covers. Manually turn the compressor through several revolutions in the direction shown by arrow. Turn on full supply of cooling water through oil cooler, process gas and compressor cylinders. (Prior to starting, disconnect water lines at cylinder and cooler outlet and thoroughly flush the system.) Start and then immediately stop the driver to determine direction of motor and compressor. Run the compressor for 5 minutes, check sump oil level, frame oil pressure (to be 1.8-3.5 kg/cm2g), cooling water flow and temperatures, excessive heating, unusual sound or any other abnormal condition. Shutdown, remove frame and crosshead inspection covers. Check the main and crank pin bearings, crosshead pin bearings, and crosshead running surface to see. Re-install the inspection covers. If everything is found to normal, Re-start the compressor and operate for one hour at no load. Stop the machine and once again check running parts for excessive heat. Monitor cylinder temperatures to be sure that the parts are not overheating.

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Re-install the inlet valves. Crack open main valve in the suction line and allow the pressure to build up to 3.5 kg/cm2g. Check and attend for leaks. Purge the unit and the compressor is ready to start and load. Prime the frame oil pump just prior to starting the machine. Ensure that breather is not covered / obstructed.

3.3

START UP PROCEDURE Check the oil level in the frame sump and refill as required to bring the operating level to the line on the gauge glass.

Start the auxiliary oil pump for the lubrication at least 10-15 minutes before the start up of the compressor. Open the suction and discharge B/V of the compressor. Manually turn the compressor through at least one complete revolution to be sure all moving parts are clear. Turn on the cooling water supply to the inter coolers, after cooler and also to cylinders. Drain the liquid if any from the first stage suction knock out drum Start the driver and run the compressor with no load for a few minutes to warm up the unit. Listen for unusual noises during the warm up period. Check the oil pressure in the frame lubrication system; the normal operating oil pressure should be 1.8 to 3.5 kg/cm 2g. When the unit is warmed up and determined to be running satisfactorily, the compressor can be loaded.

CAUTION If the compressor was started without turning on the cooling water and the cylinders have heated up, shut down immediately and allow the cylinder

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PART-G

parts to cool. Do not introduce cooling water to hot parts or they may crack. After the unit has cooled, the water can be turned on and the machine restarted.

3.4

STOPPING PROCEDURE Unload the unit. Stop the driver. Shut off the cooling water supply.

3.5

EMERGENCY STOPPAGE If an emergency occurs requiring immediate shutdown of the compressor, the unit can be shut down under load; however open the final stage bypass

valve to reduce the back pressure load on the compressor, permitting the machine to coast to a stop versus stopping in several revolution under load. In the event of an automatic shutdown, the system pressure to be relieved immediately. Shut off the cooling water supply, if the compressor will not be operating again within ten minutes.

3.6 S.No

1 2 3 4 5

INTERLOCKS DESCRIPTION

ALERT TAG Lube oil supply pressure Kg/cm2g PAL-1001 1st suction pressure Kg/cm2g PAL-1003 1st stage discharge temp. oC TAH-1001 2nd stage discharge temp. oC TAH-1003 o 3rd stage discharge temp. C TAH-1005 

UNITS

TRIP VALUE TAG 0.55 PALL-1002 3.8 PALL-1004 125 TAHH-1002 128 TAHH-1004 130 TAHH-1006

VALUE 0.35 3.6 130 135 136

The above data has been taken from Instrument schedule RIN-40935EW

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PART-G

4.0

CYLINDERS UNLOADING FACILITY For initial commissioning, Hydrogen required has to be brought from outside and stored in bullets. Gaseous Hydrogen cylinders in different capacities are available at a pressure of 120 Kg/cm 2g (approx.). To off-load the Hydrogen, cylinders unloading rack with a provision to connect forty cylinders (20 numbers each in two racks) has been provided. Cylinder unloading racks is connected to compressor suction and the Bullets through self-regulating PCV-2001 (Inlet pressure 40-150 Kg/cm2g, d/s set point 20 Kg/cm2g) and PCV-2002 (Inlet pressure 4-40 Kg/cm2g, d/s set point 4 Kg/cm2g). Cylinder to be unloaded into Bullets is first lined up through PCV2001 till the cylinder pressure comes down to 40 Kg/cm2g, then cylinders are lined up

with PCV2002 and taking 42-K-1 in line. The compressor has to be stopped when cylinder pressure reaches 4 Kg/cm2g. Close all the valves and depressurize the cylinder rack to cold stack and replenish the empty hydrogen cylinders. During unloading of cylinders, Hydrogen can be supplied to CRU (i.e. cylinder outlet is connected to Bullets as well as CRU). The ROV on the Bullet under receipt is to be kept in open position, while ROV's of other two Bullets to be kept in closed position.

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5.0

HYDROGEN TRANSFER TO/FROM BULLETS Hydrogen gas is to be transferred from Bullets to CRU for initial start up and also in the subsequent start-ups. For supplying Hydrogen to CRU, first line up 42PC2001 D/S side with the system. Open the bullet ROV & B/V. Put 42PV2001 on auto (set pressure 4.0 Kg/cm 2g). Slowly line up 42PC2001 watching D/S pressure in co-ordination with control room. As soon as CRU header pressure will reach 4.0 Kg/cm 2g 42PC2001 will get close. Hydrogen transfer from bullets to CRU will take place by the bullet pressure, which is to be kept more than 4.0 Kg/cm2g. For supplying hydrogen to HGU-I, HGU-II & NHTU from bullets line up the bullet(s) with corresponding headers.

For storing Hydrogen in Bullets Hydrogen generated in HGU will be compressed in 42-K-1 and transferred to the bullets. During this operation ensure the bullet to receive compressed Hydrogen from compressor is lined up (ROV & B/V open). Initially pressurise the bullet upto 20 Kg/cm 2g without starting compressor. Then start the compressor as per procedure. Continue the topping up of the Bullet till the Bullet pressure reaches 40 Kg/cm2g and then switch over the topping up to other Bullet. While switching over the topping up operation first unload the compressor and close the ROV of the bullet under receipt, then open the ROV of the fresh Bullet and reload the compressor. When topping up of the Bullet is over, first unload the compressor, close the ROV, and then stop the compressor. Keep the bullet lined up to HGU-I, HGU-II and CCRU/NHTU through proper line up the system (keeping B/V at CRU closed) for normal/emergency operation in the Unit. CAUTION: Topping up / Transferring of Hydrogen to be done in co-ordination with the CRU / HGU-I / HGU-II Control room operator.

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PART-G

6.0

HYDROGEN PROPERTIES & SAFETY DATA SHEET

6.1

PROPERTIES:

Reference Temperature Standard pressure (1atm) psia Density (at 68 deg F and 1 atm) Flammability Limits Hydrogen-air mixture Hydrogen-oxygen mixture Explosive limits Hydrogen-air mixture Hydrogen-oxygen mixture

68 deg F 14.69 KPa 0.00523 lb/ft3 Lower = 4% volume Lower = 4% volume

Higher = 75% volume Higher = 95% volume

Lower = 18.3% volume Lower = 15% volume

Upper = 59% volume Upper = 90% volume

The major hazards associated with hydrogen are fires and explosions, and in the event of contact with the liquid or cold boil off vapor, frostbite and burns. Deflagration and detonation: Hydrogen gas can burn in two modes, as a deflagration or as a detonation. In a deflagration, the ordinary mode of burning, the flame travels through the mixture at Subsonic speeds. This happens, for instance, when an unconfined cloud of hydrogen-air mixture is ignited by a small ignition source. Under these circumstances, the flame will travel at a rate anywhere from ten to several hundred feet per second. The rapid expansion of hot gases produces a pressure wave. Witnesses hear a noise, often a very loud noise, and may say that an explosion occurred. The pressure wave from rapid unconfined burning may be strong enough to damage nearby structures and cause injuries to personnel.

In a detonation, the flame and the shock wave travel through the mixture at supersonic speeds. The pressure ratio across a detonation wave is considerably greater than that in a deflagration. The hazards to personnel, structures, and nearby facilities are greater in a detonation. A detonation will often build up from an ordinary deflagration that has been ignited in a confined or partly confined mixture. CCRU OPERATING MANUAL

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This can occur even when ignition is caused by a minimal energy source. It takes a powerful ignition source to produce detonation in an unconfined hydrogen-air mixture. However, a confined mixture of hydrogen with air or oxygen can be detonated by a relatively small ignition source. Leakage, diffusion, and buoyancy: These hazards result from the difficulty in containing hydrogen. Hydrogen diffuses extensively, and when a liquid spill or large gas release occurs, a combustible mixture can form over a considerable distance from the spill location

Leakage: Hydrogen, in both the liquid and gaseous states, is particularly subject to leakage because of its low viscosity and low molecular weight (leakage is inversely proportional to viscosity). Because of its low viscosity alone, the leakage rate of liquid hydrogen is roughly 100 times that of JP-4 fuel, 50 times that of water, and 10 times that of liquid nitrogen. Diffusion and buoyancy: The diffusion rate of hydrogen in air is approximately 3.8 times faster than air in air. In a 500-gallon ground-spill demonstration experiment, liquid hydrogen diffused to a non-explosive mixture after about 1 minute. Air turbulence increases the rate of hydrogen diffusion The buoyancy of hydrogen tends to limit the spread of combustible mixtures resulting from a hydrogen release. Although hydrogen vapor is heavier than air at the temperatures existing after evaporation from a liquid spill, at temperatures above – 418o F the hydrogen vapor becomes lighter than air, thereby making the cloud buoyant. (See NASA STD 8719.16, Safety Standard for Hydrogen and Hydrogen Systems, Chapter 2, for more specific related information)

6.2

Hazardous properties of Hydrogen Gas:

Un-detectability: Hydrogen gas is colorless and odorless and not detectable by human senses. Flammability: Mixtures of hydrogen with air, oxygen, or other oxidizers are highly flammable over a wide range of compositions. The flammability limits, in volume percent of hydrogen, define the range over which fuel vapors ignite when exposed to an ignition source of sufficient energy. CCRU OPERATING MANUAL

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The flammable mixture may be diluted with either of its constituents until it is no longer flammable. Two limits of flammability are defined: the lower limit, the minimum amount of combustible gas that makes a mixture flammable; and the upper limit, the maximum amount of combustible gas in a flammable mixture. The flammability limits based on the volume percent of hydrogen in air (at 1.03 Kg/cm2) are 4.0 and 75.0. The flammability limits based on the volume percent of hydrogen in oxygen (at 1.03 Kg/cm 2) are 4.0 and 94.0. Reducing the pressure below 1 atmosphere tends to narrow the flammability range by raising the lower limit and

lowering the upper limit. No mixture of hydrogen and air has been found to be flammable below 0.077 Kg/cm2. Auto ignition: Temperatures of about 565.5 oC are usually required for mixtures of hydrogen with air or oxygen to auto ignite at 1.03 Kg/cm 2; however, at pressures from 0.21 to 0.56 Kg/cm2, autoignitions have occurred near hot hydrogen and flash fire. The primary hazard of using hot hydrogen (565° to 3315° C) is that a large leak at temperatures above the autoignition temperature will almost always result in a flash fire. Other safety criteria are the same as for ambient temperature gaseous hydrogen. System construction materialsmust be suitable for use at the elevated temperatures Ignition at low energy input: Hydrogen-air mixtures can ignite with very low energyinput, 1/10th that required igniting a gasoline-air mixture. For reference, an invisible spark or a static spark from a person can cause ignition. Lack of flame color: Hydrogen-oxygen and hydrogen-pure air flames are colorless. (Any visible flame is caused by impurities.) Colorless hydrogen Hydrogen diffuses rapidly if not confined. At room temperature, hydrogen is the lightest of all gases, only 1/14th as heavy as air; consequently, it rises. Therefore, inverted pockets will trap hydrogen gas. Avoid covers, suspended ceilings, or places where pockets may form and trap hydrogen gas. Fire Classifications: CLASS A

: Ordinary combustible solids

CLASS B

: Flammable liquids

CLASS C

: Flammable gases under pressure

CLASS D

: Water reactive metals

Hydrogen gas falls under CLASS C fire. CCRU OPERATING MANUAL PART-G

H2- 06 - 03

MISCELLANEOUS 1.0 UTILITY SYSTEM GENERAL Utility system consists of cooling water, DM-Water, Boiler feed water, HP system, Fuel gas, nitrogen, LP system, service water, Plant air, Drinking water, Flare system, HC’s/CBD system. Brief descriptions of the aforesaid facilities for each system are given below: 1.1

Instrument air: Instrument air enters the unit through a 3” line with a spectacle blind at the down stream of battery limit block valve. Various tapping are taken from the main header inside the unit to supply dry, clean air to the instruments of different sections.

1.2

Drinking Water: Drinking water enters the unit through a 2” line with a spectacle blind at the down steam of the battery limit block valve. Drinking water is distributed in side the unit to two eye wash and safety shower points hear chemical drums.

1.3

Steam: 1.3.1 Low Pressure Steam: Low pressure steam enters into the unit at the battery limit through a 14” line with a spectacle blind at the down steam of 05BL block valve, two block valves, one on the OSBL side and another on the ISBL side

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MISC- 01- 01

are provided at the battery limit. One ¾” condensate drain line is provided in between two B/V’s. LP steam battery limit pressure is normally about 3 Kg/cm 2 and temperature 1500C, it may vary from 2Kg/cm2 to 4kg/cm2 and the corresponding temperatures are 130 0C to 1700C. LP steam is distributed in various sections as mentioned below: i.

Atmospheric vent of CBD vessel 15-V-9.

ii.

At different hose stations i.e. utility points.

iii.

9-C-1 purging steam.

iv.

15-F-1/F-2/F-3 radiation sections.

v.

Convection and radiation sections of 14-F-1 and 14-F-2.

vi.

Convection section of 15-F-4.

vii.

Radiation section of 15-F-4.

viii.

Duct E is 15-K-3 (ID Fan) suction.

ix.

ID Fan.

x.

9/F-1.

LP steam from 15-K T-1 (steam turbine of 15-K-1) out let joins the LP steam header in side the unit so also the 15-K-1 lube oil turbine outlet steam. LP steam header pressure is maintained by venting excess steam through a PCV provided at the up steam of air atmospheric vent. The atmospheric vent is provided with a silencer near 15-F-4. One LP steam tapping has been taken from 15-KT-1 out let line which joint the LP steam header for the new units out side the south side battery limit. This take off line is provided with a block valve at the take off point and two block valves at the battery limit. 1.3.2 Medium Pressure Steam: MP steam enters the unit through a 8” line provided with OSBL and ISBL block valves. OSBL block valve is provided with a spectacle blind. This steam line is provided with local as well as DCS mounted PI and TI. Flare indication is given in DCS.

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MISC- 01 - 02

MP steam pressure at the battery limit is normally 12Kg/cm 2 and temperature 2500C, but it may vary from 10kg/cm2 to 13kg/cm 2 and corresponding temperature from 2000c to 2600C. MP steam is distributed in the unit to different sections as mentioned hereunder. i.

15-J-1 provided with a spectacle blind at the down stream of take off valve.

ii.

17-DR-1

iii.

14-F-2 convection section

iv.

HY-1402

v.

15-K-1 Lube oil turbine

vi.

14-F-1 Convection section (divided into two streams)

vii.

9-F-1 atomizing steam.

viii.

9-F-1 soot blowers

ix.

15-F-4 convection section

x.

9-F-1 Coil purging steam provided with block valves and NRV’s.

1.3.3 High Pressure Steam: HP steam enters the unit through a 8” line provided with OSBL and ISBL side block valves and a condensate drain line in between the two block valves. A spectacle blind is provided at the down steam of OSBL side block valve. At the battery limit, local TI and PI are provided so also in the Control room. Facilities are provided in DCS for flow integration, pressure and low pressure audiovisual alarm. HP steam pressure, at the battery limit is normally about 60kg/cm2 and temperature3300C.

CCRU OPERATING MANUAL PART-H

MISC- 01- 03

Steam produced in the CRU steam generator joins the HP steam header inside the unit through a 8” line HP steam and steam generated in the unit are jointly required for running 15-KT-1. Steam generated in the unit can be vented to atmosphere through a silencer near 15-F-3. 1.4

Cooling Water: Cooling water enters the unit through a 22” line.

A spectacle blind is

provided at the down steam of the battery limit block valve. Cooling water pressure and flow indications are given in CRT. Cooling water is used in different equipments as mentioned below: i.

15-V-9 CBD vessel coils.

ii.

14-E-5 stripper bottom water cooler.

iii.

15-E-3 recontacting drum feed cooler.

iv.

15-E-2A/B reforming reactor effluent trims coolers.

v.

9-E-4 naphtha splitter bottom trim cooler.

vi.

9-E-1 light naphtha run down cooler.

vii.

14-E-8 makes up gas compressor by pass cooler.

viii.

14-E-2 reactor effluent trims cooler.

ix.

14-E-4A/B stripper trim condensers.

x.

17-E-3 Caustic recycle cooler.

xi.

15-E-8A/B/C/D stabilizer trim condenser.

xii.

17-E-5 nitrogen lift gas cooler.

xiii.

15-P-4A stabilizer reflux pump.

xiv.

15-P-4B stabilizer reflux pump.

xv.

15-P-5A stabilizer reboiler pump.

xvi.

15-P-5B stabilizer reboiler pump

xvii.

17-K1A/B regeneration loop compressors.

xviii.

14-K-2A/B HTU make up gas compressors.

xix.

15-K-1 L.O. coolers (CRU recycle compressor L.O. Coolers)

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MISC- 01- 04

xx.

17-K-3A/B nitrogen lift gas compressors.

xxi.

14-K-1A/B HTU recycle compressors.

xxii.

17-DR-1 regeneration loop dryer.

xxiii.

To APH system.

Cooling water returning from the above mentioned equipment’s join a common cooling water return header of diameter 22”. Cooling water supply and return headers are joined together by a blinded Ubend near nitrogen plant. Cooling water return header is also provided with a battery limit block valve having a spectacle blind at its upstream. One cooling water tapping is taken from the upstream of cooling water supply line battery limit block valve for supplying cooling water to the different equipment of nitrogen plant. Cooling water common return line from nitrogen plant joins the main cooling water return line at the down stream of battery limit block valve. Both the cooling water supply and return line for nitrogen plant are provided with battery limit block valves. 1.5

DM water: (De-mineralized Water) DM water enters the unit through a 2” line, which is provided with a block valve at the battery limit and a spectacle blind at its down stream. Local PI and TI are provided at the battery limit. Flare indication is given in DCS. DM water is used in the steam generation section. 17-P-1A/B section and to 15-T-1 now this line has been kept blinded.

1.6

Boiler Feed Water: BFW line is provided with a battery limit block valve having a spectacle blind at its down stream. It is used for steam generation in the unit.

1.7

Fuel Gas System: F.G. enters the unit through a 8” line having two block valves at the battery limit with a spectacle blind at the down stream of the OSBL side block valve. Local PI and a DCS mounted flow indication facility has been provided. CCRU OPERATING MANUAL PART-H

MISC- 01- 05

FG from the battery limit is received in FG knock out drum 15-V-11, through pressure controller 15PC91. The drum is also provided with L.G. and high level switch and visual alarm and level indication in CRT. FG from 15-V-11 goes through a 8” line to the burners of the following furnaces after passing through isolation block-valves, shut down valves and pressure control valves. i

15-F-1/F-2/F-3 CRU heaters.

ii

14-F-2/14-F-1/9-F-1 and 15-F-4.

These are stripper reboiler,

hydrotreater reactor feed header, splitter reboiler heater and stabilizer reboiler respectively. One part of FG is used for maintaining positive pressure in the following vessels. i.

14-V-1

ii.

14-T-1

iii.

9-V-1

iv.

14-C-1

v.

15-C-1

gases from 15-V-2, 15-V-3 and 17-AC-2 through 10” , 1.5”, 4” line join a 12” line with two branches one goes out from the unit through a 8” line with a flow indication at the battery limit and a block-valve. There is a spectacle blind at the upstream of the battery limit block valve. The other branch through a block valve and a NRV joins a 10” header. FG can flow to the 10” header through the NRV. The 10” FG header is connected to the 8” out let line of 15-V-11 through two block valves with a NRV and a spectacle blind in between, the HRV opens in the direction of 10” line at the down stream of the previous NRV. FG to the non IFP furnaces are supplied through this 10” line, 15-V-11 outlet 8” line supplies FG to the IFP furnaces.

CCRU OPERATING MANUAL PART-H

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One 1” line is provided from the 10” line for purging the line into flare header. This line is provided with a block valve. To tackle frequent chockage of fuel gas C/V, strainers, FG KOD demister and foreign particles basket filter of 80-100 microns with bypass facility has been installed on the u/s of 15V11.process scheme MR/TS/PS/CRU/2008/05 An electric heater 15EH1 (modified heater) has been provided on upstream of 15V11for heating the fuel gas to get rid of salt deposition. Also on the absence of electric heater a MP steam jacket on the upstream of 15V11 has been provided to heat up the fuel gas. 1.8

Nitrogen System: Nitrogen (gas) is supplied in the unit from nitrogen plant installed within CRU battery limit. Gaseous nitrogen is supplied through two headers (header-I and header –II) to meet the requirement of CRU. Gaseous nitrogen from the cold box of nitrogen plant is divided into two parts. One part goes to the off side through a battery limit block valve. The other part taken from the upstream of battery block-valve through a 3” line, which is provided with two block valves and a spectacle blind I between, and this line is marked as Header-I. Header-I flow is measured by a FE and its indication is given by FI in CRT. Gaseous nitrogen can be supplied from liquid nitrogen storage vessels via vaporisers through header-I. Nitrogen (gas) from Header-I is required to serve the following purposes: i.

N2 (g) blanketing in 14-T-1 (Antipolymerisation agent tank)

ii.

9-V-1 for maintaining positive pressure in splitter reflux drum.

iii.

14-C-1 for maintaining positive pressure in stripper.

iv.

15-C-1 for maintaining positive pressure in stripper.

v.

17-T-2 for maintaining positive pressure in stripper CCRU OPERATING MANUAL PART-H

MISC- 01- 07

vi.

14-K-1A HTU recycle gas compressor of HTU, through 1” line

vii.

14-K-1B HTU recycle gas compressor of HTU, through 1” line

viii.

14-K-1A/B HTU recycle gas compressor of HTU, through 2” line

ix.

14-K-2A HTU make-up compressors, through 1” line

x.

14-K-2B HTU make-up compressor through 1” line

xi.

14-K-2A/B HTU make-up compressor through 1.5” line

xii.

15-K-1 CRU recycle compressor through 3” line 

in all compressors, N2 (gas) is used for purging.

Header-II: Two nos. nitrogen booster compressor are provided in the nitrogen plant. These compressors take suction from the cold box outlet nitrogen line and boos-up the pressure from 7Kg/cm2 to about 11.5Kg/cm2. The discharge line of booster compressor is marked as Header-II. This line is provided with two block valves and a spectacle blind in between at the west side of nitrogen plant battery limit. This line is provided with a FE to give the flow indication in CRT. Gaseous nitrogen is supplied to the following vessels and reactors to serve different operational functions. i.

17-V-5

ii.

17-V-6

iii.

17-G-1A/B

iv.

17-R-1

v.

17-V-1

vi.

17-V-3

vii.

17-V-10

viii.

17-V-23

Gaseous nitrogen can also be supplied from liquid N2 storage vessels (new) through vaporiser (new) at the down stream of gaseous nitrogen battery limit block-valve.

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MISC- 01- 08

1.9

Plant Air: Plant air enters the unit through a 6” line having a spectacle blind at the down stream of the battery limit block-valve. One local PI is provided at the battery limit. One FE is installed on the line to give the flow indication through a FI in CRT. Plant air is used in the unit for different operations as follow: i.

Plant air to regeneration system.

ii.

To all hose stations

iii.

To 14-F-1 for Catalyst regeneration.

Dry air from the nitrogen plant is used in 17-R-1 for catalyst regeneration. 1.10

Service Water: Service water enters the unit through a 3” line having a spectacle blind at the down stream of the battery limit block valve. A local PI is provided at the battery limit. A battery limit a FE is installed in the line to give the flow indication in the CRT. Service water is used at the following points in side the battery limit. i.

At all hose stations.

ii.

To 17-P-2A/B suction

iii.

To steam generator

iv.

To APH system.

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MISC- 01- 09

1.11

Flare system: Gases from, columns, vessels, compressors and reactors after passing through PSV’s join a Common 26” Flare header that runs across the unit. FG lines for IFP and non-IFP heaters are connected to the flare line through double block valves with a spectacle blind in between. All compressor discharge line PSV’s are connected to the flare header. 9-V-1 pressure can be controlled by venting excess gas through a pressure control valve into the flare header. 14-V-1 pressure is also controlled by a split range control system, which vents excess gas into the flare header 15-V-1, 15-V-2 and 15-V-3 pressures can also be controlled by venting excess gas into the flare header. The common flare header is connected to a flare knock out drum 15-V-8. Pump seal pot vents are connected to the flare header 15-V-8 is having LG, high and low level alarms in CRT. Gases from 15-V-8 finally goes to the flare through a 26” line provided with a block valve at the battery limit. HC’s and CBD system: Hydrocarbons from columns, vessels exchangers pumps and compressors can be drained into CBD drum, 15-V-9. 15-V-9 is provided with high and low level alarm and a local level indicator as well as a level indication in the CRT. 15-P-10 is a submerged pump, which is installed in the CBD drum for pumping out liquid into the slop header.

CCRU OPERATING MANUAL PART-H

MISC- 01- 10

2.0 STANDING INSTRUCTIONS PREFACE: These Standing Instructions are of general nature and shall be valid under most of the conditions. These instructions have been prepared keeping in view the safety of the plants, personnel and environment. These instructions can be superseded only by another written instruction. Attempt should be made to follow these instructions religiously. If under any condition, the safety of the plant and or personnel or the normal operation of the refinery is expected to be in danger, the same is to be reported immediately to RSM & DMPN / PNM / SPNM for fresh guidelines to tackle such situation. Addition or change of any of the Standing Instruction will be documented as Supplementary, Standing Instructions and the same will attached at the end of these Standing Instruction. Those supplementary Standing Instructions will be incorporated in main Standing Instruction under the under the respective heading while bringing out the next revision. The sections covered under these instructions are Naphtha Splitting Unit (NSU, unit-09), Naphtha Hydrotreating Unit (HTU, unit014), Reforming and Regeneration Unit (CRU, unit –15 & 17), Nitrogen Plant (Unit40) and Hydrogen Storage and unloading facility (unit-42).

A – GENERAL: A-1.

No shift personnel shall leave the plant unless properly relieved or permitted by his supervisors. However persons completing sixteen hours shall be released by the supervisor by making alternate arrangements.

A-2.

Fire of any nature and intensity must be immediately reported to Fire Station, RSM and DMPN/PNM/SPNM(U).

A-3.

Whenever any accident takes place, shift PNE/SPNE shall act as follows: 

Report the matter to RSM and DMPN/PNM/SPNM(U).



Arrange for Ambulance to transfer the injured to First Aid/Hospital

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

Fill up form A-1 for accident reporting and send one copy each to Fire Station and Medical.



If form A-1 is not available, inform Fire Station Shift In-charge on phone. Also inform RSM.



Shift PNE/SPNE to make quick investigation regarding cause of the accident and record it on the office copy of A-1 form and also in the shift Log-Book.



Accident report is to be filled on the same day by the PNE/SPNE in whose shift accident occurred.

A-4.

Absentee and Overtime Statements shall be sent to time office with in fortyfive minutes of the commencement of the shift.

A-5.

PNE/SPNE in each shift shall initial the previous shift Log-Book and also the Instruction Book to conform that they have read it.

B-GENERAL WORK INSTRUCTIONS: B-1.

Any operational variation/equipment breakdown which is likely to have effect on unit T’put, product quality, equipment safety must be immediately brought to the notice of Refinery Shift Manager (RSM) and Unit DMPN/PNM/SPNM(U) at the earliest.

B-2.

For Normal operation, Planned S/D and Start-up, and Emergencies handling follow procedures given in the Operating manual.

B-3.

Any intermitted operation done in the plant should be specifically written with starting and completion time.

B-4.

Clearance to be issued for all maintenance jobs. On the work clearance all column must be ticked / crossed as applicable for the clearance part. Pollution and Environment related jobs to be given top prooity (priority no. one).

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B-5.

All clearances / work orders to Maintenance to be issued on SAP. If the SAP system is out of order, issue clearances on the clearance book and record the same in the log-book.

B-6.

All work clearances/work orders issued must be recorded in the Log-Book. Jobs completed by different maintenance agencies also should be logged.

B-7.

Copy of clearances / work orders issued and job completion certificates must be kept for record.

B-8.

Before effecting any change in the consumption pattern of utilities, PUE (Water Block) and RSM to be informed in advance. Where it is not possible to inform in advance, it should be done as soon as possible.

B-9.

Follow lab. Sampling schedule. Log reason if any of the sample could not be sent along with the reason.

B-10. Follow pumps change over schedule. Record the same in the log-book. Also record reason if any change over could not be done. B-11. Morning shift PNE/SPNE to ensure that daily log-sheet print outs are taken and filed. He should also check if the field and panel log books and registers are filled and duly signed.

C-GENERAL SAFETY INSTRUCTION: C-1.

All employees must follow safety guidelines and safety rules as framed in Mathura Refinery Safety manual.

C-2.

Use Safety Halmet while entering HARD HAT AREA. This is for the safety of all of us. The usage of Safety halmet in-side the B/L is to raised to maximum.

C-3.

In-build security system to be always kept in line. If any system is giving problem it should be quickly attended and to be taken in line. However procedure for by passing of security system is as follows:

SYSTEM

AUTHORITY

ACTION

PROCESS TRIP

CPNM

To be discussed in RSM meeting within 24 hours with CTSM, CITM, and DGM (T).

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EQUIPMENT TRIP

GM(T)

In case trip bypass is required for more than three days

CMNM/CITY/ SITM/CPNM

To be discussed in RSM meeting with in 24 hours with CTSM, and DGM (T).

GM(T)

In case trip bypass is required for more than three days

C-4.

All Safety valves must be kept in line with both sides isolation valves car sealed/wire sealed in wise open condition. If any of the Safety valves is required to be isolated due to passing or leak, take the standby safety valve in-line and isolate the defective one. Standby PSV to be attended on priority and kept and stand-by. For isolation of safety valve where stand-by is not available, procedures outlined above for security system shall be used.

C-5.

While handling chemicals, use safety wears. Shift PNE / SPNE should satisfy themselves regarding the adequacy of protection (use of PVC hand gloves, apron, face shield, safety goggle, hand gloves or gas mask etc.) required to carry out the job.

C-6.

All drains and vents on lines and equipments handling hydrocarbons and dangerous chemicals are to be kept properly capped or blinded. Even sample points from where regular samples are collected should be kept preferably capped hand tight.

C-7.

Draining of oil / water / caustic etc. wherever it is done manually is not to be left unmanned even for a short while. If person doing the operation has to move to some other urgent job, he must close the draining operation before moving out even if the job is unfinished.

C-8.

Draining of oils from system should be done to DBD system. As the reforming unit handles light HC’s, If draining is required, to be done to OWS for any reason, ensure that the material being drained is a small quantity and it is sufficiently cold so as to avoid vapour cloud formation.

C-9.

LPG and Light Naphtha are not to be drained into OWS as it may create vapour cloud at various places leading to fire and explosion.

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C-10. Any line / equipment which has been under hydrocarbon service, should not be exposed to atmosphere / air unless it is made free of hydrocarbons either by streaming or by water flushing. Similarly when any equipment is exposed to air, it is to be made free of air before putting it into hydrocarbon service. C-11. Rotary equipment is to handed over to Maintenance only after proper isolation (process isolation, draining and electrical de-energisation). Confirm the de-energisation by pressing the start button in the field. C-12. Any excavated area or opening at higher attitude must be properly barricaded to eliminate chances of anybody falling down. C-13. Wooden planks, bamboo’s ropes, oil soaked cotton wastes or any other combustible material must not be allowed to remain in the unit area specially near hot equipments as it can result in fire. C-14. First – aid box must be available in PNE/SPNE office. Ensure refill of the box as and when required. Record in the log-book for deficiency. C-15. Constant watch to be kept on firebox conditions. Boxes must be clear and there should be no flame impingement on the tubes. C-16. Naphtha is not to be given to any person / section for washing or cleaning purposes. C-17. Scales / mucks taken out from equipments under lighter hydrocarbon service (e.g. fuel gas, LPG and naphtha) are to be kept wet and carefully removed to a safer place and buried. This is to prevent fire due to presence of pyrophoric iron. C-18. Naphtha / Reformate rundown temperature should not exceed 45-46 deg. C. Keeping it on the lower side will be preferable. This is to reduce fugitive emission, hydrocarbon loss and reduce the possibility of hydrocarbon vapours coming out of receiving tank and forming vapour cloud that may result in fire. C-19. Utility steam points have been provided at various locations in the plant. At all critical areas (such as furnaces, Reboiler pumps, columns bottom platforms, Reforming reactors different platforms. LPG pumps etc.) steam hoses should be kept connected and rolled for fire fighting purpose.

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C-20. If any nitrogen leak is observed in the nitrogen plant, which might has made the area oxygen deficient, use air mask or an air hose provided for this purpose near. C-21. Steam leak can cause steam burn while working on it. To reduce the risk of person getting injured due to the HP steam leakage. -

Reduce the steam leakages by properly commissioning and operating the HP steam lines. Ensure condensate draining the slow warm up while commissioning.

-

As the steam leak will increase if allowed unattended for prolonged period, get the leak attended by tightening of by isolation of the system if possible. Other get it attended by Online sealing.

-

Keep the record of leaks attended by on-line sealing so as to take corrective actions during shutdown.

C-22. All floors to be kept clean and dry to avoid person falling due to uneven surface or slippery area. Get the area’s levelled if any sagging is observed. To keep the area dry, minimise Hydrocarbon, Chemicals, Steam and Water leaks by attended them as and when noticed.

D-HOUSE KEEPING: D-1.

All utility hoses must be kept rolled in their position.

D-3.

Ensure that the bins provided in the area are used for the collection of garbage. Garbage collected in the bins should be disposed off at regular intervals by civil maintenance. Record follow up for the same in the logbook.

D-4.

Shoes are not allowed inside the DDCS Control room. Control room to be maintained dust free to avoid frequent Electronic Cards Failure.

D-5.

No foodstuff/eatables are to be stored/eaten inside the DDCS control room.

D-6.

Waste food/packing materials to be disposed off in the garbage bins only.

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D-7.

Ensure that sample point and chemical / oil drum valves are closed properly immediately after the completion of the job. This is essential as; 

It reduces chemicals and oils wastage.



It reduce the load on our environment.



It can lead to hazardous situation.

In case if any valve is found passing/defective, the same to replaced at the earliest.

E-ENVIRONMENT RELATED: E-1.

E-2.

E-3.

E-4.

E-5.

Excess O2 level in furnaces to be kept in the range of 3 to 4 % so as to have high efficiency and minimum fuel firing. This will avoid excessive fuel firing and extra environment pollution. Excess O 2 to be controlled based upon oxygen analyser available on each of the furnace. Also compare the flue gas samples analysed on weekly basis (ORSAT analysis) with the on-line O 2 analyser readings for corrective action including calibration of on-line analyser. SO2 emission from CRU is to be kept less than 10 Kg/hr. In case of increase of SO2 emission level, cross check the emission levels of other unit’s stacks. If the increase is in all the stacks, check H2S content of the 15K-1 recycle gas (to be normally less than 2 ppm.) and sulfur contents of FG. Otherwise get the SO2 monitor checked by the Instruction Maint. Inform RSM and DMPN/PNM/SPNM and record in the Log-book. Furnaces stack should be maintained smoke free. If due to any upset smoke is observed from the stack, corrective actions are to be taken to clear the stack. The duration for which smoke is observed from the stack must be logged in the Shift PNE/SPNE logbook along with the action taken. Inform RSM also. NOX control in the furnaces can be better achieved by uniform air distribution to the burners and uniform box temperature control. Hence the burners to be kept in healthy conditions and box temp. to be maintained uniformly. Record deviations. Under normal unit operations there shall not be any flaring from the unit. Ensure that 14V-2 and 14V-4 gases are lined up with the Sour gas system. Adjust 15V-2 pr. between 5.0 to 5.5 Ktg/cm2 so as to have no flaring from 15PV-07, 15V-3 pr. controller also should be kept lined up with FG system. CCRU OPERATING MANUAL PART-H

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E-6. E-7.

Steam, process water, process cooling water and fire water leaks should be reported in the Log-Book and attended at the earliest. While taking round of the unit, check open channel for any oil. No oil is to be allowed to go to open channel. If oil is noticed, act as follow: 

Block the channel to prevent the oil going further. Locate and stop the

 

oil leak from the source. Inform RSM and DMPN/PNM/SPNM. Recover the oil from the channel by gully sucker/portable pump and take it to nearby OWS.

E-8.

During normal plant round, if any Hydrocarbon leak is notices, report it in the Log-Book and get it attended at the earliest. If required isolated the system/equipment and get the leak attended. Gaseous hydrocarbons in addition to fire hazards have effect on environment also. Liquid hydrocarbons in addition to fire hazards have affect on land and water pollution. E-9. To minimise risk associated with Naphtha leak in cooling water (EMS programme) check visually on weekly basis (preferably on Monday’s) cooling water sample at B/L for any naphtha and send the sample to lab. for the HC’s content as per the schedule. This checking is highly important as cooling water is used in the number of naphtha exchangers. (09E-1, 9E-4, 14E-2, 14E-4A/B, 14E-5, 15E-2A/B, 15E-3, 15E-8A/B/C/D & 15E-11) where naphtha pressure is higher than the cooling water pressure and any leak in the exchanger will lead to naphtha carry over to the cooling tower. In case of any abnormality inform PUE(Water block), RSM and PNM/SPNM, identify the leaking exchanger and isolate the cooler if leak is confirmed. E-10. Service water consumption is to be minimised (EMS programme). Ensure the following for the same;   

No unwanted service water point is left open. Oil/Chemical leaks are attended at the earliest whenever observed. Proper levelling of the floor to avoid spreading of spilled chemical/oil.

E-11. Hydrogen leak if any should be attended on priority as the leak may increase very soon due to high pressure. E-12. Freon refrigeration system should be maintained leak proof. Periodically check the system for leaks and get the same attended on top priority.

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F- CBD SYSTEM As the reforming unit handles light HC’s , The closed blow down system needs special attention. F-1.

F-2.

F-3. F-4.

F-5. F-6.

Ensure blanketing steam to CBD vent line is always kept charged. In case of LP steam failure, isolate the steam to CBD vent to avoid any back flow HC’s to LP steam header. Normally CBD system is to be kept floating with flare and isolated from the atmospheric vent. This requires CBD network to be all leak proof. However, if due to any reason (such as leakage), the system may be floated with atmosphere. While floating with atmosphere, ensure that blanketing steam (LP steam) is opened prior to opening of the atmospheric vent. Check CBD vessel level in each shift. Pump out the CBD vessel if level is more than 30%. Level to be kept in the range of 10-30%. Weekly (preferably on Wed. Evening shift) check CBD pump performance (even if the level is low) with discharge valve close. This is to ensure that pump motor is in energised condition and pump develops pressure. Record observation in the log-book. Before and after draining any material to CBD, check the CBD level and record in the log-book. CBD all the clean out points must be kept blinded. All columns, Vessels and exchangers drains to CBD to be kept blinded.

G- OWS SYSTEM As the reforming unit handles light HC’s The OWS system needs special attention. G-1. G-2.

G-3.

OWS drain lines for the system, equipment’s and lines under hydrocarbon service must be kept blinded. Unit OWS and Storm sewer system are common. The storm channel inside the unit to be kept lined up to OWS and isolated to the open channel near steam drum. Oil spillage if any, must be contained and not to be allowed to spread, Draining of Naphtha in OWS will lead to the formation of HC’s vapour cloud, which can catch fire from the unit heater. However in case of spillage, flush out the OWS system thoroughly. CCRU OPERATING MANUAL PART-H

MISC- 02- 09

G-4. G-5.

All sewage /OWS / Storm water manhole must always be kept covered. Screens, mesh provided in the OWS funnel shall be kept cleaned to avoid funnel chokage, which will lead to oil / chemical spillage on the floor while draining.

H- FLARE / PSV’S SYSTEM The unit has been provided with flare system, which is hooked up with the existing flare system by an isolation valve at the B/L H-1. H-2. H-3. H-4.

H-5.

H-6.

Unit B/L Valve shall be always full open and car sealed. Under no condition it is to be isolated without the permission of DMPN / PNM or RSM. Keep fuel gas purge to flare header charged near Non-IFP heaters. Keep Flare KO pot drain to CBD and OWS in de-blinded condition. However normal draining shall be done to DBD only. Flare KO drum pr. and level to be checked while checking the unit. Level in the KO pot to be kept in the lowest level gauge only. Under no case the flare header Pr. will be more than 0.5 bar. Under normal operations, no level build up is expected in the flare KO drum, however if level build up is experienced, then check all the safety valves for passing and simultaneously inform PNE VBU/MEROX for him to take care of levels at the flare KO vessels. All safety valves, which are to be kept in line, must be with safety valve inlet and discharge valves wide open and car-sealed. Spare / Stand-by safety valves should be with inlet valve close and discharge valve open and carsealed.

I – INERT-HC’S & INERT-AIR SYSTEM. The unit has Nitrogen as an inert media, Hydrocarbon’s as process fluid medium and air as a media for pr. testing and / or for use during catalyst regeneration. To avoid the mixing, follow the instruction as given below : I-1.

Keep air and HC’s system isolated by blind. Air to unit 17 for regeneration to be de-blinded at the time of regeneration only.

I-2.

Air / Nitrogen connection at 14 R-1 is to be kept blinded to avoid the ingress of air in the inert media.

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I-3.

Nitrogen / Hydrocarbons lines to be kept isolated by blinds to avoid nitrogen contamination by HC’s. However the places where nitrogen is required in

emergency, the system is to be kept isolated by double block and bleed. I.e. keep both the valves isolated and bleeder open. Any minor passing of any of the valve will vent out the leak to atmosphere. I-4.

While charging Nitrogen in any system, ensure that nitrogen pr. is higher than the system pressure.

I-5.

Isolate nitrogen product block valve installed at the D/S of product valve when the nitrogen unit is under start-up.

I-6.

Route nitrogen product to nitrogen header when Oxygen content of the nitrogen produced is less than 10 ppm.

Charge handing over and Taking over Procedures

J- NUCLEONIC LEVEL INDICATORS. The unit has provided with nucleonic level indication / switches for the catalyst levels in the reforming section. Cesium-137 with half life period of approx. 30 years have been provided as the gamma ray source. The source is well protected against mech. Impacts and high temperatures. The source approx. 10 mg. is in a ceramic capsule which has be following outer casings: -

Stainless steel inner capsule

-

Stainless steel outer capsule,

-

Lead box,

-

Outer MS shell

J-1.

Ensure Radiation danger boards are kept displayed near the source location.

J-2.

While working on the source or in the very vicinity, isolate the source by closing its shutter.

J-3.

During long shutdown or while man-entry in the vessel provided with Nucleonic level transmitter, isolate the source by shutter and lock it in close position.

J-4.

In case of major fire in the vicinity of the source, isolate the source and inform RSM, and DMPN/PNM/SPNM.

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J-5.

Loss of any source from the position to be immediately reported to RSM, DMPN/PNM/SPNM and refinery gate CISF.

K-OPERATIONAL K-1.

Follow the procedures as given in the operating manuals for the unit and its different sections for the normal operations, start-up/ shutdown and emergencies handling.

K-2.

NSU lighter product to be normally kept lined up with AVU. Heavy Naphtha product to be routed to either HTU feed or to the Naphtha tank as per the daily instruction through production line / Stop line.

K-3

Normal NSU product routing to HTU feed tank shall be: BH stock : Tank 106 Nig stock : Tank 106 HS stock : Tank 105

K-4

Any Variation in NSU T’put should be communicated to PNE (OM&S –I) & AVU and variation in HTU and Reformer T’put to PNE.

K-5

If Sulfur slippage of more than 1 ppm is observed from the hydrotreating unit in two consecutive results with hydrotreating unit at normal operating condition, reduce the High Sulfur feed processing in HTU to 25% of the total feed.

K-6

Keep constant watch on Stripper / stabiliser level and ensure that level is not lost. This is to ensure that gases / LPG do not escape through the bottom circuit to rundown tank creating fire hazard.

K-7

Ensure that liquid hydrocarbons are not carried by the fuel gas ex 14V2&14V-4 to 20C-6.

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K-9

Ensure that liquid hydrocarbons are not carried by gases ex 15V-2 to the fuel gas system. This may create a fire situation. Cross check its level indication with level gauge.

K-10. Chemical dosing to be done at the rates as specified in the operating manual. Refer CRU folder for Batch preparation / dosing rates calculation. However the following changes w.r.t. the operating manual are to be followed: a)

Antipolymerisation agent dosing to be kept suspended till vis breaker naphtha processing is not starting in the unit.

b)

DMDS dosing to the reformer feed shall be done only if instructed in the daily instruction. Due to the presence of more that 0.2 ppm of S in the reformer feed, it shall probably be not required.

c)

Caustic, Chloride and water dosing to unit 17 shall be done during the catalyst regeneration only.

K-11. During each shift, confirm the level indications response by varying the level of the vessels / column by  5%. Simultaneously get the levels cross checked in the field LG’s. K-12. While topping up DSN tank, ensure the followings: a)

Stripper operation is steady and the Desulfurised naphtha is meeting the Sulfur spec of less than 0.5 ppm.

b)

Manifold valves at B/L are properly lined up.

c)

Close follow up with OM&S, to know the DSN tank dip.

K-13. Keep Nitrogen-I and Nitrogen-II headers charged and pressurised to minimum of 5.0 Kg/Cm2. In case if nitrogen plant is down, take nitrogen from the bullet. K-14. The regeneration loop system and the nitrogen lift gas systems pressure’s to be maintained higher ( + 0.2 bar ) than the HC’s system pressure even if the regeneration and or the lift gas compressor / regeneration loop compressor are not running. This is to avoid any contamination of the regeneration loop / nitrogen lift loop with HC’s.

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K-16. Air diversion to oxichlorination bed to be done only, once: -

The performance of analyzer is confirmed:

-

All the catalyst levels in the reactors/vessel is OK.

-

All the temperature indications of the oxychlorination are responding well.

-

Residual oxygen in AC-03 of the order of 0.2 – 0.4 % confirming that coke burning in the combustion bed is complete.

K-17 Ensure furnace draft physically by looking at the furnace.Also cross checks the draft readings with local gauge and that of DCS. K-18 Ensure the box temperature, skin temperature of every furnace and make sure to keep them within the limits. Maximum Skin temperature limits for

9F1 - 253 deg C 14F1 – 393 deg C 14F2 – 305 deg C 15F1 – 615 deg C 15F2 – 615 deg C 15F3 – 615 deg C 15F4 – 300 deg C

K-19 Ensure the status of interlock while taking charge on every shift. K20. Update interlock register as and when any interlock is bypassed. K21.Ensure no flaring during normal operation. In Case so take corrective actions immediately without any delay. K22.whenever feed pumps of NHTU fails in OM&S survive the unit by taking hot feed from NSU bottom. Please ensure the specification w.r.t the line foreign materials of the feed before taking the feed. K23.Whenever temperature in ox chlorination is found on higher side, burning in regeneration to be converted to black burning mode.

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K24. All the Advance Process Control strategies to be kept on-line. In case of a problem forcing a strategy to be taken to Auto mode, report in the shift logbook as well as to the advance control group. K25.Ensure the performance of all electric heaters by analyzing their trends in dcs and mention in log book in case of any abnormalities.

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PART-H

3.0 WORK PERMIT SYSTEM 3.1

Introduction

The human element of the system has one of the biggest potentials for either causing or preventing a major incident. Safe job performance by operators,

maintenance personnel and contractors has a tremendous positive impact on safety. The objectives of the Work Permit System are to exercise control over the maintenance activities by assigning responsibilities, ensuring clear cut communication between interested functions and requiring that proper consideration be given to the job, its hazards and the precautions required. It ensures that the work is properly defined, authorised, operating personnel are aware what is going on, precautions to be taken are specified and the persons executing the job understand the nature and extent of hazards involved. Safe work practices should provide for the safe conduct of operating, maintenance and modification activities. Work Permit System is an element of safe work practices. Requirements of OISD Standard 105 on 'Work Permit System' & requirements under section 36 & 37 of The Factories Act, 1948 are to be complied with.

3.2

Scope

For performing any work in the refinery by any person other than the operating personnel of that area, a duly authorised written permit shall be obtained for by the person/agency executing the work before commencement of the work. In exceptional cases, the operating personal may require to issue permit to other operating personnel such as in case of entry into confined space or so. Separate permit shall be obtained for each activity. Following jobs should be undertaken only after obtaining work permit: Hot job, Excavation, Road/dyke cutting, Electrical lock-out/energising, Confined space entry, Boxing up of vessel/furnace/ column, Working at elevation, working on fragile roof structures, Radiography, Crane Operation. The above list of jobs is indicative and not exhaustive.

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3.3

Types of Work Permit

Depending on the nature of the job as mentioned in 3.2, there are seven types of permit: Cold work permit Hot work permit/ Vessel entry / Vessel box up/ Excavation permit Working at height permit Radiation permit

3.3.1

DEFINITIONS

a) Hot Work: Hot Work is an activity that may produce enough heat to ignite a flammable air - hydrocarbon mixture or a flammable substance. This includes all works which produces spark, running of IC engine, breaking of concrete, use of ordinary torches 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 2.5 meters & above on temporary structure, scaffolds etc. e) Excavation: Any excavation work inside refinery of depth 200mm or more. f) Confined space: A restricted space, not meant for human occupancy and where there is likelihood of presence of undesirable condition for human safety.

3.4

General Requirements

All jobs in the refinery shall be carried out under valid work permit only. Normally operating personnel do not require work permit, however in exceptional cases, work permit is require Work permits in the refinery shall meet the requirements of OISD-STD-105 titled 'Work Permit System'. CCRU OPERATING MANUAL

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Separate permit must be issued for each job. Multiple jobs in a single permit are prohibited. Permits should be in printed forms, in triplicate or duplicate depending on nature of job, serially numbered and different colour code may be adopted for different types of permits. Depending on nature of jobs, type of permit required shall be decided.

'Working at Height Permit' shall be required for working at a height of more than 2.5 meters from where the working personnel are liable to fall. Safety harness with lifelines secured with a fixed structure is a must for working at height. Provision of safety net shall also be considered based on site condition. For excavation jobs, the following is to be ensured: A warning or protective barricade of 1 meter height with red & white band/ selfglowing caution board is provided around excavation site. Excavated material is piled at least one meter away from the edge of the trench or depth of the trench whichever is greater. Provision of two entries/exits is made. Safe angle or repose or proper shoring/strutting to prevent cave-in is provided. Permit issuing authority shall satisfy him that permit conditions are met before issuing permit. It is also to be ensured that permit conditions are maintained in course of execution of the job. Before issuing a permit, equipment is inspected to ensure that the equipment/ facility is prepared and safe to carry out the assigned work, the area is cleaned and all safety precautions have been adopted. Wherever necessary, equipment is isolated, drained/ depressurised, properly purged, water flushed, gas test and oxygen deficiency test are done. All concerned are to be trained on Work Permit System for proper implementation. Certification and documentation of the training imparted is a must.

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PART-H

3.5

RESPONSIBILITIES

3.5.1 ISSUING AUTHORITY To prepare the equipment/ facility/ area properly before handing over for Maint/ Repair/ construction etc. Ensure that equipment/ facility and area is safe for particular work. 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). 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 tag. Ensure positive isolation of electric equipment and decide about the extent of isolation required for the job. Close the permit on completion of work and retain the copy for at least one month. Keep your copy of permit always with you. Don’t sign the permit without authority.

3.5.2 EXECUTING AUTHORITY On issue of permit, go through the permit and pass the instruction down the line as has been mentioned in the permit. If case of any doubt get it clarified from Issuer. Do not sign without authority. Ensure that precautions mentioned in the permit are complied at site. Ensure that equipment being used by you is safe to perform the task. 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. To 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. The checking and certifying including proceeding tag on each scaffold shall be the responsibility of executing authority. Clear the site on completion of work. Close the permit on completion of work and hand it over to issuing authority.

CCRU OPERATING MANUAL

MISC- 03- 04

PART-H

3.6

PROCEDURES

General Refinery Management shall issue the appropriate authority limits for various types of permits. For blanket hot work and dyke cutting, permits should be obtained from higher authorities and the facility should be restored as quickly as possible.

Entire refinery shall be divided into various zones. For each zone, Gas Safety Inspector (GSI) and Fire Permit Signatory (FPS) shall be authorized. Normally, 'A' and 'B' grade officers are made GSI and officers in grade 'C' and above are designated as FPS. In addition, SRSM/RSM shall be authorized as FPS for the entire refinery. Dy. General Manager/General Manager shall authorize gas Safety Inspectors and Fire Permit Signatories. List of authorized GSI and FPS shall be updated and issued to all concerned at least once in a year. Hot work permits shall be normally valid for 7 days. The authorized person can extend validity after ensuring that all permit conditions are complied. However shift wise clearance for the job is to be obtained. Blanket hot work permit shall be issued with the authorization of DGM (PN) for one month or above as mentioned below: For Laboratory and Workshop or any place where hot work is required everyday and the same is safe. In instances like plant turn around or an activity where work is of continuous nature involving round the clock activity. For project construction area in non-operating areas. However, for cutting process lines, specific permit shall be required. For road cutting HOD permission is required and in case of dyke cutting, permission of DGM shall be obtained.

CCRU OPERATING MANUAL

MISC- 03- 05

PART-H

For carrying out hot jobs beyond normal working hours (General Shift) or on Sundays/Holidays, permission shall be obtained from HOD/DGM. In case concerned HOD/DGM is not available on duty, SRSM/RSM may give the permission on instruction from HOD/DGM. Whenever required, permit shall be renewed by the authority that is competent to issue permit after ensuring all necessary checks as required in case of fresh permit. The renewal is to be recorded on all the three copies of the permit.

Each and every permit shall accompany a clearance certificate. Job can be executed only after obtaining clearance certificate from operating department. Clearance certificate shall be renewed in each shift by GSI. Permits and clearance certificate shall be available at the job site while the job is being executed. Permits shall be signed and returned to the issuing authority after completion of the job. It is to be ensured that the area has been cleared of all debris and temporary electrical connections have been removed. The issuer on receiving back the permit would satisfy himself regarding completion of the job and that the area has been cleaned. Then he shall also sign the permit and keep the records for one month. In case of hot work permit and confined space entry permit, the same shall be forwarded to F&S Department along with the issuer's copy.

3.6.1 ISSUE OF PERMIT Permittee i.e. under whose direct supervision the job is to be carried out shall raise the appropriate permit. All permits shall be issued in triplicate. Based on type of job, following permit shall be used: 1. 2. 3. 4.

Cold Work Hot Work/ Vessel entry/ Vessel box up/ Excavation permit Working at Height Radiation permit

Hot Work Permit also covers permission for vehicle entry inside operation area.

CCRU OPERATING MANUAL

MISC- 03- 06

PART-H

In case the job is planned to be executed through a contractor, permit shall be raised and signed by maintenance/project/ construction engineer and not by the contractor, unless approved by management. The period of validity, in terms of the date, start time and completion time should be entered.

The location of the work should be specified clearly in terms of the plant, plant area, building, vessel or equipment. Identification number of the equipment should be mentioned. Area in-charge/GSI shall check the permit conditions prescribed in the format. Permit shall be issued only after satisfying all the conditions. Additional precautions and remarks, if any, shall be clearly mentioned. All the items shall be marked appropriately in the boxes under heading done and Not Required.

3.6.2 EXPLANATORY NOTES TO WORK PERMIT FORMS The check-listed items in the Work Permit Forms are elaborated below to amplify the underlying concepts and highlight their significance: (i)

Equipment / Area inspected

Equipment or area where work is to be conducted, should be inspected to ensure that it is safe to carry out the work and assess other safety requirements / stipulations. In case of vessel box-up permit, it should be ensured that the work is complete, all personnel are out, no maintenance gear is left behind and debris removed. (ii)

Surrounding area checked / cleaned

Unsafe conditions for performance of work may arise from surrounding area. It should be cleaned-up to remove flammable material such as oil, rags, grass etc. (iii)

Sewers, Manholes, CBD etc. and Hot Surfaces covered

Flammable gases may be released from nearby sewers. Hot un-insulated surfaces/pipelines may provide a source of ignition. Therefore, these are to be properly covered to prevent fires. CCRU OPERATING MANUAL

MISC- 03- 07

PART-H

(iv) Considered hazard from other routine / non-routine operations and persons alerted Other activities (routine / non-routine) being carried out near-by which can create conditions unsafe for performance of the permit work, should be taken into consideration and the concerned persons should be alerted accordingly. (v)

Equipment electrically isolated and tagged

Before issuing permit for mechanical / electrical work in the operating area, it should be ensured that electrical switches are locked-out and cautionary tags duly signed with date and time are attached. Wherever local locking arrangement is provided in the field, the same should be used. Refer format for electrical lockout / energizing given in OISD-STD-137 on "Inspection of Electrical Equipment". (vi)

Running water hose/Portable extinguisher provided

Running water hose and portable fire extinguisher are required respectively to flush / dilute in case of release of any hazardous chemical or to quench sparks and to put out small fires immediately. (vii)

Fire water system checked for readiness

In order to meet any contingency, it should be ensured that the fire water system including firewater pumps, storage, network etc. is checked and kept ready for immediate use. (viii)

Equipment blinded / dis-connected / closed / isolated / wedge opened

Equipment / Vessel, on which the work permit completely isolated from the rest of the plant with normal operation, in order to ensure that there environment with respect to presence of toxic hazardous chemicals etc. in the course of the work.

is being issued, should be which it is connected during is no change in the work / flammable gases, liquids,

Blinding is one of the most effective ways of isolation. Blinds should be installed as close to the vessel as possible. If lines cannot be blinded, they should be disconnected and the open ends should be made safe by installing pipe caps/plugs, blind flanges, mud packing etc.

CCRU OPERATING MANUAL

MISC- 03- 08

PART-H

(ix)

Equipment properly drained / depressurized

Equipment under pressure should be depressurized after isolation. This will be followed by draining / purging / water flushing etc. as the case may be. Equipment containing liquid hydrocarbons should be drained completely. There may be a possibility of overlooking liquid collected in pockets or inaccessible areas

such as level gauges, small nozzles / bleeders on vessels, laterals in pipe work etc. All low point drains should be in unplugged condition. (x)

Equipment properly steamed / purged

Purging of equipment (vessels, pipelines, compressors etc.) is done to make them free of flammable hydrocarbons and toxic gases. Steam / Inert Gas is used for gasfreeing of vessels and pipes in refineries and other locations. Other means of purging is by displacement with water and final traces of gas removed by air eductor. All high point vents should be unplugged while purging. Purging may be done continuously or in batches to conserve purge medium. It should be done in a systematic manner to cover the entire equipment/plant and continued till the concentration of toxic / flammable gas is lowered to allowable level. (xi)

Equipment water flushed

Water flushing is an effective means of cooling, cleaning and even gas-freeing of equipment. It is also employed to remove traces of acids / chemicals. Equipment metallurgy must be considered before using sea / saline water. Sometimes, flushing with dematerialized water would be necessary depending upon the metallurgy of the equipment. (xii)

Gas / Oxygen deficiency test done and found OK Gas test includes measurement of : (a) Hydrocarbons by Explosivemeter (b) Oxygen Deficiency by Oxygen Meter (c) Use of Calibrated Meters

CCRU OPERATING MANUAL

MISC- 03- 09

PART-H

(d) Toxic gases like Hydrogen Sulphide, Carbon Monoxide, Nickel Carbonyl, and Chlorine etc. by techniques like Indicator Tube method, Lead Acetate Paper etc. Gas tests may be specified for vessel entry including open excavation where head of a man will be below ground level and when hot work is being carried out. The person carrying out gas test must wear proper protective gear.

No hot work shall be permitted unless the Explosive meter reading is zero. Vessel entry, where no hot work is to be carried out, may be permitted if combustible gases are up-to 5% of lower explosive limit (LEL). Entry with an air supplied mask may be permitted with LEL of upto 50%. The oxygen level should be at least 19.5 % vol. and the concentration of toxic gases below the threshold limits. (xiii)

Shield against sparks provided

In order to protect against welding sparks which can provide ignition in operating areas, shields are to be provided. The shield material should be non-flammable and should be kept wet with water. (xiv)

Proper ventilation and lighting provided

Where natural ventilation is not available, fans/air eductors are provided. Some types of work like welding may generate fumes. Facilities may be required for the speedy dispersal of these fumes. Only approved reduced voltage extension lights (not exceeding 24 volts) are to be allowed for work inside vessels from consideration of personal safety. (xv)

Proper means of exit provided

Proper means of exit is required in case of emergencies developed on account of the work or otherwise. Availability of an alternate route of escape should be considered. (xvi)

Precautionary tags / boards provided

To prevent any unwarranted entry in the work area and also to caution other personnel taking actions which may endanger people working on the permit job, precautionary tags/boards are to be provided like "No Entry" sign on roads or "Caution-Men at Work Inside" on the manhole of a vessel. CCRU OPERATING MANUAL

MISC- 03- 10

PART-H

(xvii) Portable equipment / Hose nozzles properly grounded As a precaution against static electricity generation, portable equipment / hose nozzles e.g. nozzle of a shot / sand blasting gun, are to be grounded. Use of hydrocarbon lines for earthing should be avoided. (xviii)

Standby person provided for vessel entry

Whenever a person is entering a vessel or work is being carried out in confined space, it may be necessary to keep standby persons (minimum two) at the manhole or entry point holding the rope connected to the safety belt of the person inside. In case of any emergency inside or outside the vessel, the standby will be able to pull the person out. (xix) Standby personnel provided for fire watch from Process / Maintenance / Contractor / Fire Department Depending on the criticality of the job, work permit issuer shall decide the type of standby to be provided i.e. from which department, of which level, how many and also additional fire fighting support facilities. (xx)

Iron Sulphide removed / kept wet

Pyrophoric substances may be present in operating area / equipment handling hydrocarbon. Iron sulphide scales is the most common pyrophoric substances encountered. These should be either removed to safe locations or kept wet all the time to prevent their auto-ignition. (xxi) Area cordoned off In order to prevent the un-authorised entry of people and to avoid accidents during excavation jobs, work area is to be cordoned off.

3.6.3 EXPLANARY NOTES FOR WORKING AT HEIGHT: (I) Scaffolds been checked and certified in prescribed form by scaffold supervisor All scaffolding shall be inspected after completion of erection and then at least every seven days and after weather likely to have affected stability. CCRU OPERATING MANUAL

MISC- 03- 11

PART-H

(II) Scaffolds been tagged with green card duly filled and signed by scaffold supervisor Scaffolding should be tagged with red tag or green tag, Green Tag: Means scaffold is safe for use. Red Tag: Means not for use. (III) Scaffold erected on firm ground and sole plate & base plate have been used

A good base is essential, so that the ground or floor on which the scaffolding is going to stand should be carefully examined. Soil or made up ground will need consolidating. Sole plates at least 9" x 1½" (230 mm x 40 mm) cross section are required to spread the load on earth, made up ground, asphalted surface etc. Sole plates shall extend under at least two standards and joints shall be positioned so that they fall within one half to one third of the distance between any two adjacent standards. At the end standard the sole plate shall project a similar distance. (IV) Platforms been provided with Toe board, guardrail & area below is barricaded. TOE-BOARD (Also known as a Kicking Board) - A board positioned at the edge of a platform or place so as to prevent persons, tools and materials falling from the platform or place. GUARDRAIL - (Also wrongly known as a Handrail) - A tube connected at the edge of platform and other places to prevent persons falling from platform of place. (V) Proper means of access to the scaffold including use of standard aluminum ladder provided Access to a working platform is best achieved by providing a separate ladder tower or cantilevered access platform so as not to obstruct the platform and to minimize the possibility of persons falling through the gap in the guardrail or decking Work permit is a document, which certifies that all practicable precautions have been taken for carrying out the job. Hence, it is desirable that the work permit form shall be filled up personally by the GSI. GSI shall satisfy himself that all precautions have been taken to ensure that the work site is gas free and will remain so during execution of the job. In case of cold work, radiography, working at height, only GSI shall sign the work permit. In case of hot work, both GSI and FPS shall sign the permit. FPS must satisfy himself that the job can be carried out safely and the permit conditions will remain valid during execution of the job. For major construction sites, the contractor/ consultant/ shall issue permit for working at height. CCRU OPERATING MANUAL

MISC- 03- 12

PART-H

In case, electricity is involved, GSI shall request P&U Department for electrical isolation. No work permit shall be issued unless electrical isolation is obtained. In case of hot job, permits signed by both GSI and FPS shall be registered in Fire Station. Fire Safety Officer in the shift shall check that the permit is filled properly in all respect before registering the permit. FSO shall allot a number on the permit with validity and put his signature. The registration shall be carried out at F&S control room after ensuring signature of authorized signatory for the zone.

For excavation permit, permittee shall obtain the clearance from the respective discipline like Civil Maintenance, Electrical Maintenance, Telecom, MIS, Production/ P&U, Fire & Safety in prescribed form as a prerequisite condition. The authorized original copy of the permit shall be given to the receiver. Duplicate copy shall be retained in the book. In case of Hot Work Permit, F&S Department shall retain one copy. Job can commence only after getting clearance certificate. Clearance in each shift shall be given by GSI of the area after checking permit conditions.

3.6.4 Surveillance and Withdrawal of permit The permit issuing authority shall inspect the work site frequently to ensure that permit conditions are being complied and maintained. F&S crew shall make surprise check at the sites where hot work, working at height and working in confined spaces are in progress. Surprise checks shall be carried out on a structured checklist and findings shall be documented. Date and time of such surprise checks shall be recorded. The permit can be withdrawn by issuing authority, executing authority, F&S personnel or any person authorized by management in case of violation of permit condition, plant emergency or any other unsafe situation.

3.6.5 Surrendering the Permit On completion of a cold work, Radiation and Working at height, the permit shall be signed by permittee and returned to the issuer along with clearance certificate. The issuer along with the duplicate copy shall keep the permit. CCRU OPERATING MANUAL

MISC- 03- 13

PART-H

On completion of a hot work/ Vessel entry/ Vessel box up/ Excavation, the permit shall be signed by permittee and returned to the issuer along with clearance certificate. The issuer will then send the permit to F&S Department along with his copy. F&S Department shall record the completion of the job and keep the permits (two copy) along with the F&S copy, which was submitted during registration. Hence, after completion of the job, shift in-charge of F&S Department will keep all the three copies of hot wok permit together and preserve these at least for one month.

In case of serious lapse or violation of permit conditions where safety of the working personnel or equipment is likely to be affected, the execution of the job shall be stopped. In case of any accident or fire at the work site, the permit shall be cancelled. Fresh permit shall be obtained for restarting the job.

3.6.6 Training and Awareness Training and awareness programs are to be organized from time to time for issuer & receiver of permit to make them conversant about work permit system. These programs should include “class room” as well as “on the job training” like Filling of permits Atmosphere monitoring Use of PPE including SCBA & air line respirators Carrying out different jobs safety

CCRU OPERATING MANUAL PART-H

MISC- 03- 14

4.0 UNIT HOUSE KEEPING Good house keeping always added safety at work place. Ensure following for good house keeping: All surface drain around the unit is free from silt. All saucer drain in unit is free from silt. All OWS manhole covers are properly placed. All OWS funnel are free form congealing material. All unit accesses free from obstruction. All platforms & staircases are free form obstructions. No steam leaks. Hydrocarbon leak from valve glands and flanges etc to be arrested at earliest. No water logging in any area of unit. Steam lancers fitted at various utility points. Valve keys are placed in key stand. DCP fire extinguishers are properly placed in unit area. All hot lines are properly insulated & cladding provided. COLOUR CODE OF MANHOLES OWS

-

Yellow

Open Channel

-

Blue

Domestic Sewage -

CCRU OPERATING MANUAL PART-H

Green with white bonds

MISC- 04- 01

5.0 ROLES AND RESPONSIBILITIES

5.1 5.1.1

ROLES RESPONSIBLITY RESOURCES AND RELIABILTY PLANNING Planning for feed processing products quality, equipment

Reliability and manpower requirement

during Shutdown through

co-ordination/participation

in: 

Daily zonal maintenance meeting.

SPNM(U)/PNM



RSM co-ordination meeting.

SPNM (U)



Feed, product & quality planning meeting.

SPNM (U)



Shut-down planning meeting

SPNM(U)/PNM / DMPN



Chemical review meeting with material.

PNM / DMPN

5.2 IMPLEMENTATION MEASURES 5.2.1

Relevant instructions instructions.

to

shift

officers

through

5.2.2 Ensuring availability of catalyst, caustic, Freon, DMDS,C2CL4 additive, lube oil, APA, Corrosion Inhibiter, TSP, Ammmonia

CCRU OPERATING MANUAL PART-H

5.3

CONTROL MECHANISM

PNM / DMPN DMPN

MISC- 05- 01

5.3.1 process control to be done in accordance with Procedure and instructions given in operating Manual, emergency/handbook and daily instructions. The activities are to be coordinated in both field and Control room by shift personnel for unit operation Maintenance in following areas: 

DDCS panel operation

Panel operator



Field operation

Field operator



Flare area

Field operator



Sampling & field jobs

Operator C

5.3.2 Overall coordination with supervision of plant operation.

maintenance

group

Shift officer

5.4 TEST & INSPECTION 5.4.1 Noting lab results in lab resister & taking corrective

Panel operator

Action for deviation in lab results in consultation with Shift officer. 5.4.2 Carrying out field test & entering in lab register.

Panel operator & Field operator

5.4.3Any abnormalities observed in any equipment while On

Panel operator & Field operator

round in the field or in panel to be conveyed to Shift officer. 5.4.4 Log the abnormality in logbook & convey critical Ones

Shift officer

to SPNM (U) / PNM and to RSM beyond general shift hours.

CCRU OPERATING MANUAL PART-H

MISC- 05- 02

5.5 CRITICAL ISSUES 5.5.1

Beyond eight hours of non-conformance of products

Shift officer

with respect to manufacturing specs., seek the advice of SPNM(U) and act accordingly. 5.5.2.

Ensuring field tests for quicker corrective actions.

Field operator

5.6 FEED BACK

5.6.1 All the activities of the shift along with critical parameters To be logged in log book & lab results to

Panel operator & Shift officer

be noted in lab Register. 5.6.2

Generate Monthly Operating Report (MOR)

DMPN

5.6.3

For feed back on unit operations refer log book & lab

DMPN / PNM / SPNM

register

CCRU OPERATING MANUAL PART-H

MISC- 05- 03

6.0

LIST OF VARIOUS OISD STANDARDS:

STANDARDS

NAME OF STANDARD

OISD-STD-105

Work Permit system

OISD-STD-106

Process design and operating philosophies on pressure relief & disposal system

OISD-STD-108

Recommendation handling.

OISD-STD-109

Process design & operating philosophies on blow down & sever system.

OISD-RP- 110

Recommended practices on static electricity.

OISD-STD-111

Process design & operating philosophies on fired process furnace.

OISD-STD-112

Safe handling of air pyropheric substances.

OISD-STD-113

Classification of areas for electrical installation at H/C processing & handling facilities.

OISD-STD-116

Fire protection facilities for petroleum refineries & oil/gas processing plants.

OISD-STD-118 (Rev – 1)

Layouts for oil & gas installations

OISD-STD-119 (Rev –1)

Inspection of pumps.

OISD-STD-120

Inspection of compressors.

OISD-STD-121

Inspection of turbine & diesel engine

OISD-STD-122

Inspection of fan, blower, gearboxes & agitators.

OISD-RP-123

Inspection of rotating equipment components.

CCRU OPERATING MANUAL PART-H

practices

on

oil

hydrocarbon

storage

mixture

MISC- 06- 01

&

&

STANDARDS

NAME OF STANDARD

OISD-RP-124

Predictive maintenance of mechanical seals.

OISD-RP-125

Inspection & maintenance of mechanical seals.

OISD-RP-126

Specific maintenance equipments.

OISD-STD-127

History of recording of rotating equipments.

OISD-STD-128

Inspection of unfired pressure vessels

OISD-STD-129

Inspection of storage tank.

OISD-STD-130

Inspection of pipes, valves & fittings

OISD-STD-132

Inspection pressure relieving devices.

OISD-STD-133

Inspection of fired heaters.

OISD-STD-134

Inspection of heat exchangers.

OISD-STD-135

Inspection of loading & unloading hoses for petroleum products.

OISD-STD-137

Inspection of electrical equipments.

OISD-STD-142

Inspection of fire fighting equipments & systems

OISD-RP-147

Inspection & installations.

OISD-RP-148

Inspection & safe practices during overhauling electrical equipment.

OISD-STD-152

Safety instrumentation hydrocarbon industry.

OISD-STD-153

Safety aspects in functional training.

CCRU OPERATING MANUAL PART-H

safe

practices

practices

for

for

during

process

rotating

electrical

system

MISC- 06- 02

in

STANDARDS

NAME OF STANDARD

OISD-STD-154 Part –I Part – II

Personal protective equipment Non-respiratory equipment’s Respiratory equipment’s

OISD-STD-163

Process control room safety

OISD-GDN-166

Guidelines for occupational health monitoring in oil & gas industry.

CCRU OPERATING MANUAL PART-H

7.0 CRU SAFETY INTERLOCK SET POINTS

MISC- 06- 03

IOCL MATHURA REFINERY - SAFETY INTERLOCK SET POINTS - CRU SL

TAG NO

DISCRIPTION

RANGE

SETTING

ACTION

09 FURNACE 1 1

09 FSLL-1201 B

09 F1 PASS FLOW P 1

0-20.66 M3/HR

19.81 M3/HR

TRIP

2

09 FSLL-1202 B

09 F1 PASS FLOW P 2

0-20.66 M3/HR

19.81 M3/HR

TRIP

3

09 FSLL-1203 B

09 F1 PASS FLOW P 3

0-20.66 M3/HR

19.81 M3/HR

TRIP

4

09 FSLL-1204 B

09 F1 PASS FLOW P 4

0-20.66 M3/HR

19.81 M3/HR

TRIP

5

09 FSLL-1210 B

09 F1 PASS FLOW P 5

0-20.66 M3/HR

19.81 M3/HR

TRIP

6

09 FSLL-1211 B

09 F1 PASS FLOW P 6

0-20.66 M3/HR

19.81 M3/HR

TRIP

7

09 PSLL 1210 B

09 FI P/G PR

-------------------

0.4 KG/CM²

TRIP

8

PSH 3103 B

FUR;ARCH PR HI - 09 F1

-25TO +25 MMWC

+2 MMWC

TRIP

9

PSH 3103 C

FUR;ARCH PR HI - 09 F1

-25TO +25 MMWC

+2 MMWC

TRIP

10 PSHH 3103 B

FUR;ARCH PR HI - 09 F1

-25TO +25 MMWC

+ 5MMWC

TRIP

11 PSHH 3103 C

FUR;ARCH PR HI - 09 F1

-25TO +25 MMWC

+ 5MMWC

TRIP

12 PSH 3103 A

FUR;ARCH PR HI - 09 F1

-25TO +25 MMWC

+2 MMWC

TRIP

13 PSHH 3103 A

FUR;ARCH PR HI - 09 F1

-25TO +25 MMWC

+ 5MMWC

TRIP

14 14 FSLL 1416

14 F2-STRI REBOI FLOW

0-52301.63 KG/HR

49103.4 KG/HR

15 14 FSLL 1404

REG STEAM FLOW

0.3111.26 KG/HR

3000 KG/HR

16 14 FSLL 1411 B

RECYCLE GAS FLOW V.L0

0-827.34 KG/HR

767.7 KG/HR

17 14 FSLL 1419 A

14 F2 PASS FLOW P-1

0-13072.05 KG/HR

10229.90 KG/HR

18 14 FSLL 1419 B

14 F2 PASS FLOW P-2

0-13072.05 KG/HR

10229.90 KG/HR

19 14 FSLL 1419 C

14 F2 PASS FLOW P-3

0-13072.05 KG/HR

10229.90 KG/HR

20 14 FSLL 1419 D

14 F2 PASS FLOW P-4

0-13072.05 KG/HR

10229.90 KG/HR

21 14 PSH 3101

14 F1 ARCH PR V.HI

-25 TO +25MMWC

+2 MMWC

22 14 PSLL 1422

14 F1 FUEAL GAS PR

------------

0.4 KG/CM²

23 14 PSLL 1422 B

14 F1 PILOT GAS PR

------------

0.4 KG/CM²

24 14 PSLL1442

14 F2 FUEL GAS

------------

0.4 KG/CM²

14 FURNACE 1 & 2

CCRU OPERATING MANUAL PART-H

MISC- 07- 01

25 14 PSLL 1442 B

14 F2 PILOT GAS

26 14 TSHH 1473

14F1 OUTLET TEMP

----------

0.4 KG/CM² 330 DEG C

14K2A HTU MAKEUP GAS COMPRESSOR 26 14 PSLL 2002A

14K2A FRAME OIL PR.V.LOW

-----------

0.35 KG/CM²

27 14 PSLL 1474A

14K2A SUCT PR V.LOW

----------

KG/CM²

28 14 TSHH 1477A

DISCH TEMP VERY HIGH

118 DEG C

29 14 PAHH 1476A

DISCH PRESS. VERY HIGH

KG/CM2

30 14 PSL 2001A

14K2A FRAME OIL PR.LOW

-------------

0.55 Kg/Cm²

31 14 PSLL 2007A

14K2A CW HDR PR V.LOW

---------

2.4 Kg/Cm²

--------

0.35 KG/CM²

14K2B HTU MAKEUP GAS COMPRESSOR 33 14 PSLL 2002B

14K2B FRAME OIL PR.V.LOW

34 14 PSLL 1474B

14K2B SUCT PR. V. LOW

35 14 TSHH 1477B

DISH TEMP VERY HIGH

--------

118 DEG C

36 14 PAHH 1476B

DISCH PRESS. VERY HIGH

--------

KG/CM2

37 14 PSL 2001B

14K2B FRAME OIL PR.LOW

--------

0.55 Kg/Cm²

38 14 PSLL 2007B

14K2B CW HDR PR V.LOW

--------

2.4 Kg/Cm²

KG/CM2

14K1A HTU RECYCLE GAS COMPRESSOR 39 14 PSLL 1002A

14 K1A FRAME OIL PR.V.LOW

---------

0.35 Kg/Cm²

40 14 PSLL 1004A

14 K1A GAS SUCT PR

----------

16.17 Kg/Cm²

41 14 TSHH 1002A

14 K1A CY 1-DIS GAS TEMP

----------

106 °C

42 14 TSHH 1004A

14 K1A CY 2-DIS GAS TEMP

---------

106 °C

43 14 PSL 1001A

14 K1A FRAME OIL PR.LOW

----------

0.55 Kg/Cm²

44 14 PSLL 1006A

14 K1A CW IN HDR PR

----------

2.4 Kg/Cm²

45 14 LSHH 1409

14V3 Level High (Com. for A&B)

---------

75%

14K1B HTU RECYCLE GAS COMPRESSOR 46 14 PSLL 1002B

14 K1B FRAME OIL PR.V.LOW

-----------

0.35 Kg/Cm²

47 14 PSLL 1004B

14 K1B GAS SUCT PR

---------

16.17 Kg/Cm²

CCRU OPERATING MANUAL PART-H

MISC- 07- 02

48 14 TSHH 1002B

14 K1B CY 1-DIS GAS TEMP

----------

106 °C

49 14 TSHH 1004B

14 K1B CY 2-DIS GAS TEMP

-----------

106 °C

50 14 PSL 1001B

14 K1B FRAME OIL PR.LOW

----------

0.55 Kg/Cm²

51 14 PSLL 1006B

14 K1B CW IN HDR PR

----------

2.4 Kg/Cm²

52 15 PSLL 1558 B

15 F1 P/G PR V.LO

-----

0.4 KG/CM²

53 15 PSLL 1568 B

15 F2 P/G PR V.LO

-----

0.4 KG/CM²

54 15 PSLL 1578 B

15 F3 F/G PR V.LO

----

0.4 KG/CM²

55 15 FSLL 1565 A

15 F4 PASS FLOW P-1

0-16133.22 KG/HR

15150.45 KG/HR

56 15 FSLL 1565 B

15 F4 PASS FLOW P-2

0-16133.22 KG/HR

15150.45 KG/HR

57 15 FSLL 1565 C

15 F4 PASS FLOW P 3

0-16133.22 KG/HR

15150.45 KG/HR

58 15 FSLL 1565 D

15 F4 PASS FLOW P 4

0-16133.22 KG/HR

15150.45 KG/HR

59 15 PSLL 1588 B

15 F4 P/G PR V.LO

60 15 FSLL 1906

Total of 15FC1903 & 15FC1904

0-308000 KG/HR

57000 KG/HR

61 15 FSL 3104

FD FAN 1-SUCT FLOW LOW

0-60000 NM3/HR

12000 KG/HR

62 15 TSHH 3141C

FD A(15K01)OIL TEM HI TRIP

0-200 DEG C

90 °C

63 15 FSLL 3142 B

(FL 142 B) ID/FD OIL FLOW TRIP 0-200 LPM

50 LPM

64 15 FSL 3105

FD 2-SUCT FLOW

0-60000 NM3/HR

12000 KG/HR

65 15 FSLL 3144 B

FL 144 B) ID FD OIL LOW TRIP

0-200 LPM

50 LPM

66 15 TSHH 3142C

FD B (15 K02)

0-200 DEG C

90 °C

67 15 PSLL 3110

COMP. AIR PR V.LO-9 F1

--

5mmWC

68 15 PSLL 3111

COMP. AIR PR V.LO-15 F4

--

5mmWC

69 15 FSLL 3101 /FC

COMP. AIR FLOW V.LO-09 F1

38000 KG/HR

10800 KG/HR

70 15 PSHH 3107

ID SUCT PR. V.LO

-250 TO +25MMWC

-40 MMWC

71 15 FSLL 3102

COMP AIR FLOW V.LO-15 F4

16500 KG/HR

4500 KG/HR

72 15 TSHH 3132

APH I/L TEMP HI

0-400 DEG C

240 °C

73 15 FSLL 3103

FD FAN TOTAL AIR FLOW V LO 54500KG/HR

15 FURNACE 1/2/3/4

-------

0.4 KG/CM²

ID/FD FANS

CCRU OPERATING MANUAL PART-H

15000 KG/HR

MISC- 07- 03

74 15 FSLL 3140 B

ID/FD OIL FLOW LOW TRIP

0-200 LPM

50 LPM

75 15 TSHH 3140 B

15 K03-OIL TEMP HI TRIP.ID

0-200 DEG C

90 °C

17K1A/B REGENERATION LOOP COMPRESSOR 76 17 TSHH 0102A/B

17K1A/B CY 2-DIS TEMP V.HI

---------

115 °C

77 17 PSLL 0301A/B

17K1A/B L.O.PR.LO-LO

---------

1.5 KG/CM²

78 17 TSHH 0101A/B

17K1A/B CY.1 DIS TEMP.V.H.

---------

115 °C

79 17 PSLL 101A/B

17K1A/B SUCN.PR.V.LOW

--------

1.5 KG/CM²

80 17 PSL 301A/B

17K1A/B L.O.HDR.PR.LO.

--------

1.8 KG/CM²

81 17 LSHH 1723

17K1A/B WASH DRUM LEVEL

75%

17K3A/B NITROGEN LIFT GAS COMPRESSOR 82 17 TSHH 1717

17K3A DIS;TEMP HI

----------

155 °C

83 17 PSLL 3002A

17K3A L.O PR; V.LOW

----------

1.6 Kg/Cm²

84 17 PSL 3001A

17K3A L.O PR.LOW (AOP Start)

---------

2.0 Kg/Cm²

85 17 LSHH 1726

NIT LEVEL V.H(17 K3 A&B)

---------

70%

86 17 TSHH 1718

17K3B DIS;TEMP HI

----------

155 °C

87 17 PSLL 3002B

17K3B L.O PR; V.LOW

----------

1.6 Kg/Cm²

88 17 PSL 3001B

17K3B L.O PR.LOW (AOP Start)

---------------------------

2.0 Kg/Cm²

15K1 'EBARA' HYDROGEN COMPRESSOR 89

VAHH 4101

15K1 COMP RAD VIB DIS

15 K 1-

103 MIC. MET

90

AAHH 4101

15K1 AUX DIS. HIGH

15 K 1-

5.2 MM

91

VAHH 4102

15K1 TUR RAD VIB EX;SIDE

15 K 1-

103 MIC. MET

92

AAH 4102

TUR AXIAL DIS; HIGH

15 K 1-

5.2 MM

93

TAHH 4101 A

COMP.TH.RRG.TEMP.HIGH

15 K 1-

138 °C

94

TAH 4101 B

TIS 4102 B

15 K 1-

132 °C

95

TAH 4102 A

TIS 4102 A

15 K 1-

132 °C

96

TAHH 4102 B

TUR.TH.RRG.TEMP.HIGH

15 K 1-

138 °C

97

PDSL 4010

15 K1 COM.BAL.PIST PR

15 K 1-

0.3 KG/CM²

CCRU OPERATING MANUAL PART-H

MISC- 07- 04

98

PSH 4204

ST;BY.OIL PUMP RUN

15 K 1-

3.3 KG/CM²

99

PSH 4205

EMER;OIL PUMP RUN

15 K 1-

1.6 KG/CM²

100 LSL 4201

RESERVIOR OIL LEVEL LO

15 K 1-

25%

101 PSL 4206

OIL HDR PR LO

15 K 1-

7.0 KG/CM²

102 PSH 4057

SEAL VENT GAS PR

15 K 1-

0.5 KG/CM²

103 PSH 4059

SEAL VENT GAS PR

15 K 1-

0.5 KG/CM²

104 PDSH 4053

BUF.GAS.FIL.PR.DISCH

15 K 1-

0.7 KG/CM²

105 PDSH 4051

BUF.GAS.FIL.PR.SUCT

15 K 1-

0.7 KG/CM²

106 PSL 4001

LO PR LO

15 K 1-

0.89 KG/CM²

107 LSL 4001

LO R/D TANK LEVEL LO

15 K 1-

25%

108 TSHH 4011

COMP DISCH TEMP HI

15 K 1-

170 °C

109 PSLL 4002 A

L.O SUP. PR V L

15 K 1-

0.76 KG/CM²

110 PSLL 4002 B

L.O SUP. PR V L

15 K 1-

0.76 KG/CM²

111 PSLL 4002 C

L.O SUP. PR V L

15 K 1-

0.76 KG/CM²

112 PSHH 4058 A

SEAL VENT GAS PR V.H

15 K 1-

0.75 KG/CM²

113 PSHH 4058 B

SEAL VENT GAS PR V.H

15 K 1-

0.75 KG/CM²

114 PSHH 4058 C

SEAL VENT GAS PR V.H

15 K 1-

0.75 KG/CM²

115 PSHH 4060 A

SEAL VENT GAS PR V.H

15 K 1-

0.75 KG/CM²

116 PSHH 4060 B

SEAL VENT GAS PR V.H

15 K 1-

0.75 KG/CM²

117 PSHH 4060 C

SEAL VENT GAS PR V.H

15 K 1-

0.75 KG/CM²

118 ST 4101 A

TURBINE SPEED HIGH

15 K 1-

8896 RPM

119 ST 4101 B

TURBINE SPEED HIGH

15 K 1-

8896 RPM

120 ST 4101 C

TURBINE SPEED HIGH

15 K 1-

8896 RPM

121 LSHH 1503

15 V1 LEVEL V.HI

15 K 1-

70%

122 SV 4001

TRIP VALVE(SOV)

15 K 1-

110 V.AC(ASCO)

123 AE 4101 A (AI)

COMP.AXIAL DISPLACEMENT

AIS 4101 -15 k1

124 AE 4101 B (AI)

COMP.AXIAL DISPLACEMENT

AIS 4101

125 XE 4101 A

COMP.RAD.VIB.(DISH. SIDE)

VIS 4101 A

126 YE 4101 A

COMP.RAD.VIB.(DISH. SIDE)

VIS 4101 A

CCRU OPERATING MANUAL PART-H

525 MICRO.M(TRIP) 525 MICRO.M(TRIP) 105 MICRO.M (TRIP) 105 MICRO.M (TRIP)

MISC- 07- 05

105 MICRO.M (TRIP) 105 MICRO.M (TRIP) 105 MICRO.M (TRIP) 105 MICRO.M (TRIP) 105 MICRO.M (TRIP) 105 MICRO.M (TRIP) 512 MICRO.M (TRIP) 512 MICRO.M (TRIP)

127 XE 4101 B

COMP.RAD.VIB.(SUCT.SIDE)

VIS 4101 B

128 YE 4101 B

COMP.RAD.VIB.(SUCT.SIDE)

VIS 4101 B

129 XE 4102 A

TURB.RAD.VIB ( EXH SIDE)

VIS 4102 A

130 YE 4102 A

TURB.RAD.VIB ( EXH SIDE)

VIS 4102 A

131 XE 4102 B

TURB.RAD.VIB.(INLET SIDE)

VIS 4102 B

132 YE 4102 B

TURB.RAD.VIB.(INLET SIDE)

VIS 4102 B

133 AE 4102 A (AI)

TURB AXIAL DISPL

AIS 4102

134 AE 4102 B (AI)

TURB AXIAL DISPL

AIS 4102

135 SE 4101 D,E

TURBINE SPEED

136 SE 4101 A,B,C

TURBINE SPEED

137 TI 4101 A

COM.THR.BRG (INACT) 15 K1

132 °C

138 TI 4101 B

COM.THR.BRG (INACT)

132 °C

139 TI 4101 C

COM.THR.BRG (ACT)

132 °C

140 TI 4101 D

COM.THR.BRG (ACT)

132 °C

141 TI 4101 E

COM.THR.BRG (ACT)

132 °C

142 TI 4102 G

TURB.THR.BRG (INACT)

132 °C

143 TI 4102 H

TURB.THR.BRG (INACT)

132 °C

144 TI 4102 J

TURB.THR.BRG (INACT)

132 °C

145 TI 4102 K

TURB.THR.BRG (ACT)

132 °C

146 TI 4102 L

TURB.THR.BRG (ACT)

132 °C

147 FT 4301

COMP. DISH FLOW

8734 RPM SSHH 4101 A,B,C

635-3810 MMWC

8734 RPM

CAL. 2400 MM

15 X1/X2 AMMONIA COMPRESSOR 148 PSHH 5004/5008

15 X1&2 Dish.Pr.V.High

17 Kg/Cm²

149 TSHH 5002/5004

15 X1&2 Dish.Temp.V.High

85 °C

150 PSLL 5002/5006

15 X1&2 Sucn.Pr.V.Low

0.2 Kg/Cm²

151 DPSL 5002/5005

15 X1&2 Oil Cooler DP low

0.5 Kg/Cm²

152 LSHH 5005

15 X1&2 K.O. Drum Level V. High

80%

153 DPSL 5003/5004

15 X1&2 Oil/Gas DP Low

1.5 Kg/Cm²

154 LSL 5001/5002

15 X1&2 Oil Sep.level V.low

20%

CCRU OPERATING MANUAL PART-H

MISC- 07- 06

42K1 HYDROGEN COMPRESSOR 155 PLL 1004 /42

COM. 42 V.L .SUCTION PR

2.0 Kg/Cm²

156 THH 1002 /42

COM. 42 V.HI TEMP.CY 1

125 °C

157 THH 1004 /42

COM. 42 V.HI TEMP.CY 2

125 °C

158 THH 1006 /42

COM. 42 V.HI TEMP.CY 3

125 °C

159 PLL 1002 /42

COM.42

1.0 Kg/Cm²

40X1/X2 FREON COMPRESSOR 160 PSL 4414

40X1 - Oil Pr. V. Low

0.8 Kg/Cm²

161 PSL 4415

40X1 - Sucn. Pr. V. Low

1.0 Kg/Cm²

162 PSH 4416

40X1 - Disch. Pr. V. High

17.5 Kg/Cm²

163 PSL 4424

40X2 - Oil Pr. V. Low

0.8 Kg/Cm²

164 PSL 4425

40X2 - Sucn. Pr. V. Low

1.0 Kg/Cm²

165 PSH 4426

40X2 - Disch. Pr. V. High

17.5 Kg/Cm²

166 TSLL 4417

40X1&X2 Com.Disch.Temp.V.Low.

3 °C

40NC1/NC2 NITROGEN COMPERSSOR 167 PSLL 7104

40NC1/2 - F.O. Pr. V. Low.

1.0 Kg/Cm²

168 PSLL 7102

40NC1/2 - Sucn. Pr. V. Low.

1.1 Kg/Cm²

169 TSHH 7103

40NC1/2 - Disch.Temp.V.High

90 °C

40AC1/AC2 AIR COMPERSSOR 170 PT 2

Low Oil Pr.

1.12 Kg/Cm²

171 VB 1

1st Stg.Vibration High

1.0 MIL

172 VB 2

2nd Stg. Vibration High

1.0 MIL

173 VB 3

3rd Stg. Vibration High

1.0 MIL

174 TE 1

High Oil Temp.

52 °C

175 TI 1

Low Oil Temp.

18 °C

176 TE 2

1st Stg.Air temp.High

52 °C

CCRU OPERATING MANUAL PART-H

MISC- 07- 07

177 TE 3

2nd Stg.Air temp.High

52 °C

178 TE 4

Disch.Air temp. High

52 °C

179 PSLL1

Seal Gas Pr. Low

0.42 Kg/cm²

PROCESS - GENERAL 180 FSLL 1514

15 P5 A/B

0-91263 KG/HR

80802

181 FSLL 1504 C

15 E1

0-7379 KG/HR

6895

182 FSLL1731

17 E1

0-4743.8 KG/HR

4000

183 FSLL1732

N2 II TO 1 ST UH

0-10 KG/HR

2

184 FSLL1733

N2 II TO 4 TH LH

0-13.41 KG/HR

185 PDSL 1730

N2 II TO RD CH

0-0.5 KG/CM2

0-0.3 KG CM²

186 PDSL 1731

N2 TO RR. CH

0-0.1 KG/CM2

0-0.1 KG/CM2

187 FSL 3141

CL.W.LIN

0-280 LPM

74 LPM

188 FSL 3142 A

CL.W.LIN

0-200 LPM

50 LPM

189 FSL 3143

CL.W.LIN

0-280 LPM

70 LPM

190 FSLL 3144 A

CL.W.LIN

0-200 LPM

50 LPM

191 FSL 3145

CL.W.LIN

0-280 LPM

70 LPM

192 TSHH 1711

17 V11 RED CH.

0-600

480 DEG .C

193 TSHH 1701

17 R1 REGEN

0-600 DEG C

520 DEG C

194 TSHH 1703

17 R1 REGEN

0-600 DEG C

535 DEG C

195 TSHH 1704

17 R1 REGEN

0-600 DEG C

535 DEG C

196 TSHH1712

II UH 17 V-12

0-600 DEG C

300 DEG C

197 TSHH1713

III RD UH 17-V-13

0-600 DEG C

300 DEG C

198 PDSL 1725

N2 II TO IST UH

0.5 KG CM2

0-0.5 KG CM2

199 ASHH 1701

O2 % IN N2 GAS

0-1.0 %

0.90%

200 17 FSL 2001

REG GAS FLOW

10000 KG/HR

5000 KG /HR

201 17 TSHH 2002

17 DR1 EX SKIN TEMP

0-600 DEG C

580 DEG C

202 17 TSHH 2001

17 DR1 EX SKIN TEMP

0-600 DEG C

580 DEG C

203 17 FL 18

RECYLE FLOW

0-20000 KG/HR

10000 KG/HR

204 ASH 1705

H2 % VOL IN GAS

0-10 %

0.80%

CCRU OPERATING MANUAL PART-H

MISC- 07- 08

205 ASH 1704

O2 % IN N2 GAS

0-1.0

0-0.8%

206 17 PL 2001

17 DR 1 PR.

0-8.0 KG CM2

3.9 KG CM2

207 PSH 3101

14 F1 ARCH PR

-25 TO +25MMWC

+2 MMWC

208 PSH 3102

14 F2 ARCH PR

-25 TO +25MMWC

+2 MMWC

209 PSH 3104

15 F4 ARCH PR

-25 TO +25MMWC

+15 MMWC

210 PSHH 3104

15 F4 ARCH PR

-25 TO +25MMWC

+20 MMWC

211 15 FSL3104

60000 KG/HR

12000 KG/HR

212 15 FSL 3105

60000 KG/HR

12000 KG/HR

213 TSHH 1755

0-600 DEG C

300 DEG C

214 17FH01

AIR TO CAL ZONE

0-300 KG/HR

150 KG/HR

215 17TSH2005

17 DR1 COOLER O/L TEMP

0-100 °C

60 °C

216 17TSH2006

REGEN.GAS TEMP.

0-400 °C

240 °C

CCRU OPERATING MANUAL

MISC- 07- 09

PART-H

8.0 CAUSE AND EFFECT DIAGRAMS 8.1 COMPRESSORS CAUSE AND EFFECT DIAGRAM - 14 K 1A / B

Comp. Trip EFFECT 14K1A/B 1 Sucn.Pr.V.Lo. PSLL1004 [PSLL1004B] CAUSE Disch.Cyl-1.Temp. V.Hi. TSHH1002 2 [TSHH1002B] Disch.Cyl-2.Temp. V.Hi. TSHH1004 3 [TSHH1004B] 4 L.O. Pr. V.Lo. PSLL1002 [PSLL1002B] 5 CW Hdr.Pr.V.Lo. PSLL1006 (Common) 6 14V3 Level V.Hi. LSHH1409

X X X X X X

Comp Start Permit

AOP Auto Start

AOP Auto Stop

(Common) 1 2 3 4 5

CW Pump ON + Capacity Control 0% + AOP ON + Trip Parameters OK + 14V3 Level LSHH1409 OK (Common)

X

1 Comp ON + L.O. Pr. Low 2 Comp OFF

X X

Comp ON + 30 Sec Delay + L.O.Pr. 1 Healthy

X

CCRU OPERATING MANUAL

MISC- 08- 01

PART-H

CAUSE AND EFFECT DIAGRAM - 14 K 2A / B

Comp. Trip EFFEC 14K2 A/B 1 Suction CAUSEPr V.Low PSLL1474A/B 2 Disch. Temp. V.High TSHH1477A/B 3 LO Pr V.Low PSLL2002A/B 4 Disch.Pr V.High PAHH1476A/B 5 C/W Hdr.Pr V.Low PSLL2007(common)

1 2 3 4 5 6 7 8

C/W Pump On+ Capacity control 0%+ AOP On+ Frame Oil Pr not low+ Disch Pressure not very high+ Diff PR across oil Filter not high+ Frame Oil temp not High+ Suction Pr not Low+

Comp Start Permit

X X X X X

X

AOP Auto Start

AOP Auto Stop

9 Purge gas Pr not low+ 10 C/W R temp not high+ 11 Disch. Temp not High+ 12 C/W S pr not low+ 13 Suction sep level not high+ 1 Comp. Off X 2 Comp On+LO Pr V.Low 1 Comp On+30 sec delay+Lo Pr healthy

X

CCRU OPERATING MANUAL

MISC- 08- 02

PART-H

CAUSE AND EFFECT DIAGRAM – 17KIA.B Comp . Trip EFFECT 17K1A/B CAUSE 1 Sucn.Pr.V.Lo. PSLL101A [PSLL101B] Disch.Cyl-1.Temp. V.Hi. TSHH2002 2 [TSHH2002B] Disch.Cyl-2.Temp. V.Hi. TSHH2004 3 [TSHH2004B] L.O. Pr. V.Lo. PSLL0301A 4 [PSLL0301B] Comp ON + 0% Loading + 3Hrs. 5 Delay

1 Capacity Control 0% + 2 AOP ON + 3 Trip Parameters OK +

Comp Start Permit

X X X X X X

AOP Auto Start

AOP Auto Stop

Wash Drum Level LSHH1723 OK 4 (Common) Comp ON + L.O. Pr. Low PSL0301A 1 [PSL0301B]

X

Comp ON + 20 Sec Delay + L.O.Pr. 1 Healthy

X

CAUSE AND EFFECT DIAGRAM - 17 K 3A / B Comp. Trip EFFECT 17K3A/B CAUSE Disch.Temp. V.Hi. TSHH1717 1 [TSHH1718] 2 L.O. Pr. V.Lo. PSLL3002A [PSLL3002B] 3 N2 Level V.Hi. LSHH1726

Comp Start Permit

AOP Auto Start

AOP Auto Stop

X X X

1 Capacity Control 0% + 2 AOP ON + 3 Trip Parameters OK +

X

Comp ON + L.O. Pr. Low PSLL3001A 1 [PSLL3001B]

X

CCRU OPERATING MANUAL

MISC- 08- 03

PART-H

Rad.Vib.V.Hi. Inlet side

3 VAHH4102 4 Axial Disp V.Hi. AAHH4102 Comp Thrust Bearing temp V.Hi

5 (TAHH4101A)

Turbine Thrust Bearing temp V.Hi

6 (TAHH4102B) 7 8

Comp Disch Temp V.Hi. TSHH4011 L.O. Pr. V.Lo. PSLL4002A/B/C

X X X X X X

LOP2 Stop

LOP2 Start

LOP1 Stop

LOP1 Start

Valve OpenAnti- Surge

X X

PermitGovr Start

CAUSE

15K1 1 Axial Disp V.Hi. VAHH4101 2 Axial Disp V.Hi. AAHH4101

PermitComp Start

EFFECT

Comp Trip

CAUSE AND EFFECT DIAGRAM - 15 K 1

9 10 11

(2/3 Logic) Seal Vent Gas Pr. V.Hi. PSHH4058A/B/C (2/3 Logic) Seal Vent Gas Pr. V.Hi. PSHH4060A/B/C (2/3 Logic) Turbine Speed V.Hi. ST4101A/B/C (2/3 Logic)

12 Governer Common Trip 13 15V1 Level V.Hi. LSHH1503 14 Emergency S/D Sw.

X X X X X X

1 Trip Parameters OK + 2 L.O. Pr.Lo. PSL4001 - OK + L.O.Tank Level Lo. LSL4001 -

3 OK + 4 Turbine Speed ST4101A - OK 1 Trip Parameters OK + 2 Govr Speed below RPM + 3 L.O. Pr.Lo. PSL4001 - OK + L.O.Tank Level Lo. LSL4001 -

4 OK + 5 External Run

X X X X X X X X X

1 Comp Trip

X

L.O. Hdr Pr. Lo. PSL4206 + A/M

1 Sw. in AUTO

CCRU OPERATING MANUAL PART-H

X

MISC- 08- 04

A/M Sw. in MAN + Standby LOP

2 Start

X

1 Standby LOP Stop

1 2

X

L.O.Pr.V.Lo. PSLL4002A/B/C(2/3) + A/M Sw. (Auto) A/M Sw. in MAN + Emergency LOP Start

X X

Emergency LOP Stop / A/M Sw.

1 in AUTO

X

CAUSE AND EFFECT DIAGRAM - 40 X 1 / 2

Comp. Trip 40X1/2 EFFECT 1 Sucn.Pr.Lo. PSL4415 [PSLL4425] CAUSE 2 Disch.Pr.Hi. PSH4416 [PSHH4426] 3 L.O. Pr. Lo. PSL4414 [PSL4424] 4 Disch.Temp.V.Lo. TSLL4417 (Common) Cooling Water Flow Lo. FSL4400 5 (Common)

1 Comp OFF 2 Oil Temp.Low 3 Trip Parameters OK + Wash Drum Level LSHH1723 OK 4 (Common) Comp ON + L.O. Pr. Low PSL0301A 1 [PSL0301B] Comp ON + 20 Sec Delay + L.O.Pr. 1 Healthy

CCRU OPERATING MANUAL

Comp AOP Auto Start Start Permit

AOP Auto Stop

X X X X X

X

X X

MISC- 08- 05

PART-H

8.2 FURNACES (NON-IFP & IFP) Legend

CRU NON-IFP FURNACES CAUSE X - First Action & EFFECT TABLE

FG Pr. V.Low 14F01 (PSLL1422)

X

XX

FG/FO Pr. V.Low (09F01)

XX X

XX

FG Pr. V.Low 15F04 (PSLL1588)

Pass Flow V.Low (FSLL1419A/B / C/D) & COT V.High - 14F02 Pass Flow V.Low & COT V.High (09F01) Pass Flow V.Low (FSLL1565A/B / C/D) & COT V.High - 15F04

XX X

XX

XX

X

XX

X

XX

XX

Trip ID Fan

Open Damper HV3105

XX

X

X

Open Damper HV3104

XX

FG Pr. V.Low 14F02 (PSLL1442)

Pass Flow V.Low & COT V.High (14F01)

CutOff Fuel to 15F04 (Close UV1541)

Open Damper HV3103

CutOff Fuel to 09F01 (Close UV1201, 1202,1203)

Open Damper HV3102

CutOff FG Supply to 14F02 (Close UV1411)

Open Damper HV3101

CutOff FG Supply to 14F01 (Close UV1401)

Close Dis. Damper (SOV3107/3108)

Start other FD Fan

XX - Subsequent action upon Furnace CutOff

XX (With delay 30Sec)

XX (With delay 30Sec) XX (With delay 30Sec) XX (With delay 30Sec)

XX

XX (With delay 30Sec)

XX

XX (With delay 30Sec)

XX

XX (With delay 30Sec)

.

X

XX

XX

XX (With delay 30Sec)

CCRU OPERATING MANUAL PART-H

MISC- 08- 06

X

X

X

XX

X

X

X

XX

X

X

XX

X

XX

X

CCRU OPERATING MANUAL

XX

MISC- 08- 07

FanTrip ID

DamOpen per

XX

XX

X

PART-H

DamOpen per

Fuel CutO to ff

DamOpen per

Fuel CutO to ff

DamOpen per

SuppCutO ly to ff FG

X

DamOpen per

Dis. Clos e

X

SuppCutO ly to ff FG

FD Start Fan other

One FD Fan Failure (XL3101/3102 & FSL3104/ 3105) Both FD Fan Failure (XL3101&3102 / FSL3104 & 3105/ FSLL3103) ID Fan Failure (XL3115 & PSHH3107 at ID Sucn./Speed Sensor) ID Fan Failure (XL3115 & PSHH3107 at ID Sucn./Speed sensor) & HV3101 Not open + 20Sec ID Fan Failure (XL3115 & PSHH3107 at ID Sucn./ Speed sensor) & HV3102 Not open + 20Sec ID Fan Failure (XL3115 & PSHH3107 at ID Sucn./ Speed sensor) & HV3103 Not open + 20Sec ID Fan Failure (XL3115 & PSHH3107 at ID Sucn./ Speed sensor) & HV3104 Not open + 20Sec

XX (With delay 30Sec)

High Arch pressure (PSH3101)

High Arch pressure (PSH3102)

X (If persist s for 20Sec with delay 30Sec )

XX

X

XX

X

XX

XX

X

X (If persist s for 20Sec with delay 30Sec )

High Arch pressure (2/3of PSH3103ABC)

X

X (If persist s for 20Sec with delay 30Sec )

X

High Arch pressure (PSH3104)

X (If persist s for 20Sec with delay 30Sec )

Extra high Pr. At Arch - 9F01 (2/3 of PSHH 3103 A/B/C) Extra high Pr. At Arch 15F04 (PSHH3104)

X

X

X

XX (With delay 30Sec)

X

XX (With delay 30Sec)

X

XX (With delay 30Sec)

X

XX (With delay 30Sec)

X

X

CCRU OPERATING MANUAL

X

X

Trip ID Fan

UV1541)CutOff Fuel to 15F04 (Close

Open Damper HV3103

UV1201, CutOff Fuel to 1202,1203) 09F01 (Close

Open Damper HV3102

UV1411)CutOff FG Supply to 14F02 (Close

X

Open Damper HV3105

XX

Open Damper HV3104

X

Open Damper HV3101

UV1401)CutOff FG Supply to 14F01 (Close

Close Dis. Damper (SOV-3107/3108)

Start other FD Fan ID Fan Failure (XL3115 & PSHH3107 at ID Sucn./ Speed sensor) & HV3105 Not open + 20Sec

X

MISC- 08- 08

PART-H

X (If ZSH31 01 not closed after 20Sec)

X X (If ZSH31 02 not closed after 20Sec)

X

X (If ZSH31 03 not closed after 20Sec)

X

X X (If ZSH31 04 not closed after 20Sec)

X

X

X

Trip ID Fan

Open Damper HV3105

Open Damper HV3104

CutOff Fuel to 15F04 (Close UV1541)

Open Damper HV3103

1202,1203)CutOff Fuel to 09F01 (Close UV1201,

X

Open Damper HV3102

CutOff FG Supply to 14F02 (Close UV1411)

Open Damper HV3101

CutOff FG Supply to 14F01 (Close UV1401)

Close Dis. Damper (SOV-3107/3108)

Start other FD Fan V.High Temp. at ID Fan Inlet (TSHH3134/31 32) V.High Temp.at ID Inlet (TSHH3134 / 3132) & Dampers fails to open within 20Sec Low Comb.Air Pr. / Flow (PSLL3110, FSLL3101) Low Comb.Air Pr. / Flow (PSLL3111, FSLL3102) High Oil Temp (TSHH3140C) or FSLL3140B

X

X (With delay 20Sec)

XX

XX (With delay 30Sec)

X

XX (With delay 30Sec)

X

XX (With delay 30Sec)

X

CCRU OPERATING MANUAL PART-H

MISC- 08- 09

CAUSE AND EFFECT DIAGRAM - IFP FURNACES 15 F1 / 2 / 3 15F1 FG 15F2 FG 15F3 FG SDV Cut- SDV Cut- SDV Cut- Common Off Off Off MSD Open UV1511 UV1521 UV1531

15F1

CAUSE

EFFECT

1 F.G. Pr.V.Low PSLL1558 15F2 1 F.G. Pr.V.Low PSLL1568 15F3 1 F.G. Pr.V.Low PSLL1578 Common for 15F1/F2/F3 1 Recycle Gas Flow V.Low. FSLL1504C 2 Steam Gen.Coil Flow V.Low FSLL1906 Furnace Shutdown (UV1511/1521/1531 3 Shut-Off)

CCRU OPERATING MANUAL PART-H

X X X X X

X X

X X X

MISC- 08- 10

9.0 RECYCLE GAS COMPRESSOR 9.1

INTRODUCTION:

Recycle gas compressor is a centrifugal compressor for the catalytic reforming unit driven by a back-pressure steam (HP) turbine and is supplied by M/S EBARA CORPORATION of Japan (Model No. 38MB6/SBHEG4-4). Compressor takes suction from the reformer separator drum and discharges into the reformer feed preheater 15E1, where it mixes as recycle gas with feed.

9.2

OPERATING PRINCIPLE:

A centrifugal compressor is a machine that converts the energy of centrifugal force into useful work of compressing gas. The gas travels more in a radial direction than in axial direction. The gas is compressed by the mechanical action of rotating impellers imparting velocity to the flowing gas. The gas enters the compressor through the inlet flange and is directed into the inlet of the first impeller through a set of inlet guide vanes, which direct the gas in proper direction. The impeller rotates at a high speed, which causes the gas to be thrown outwards by the centrifugal force and with high velocity. Centrifugal force creates a lower pressure at the impeller inlet so that more gas is forced in by external pressure in the suction pipe. The velocity is decreased and converted into pressure in the diffuser channel following the impeller. The gas then crosses over and returns to the next impeller through a set of return channels, including guide vanes to direct the gas into the next impeller properly. As gas goes through each stage its pressure is increased. After gas leaves the last stage, it is collected in a spiral shaped chamber(volute) from which it passes into the discharge pipe. This volute further reduces the velocity of the gas, converting the kinetic energy to pressure energy and then it is discharged from the compressor.

CCRU OPERATING MANUAL PART-H

MISC- 09- 01

Following conditions have been considered for the compressor’s design:

Normal

Rated

Case A

PLANT

BH+AM

BH+AM

BH+AM

CONDITION

+VB

+VB

+VB

REC.GAS

REC.GAS

69,648

GAS HANDLED FLOW, m3/Hr WEIGHT FLOW, Kg/Hr SUC/DIS PR (Kg/cm2 g) SUC/DIS TEMP DEG C MOL.WT I/L VOL, m3/Hr (WET) COMP. RATIO

Case B

Case C

Case D

BH

DRYING

REDUCTION

REC.GAS

REC.GAS

N2

H2

76,613

68,998

53,657

34,484

37,932

31,125

24,750

41,000

14,000

2.2/5.8

2.2/5.8

2.2/5.8

2.2/5.8

0.6/2.48

4.0/5.1

45/105

45/105

45/108

45/109

40/141

40/64

11.7

11.7

10.666

10.9

28

3.0

24,851

27,338

24,691

19,214

24,293

24,505

2.125

2.125

2.125

2.125

2.175

1.220

2140

2334

2151

1734

1221

955

7362

7446

7702

7498

5391

7702

KW REQD (ALL LOOSES INCL) SPEED (RPM)

The suction pressure of the compressor can go up to 3.7 Kg/cm2 g. Speed can be varied from 70% to 105% through steam turbine. Compressor rated speed is 7702 rpm, min 70% speed is 5391 rpm, max. 105% speed is 8087 rpm. Critical speed of compressor is 3400-3500 rpm and torsional critical speed is 3379 rpm.

9.3

COMPRESSOR:

It is a single process stage centrifugal compressor to serve as a recycle compressor for reformer reduction loop. It has six nos. of impellers each of dia 611

CCRU OPERATING MANUAL PART-H

MISC- 09- 02

mm. The rotation of the compressor as viewed from the turbine end is clockwise. It takes suction from reformer seperator drum 15V1 and its discharge is routed to the feed inlet side of the exchanger 15E1. A spillback flow through an anti-surge controller is provided from discharge to suction via a cooler for machine protection from surging. Compressor is equipped with dry gas seals for its shaft end sealing. A brief description of the parts of the compressor is given below: Casing is designed with a vertically split outer casing and horizontally split inner casing. The inner casing is completely assembled and slid into the outer casing on assembly. The end wall attached to the outer casing completes the casing assembly. Inlet guide vanes located in the front of each impeller provide proper gas flow direction as gas enters the impellers. Inlet guide vanes are an integral part of the diaphragm casting. Diaphragms serve as partitions between the various stages and are generally made of cast iron. They also form passages to direct the flow from the impeller discharge to the inlet guide vanes of the next stage. The accurately machined surfaces form spaces in which the impellers rotate. The extension of these surfaces form the diffuser. The diffuser effectively coverts the velocity of the gas to pressure energy. The diaphragms also contain inter stage seals. Interstage labyrinth seals are to minimize leakage between the stages. The labyrinth seal at the impeller entrance is called the impeller eye labyrinth seal while the one located behind the impeller is called the shaft labyrinth seal. Journal bearings are located in the bearing housing at the inlet and discharge ends of the compressor to support the rotor assembly. The journal bearings are pressure lubricated. Thrust bearing function is to maintain correct axial position of the compressor rotor and to absorb any thrust produced by the rotor. Normally the thrust is towards the inlet of the compressor. However under abnormal operating conditions, thrust may occur in the opposite direction. It is also pressure lubricated. The shaft is made of forged steel. The impellers are made of alloy steel. The impellers are accurately machined and balanced, then keyed and shrunk to the shaft. Sleeves are used between impeller wheels for spacing. The sleeves are also shrunk on the shaft. Balance piston: Due to pressure rise developed through the impeller, a pressure difference exists across the hubs and covers such that the impellers have a net thrust in the direction of the compressor inlet. CCRU OPERATING MANUAL PART-H

MISC- 09- 03

The majority of this thrust is counteracted by the balance piston drum located behind the last impeller. This is accomplished by subjecting the area on the outboard side of the balancing piston to a lower pressure (approx. inlet pressure), thereby creating a pressure differential opposite in direction to that on the impellers. This low pressure is achieved by connecting the area behind the balance piston to the inlet of the machine by balance piston line. The impeller thrust not balanced by the balance piston is absorbed by the thrust bearing. To minimize the amount of the gas leakage past the balancing piston, a balance piston seal is fitted in the discharge wall.

9.4

COMPRESSOR SHAFT END SEALING SYSTEM:

JOHN CRANE type 28 TANDEM seals have been installed on the shaft ends for sealing process gas leak to open atmosphere. The tandem seal is a pair of mechanical seals installed one behind the other. Primary seal seals from process to venting pressure and the secondary seal from vent pressure to atmosphere. Therefore only a small leakage is discharged into the atmosphere. The process gas leak to flare is monitored.

9.4.1 SEAL RELATED DATA: Seal design pressure

13.7 Kg/cm2 G max.

Temperature

170 deg C max

Operating Pressure

6.7 Kg/cm2 g

Shaft speed

8087 rpm

Expected leakage

8.8 std lit/min

Guaranteed leakage

22.7 std lit/min

The seals are designed to cover the widest range of operating parameters and virtually require no maintenance. A supply of filtered compressor discharge gas is injected into cavity between inboard gas seal and the inboard labyrinth. A majority of the gas will flow by inboard labyrinth back into compressor ensuring that the seal cavity is free from liquids or particles that can damage the seal.

CCRU OPERATING MANUAL PART-H

MISC- 09- 04

A small quantity of the supply gas will flow past the inboard seal to the cavity between the inboard and outboard seals. This cavity is vented and the leakage goes to the vent. The O/B ga seal will be sealing on the gas leakage past the inboard seal. This in conjunction with a separation labyrinth for bearing oil prevents the gas from entering the bearing area. The O/B gas seal also functions as a safety seal in case inboard seal starts leaking heavily. Seal performance is monitored through leakage rates. Basically the seal control unit consists of gas filter system which supplies seals with filtered gas, a leakage gas control system and a buffer gas control system to supply inert gas to the secondary seal. 9.4.2 GAS FILTER SYSTEM: Gas supplied to the seal should be clean with max particle size of 5 microns. This is ensured in the filter system. Filtration is accomplished by means of dual coalescing filters. The degree of contamination of the on-line filter is monitored by the delta P switch. Max allowable differential pressure is 2.0 Kg/cm2, the alarm is set at 0.7 Kg/cm2. Filter may be cleaned at this stage. Entrained moisture is removed from gas and collected. It may be drained periodically.

9.4.3 LEAKAGE GAS SYSTEM: The leakage gas system comprises a flow meter and pressure switches. The flow meter will provide leak flow rate data for each seal cartridge. An increase in leak flow signifies a breakdown of the inboard seal, and a decrease, a breakdown of the outboard seal. Following are the settings kept for the leakage gas system: NORMAL

ALARM

TRIP

FLOW, nm3/Hr

1

5.15

9.30

PRESSURE, Kg/cm2 g

0.1

0.5

0.75

CCRU OPERATING MANUAL PART-H

MISC- 09- 05

9.4.4 SEPARATION GAS SYSTEM: The purpose of the separation gas injection is to ensure that the bearing oil cannot contaminate the gas seal. The separation gas pressure is adjusted by a a selfactuating pressure regulating valve. Supply Pr.

Flow

Temperature

Source

Primary buffer gas

5.8 Kg/cm2 g

312-350 nm3/Hr

105 deg C

Discharge H2

Intermediate buffer gas

7.0 Kg/cm2 g

2.0 nm3/Hr

ambient

Nitrogen hdr-I

Sep. air buffer gas

6.5 Kg/cm2 g

23.3 nm3/Hr

ambient

Instrument air

NOTE: Primary buffer gas header can be supplied with nitrogen gas during start-up shutdown operations.

9.4.5 CLEANPAC™ SYSTEM

The CleanpacTMF is a dual stage liquid knock and fine particulate filter. It incorporates the benefits of a pre-filter liquid removal system and a final coalescing filter into one complete package. This model of filter has two separate chambers (lower & upper chamber) for liquid retention. In the first stage, the gas is redirected by the vane pack which acts to disrupt the flow and cause turbulence, this will cause liquids and heavier end hydro-carbons to be removed from the gas stream and allow gravity to pull them into the liquid retention area at the bottom of the vessel. Liquid drainage occurs by gravity and collects in the bottom chamber of the vessel. Secondly, the gas flows through a coalescing filter element, this filter element will remove both the particles (0.3μ Absolute) and coalesce fine liquid mists that are entrained within the gas stream after the first stage filtration. As the gas passes through the coalescing filter, the liquid aerosol in the gas stream accumulates in the coalescing filter forming droplets. These droplets will also accumulate in the upper chamber of the vessel. CLEANPAC™ DRAINAGE

Liquids drain from the Cleanpac in a continuous drain to suction. An orifice on the lower chamber restricts the flow of liquids and gases leaving the Cleanpac.

The drain can be opened and closed manually through the use of a ball valve on the drain lines. PDI-120 – HIGH RANGE (0.7 Kg/cm2) – Cleanpac Mesh Pad Differential Reaching the high alaram value (Red Band) is an indication of high differential across the Cleanpac mesh pad. Possible causes of this High DP are: Dirty mesh pad Transmitter block valves closed, partially closed 9.5

TURBINE:

The compressor is provided with a back-pressure turbine driven by HP steam. It has four stages with a single steam admission valve. 9.5.1 TURBINE OPERATING DATA: RATED POWER

2646 KW

RATED SPEED

7446 RPM

MAX CONTINUOUS SPEED

8087

OVERSPEED TRIP

8734

CRITICAL SPEED

4100

STEAM INLET PRESSURE/TEMP

60 Kg/cm2 g/420 Deg C

EXHAUST PRESSURE

4.0 Kg/cm2 g

Brief description of the turbine parts: Horizontally split casing surrounds the steam path components and supports the stationary steam parts. The turbine steam end contains the higher pressure stages and the exhaust end contains lower pressure stages and the exhaust connection. Rotor assembly consists of shaft over which the wheel discs are shrunk and keyed to the shaft. The thrust collar tripping device and the governor drive arrangement are on the steam supply end of the rotor assembly and the coupling is mounted on the exhaust end. CCRU OPERATING MANUAL

MISC- 09- 06

PART-H

Stationary diaphragms containing the interstage nozzles, expand the steam and direct it against the following rows of rotating blades. The diaphragms are located vertically in the casing grooves by shims at the bottom of the groves and laterally by the means of adjusting screws at the horizontal joint.

Sentinal valve mounted on the exhaust end casing serves as a warning signal In event the back-pressure builds upto a pre determined pressure setting above the normal operating pressure. Steam end bearing housing houses steam end journal bearing, the thrust bearing, overspeed trip assembly and the governor drive arrangement. A labyrinth seal at the inboard end prevents oil leakage along the shaft to atmosphere. Exhaust end bearing housing contains the exhaust end journal bearing. Oil labyrinth seals prevent oil leakage along the shaft to atmosphere. Journal bearings(2 nos.)-one located in the steam end and the other located in the exhaust end bearing housing are contained in bearing retainers with supports and radially position the rotor assembly. Thrust bearing is located in the steam end bearing housing. The purpose of the thrust bearing is to absorb the rotor thrust and to position the rotor axially within the casing. A thrust-bearing collar on the rotor shaft assembly transmits the rotor thrust to the thrust bearing. The thrust bearing is also pressure lubricated. Interstage shaft seals minimize leakage between the stages. Shaft end seals minimize leakage at point where shaft emerges out from the casing. Overspeed trip mechanism operates entirely dependent of the main governor system and stops the flow of steam to turbine whenever the trip speed is exceeded. Steam chest – steam flowing from the steam inlet line to the first stage nozzle ring passes through the steam chest. A strainer is contained in the steam chest along with governor valve, governor valve seat. The governor valve is a venturi type valve, which is positioned through linkage by a servo-motor.

9.5.2 TRIP & THROTTLE VALVE: This valve has two major functions, one is for use as a emergency shut-off valve to trip the turbine and other is to admit and throttle steam to turbine during start-up operation to manually control turbine speed.

CCRU OPERATING MANUAL

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PART-H

9.5.3 TURBINE GLAND SEAL SYSTEM: Turbine casing end seals are of LABYRINTH type, both in the steam end and in the exhaust end. An ejector condenser assembly is provided for the gland steam

system. All gland leak is sucked by the ejector and condensed by the condenser. Condenser is a fixed tube sheet type and uses cooling water. Condenser has one shell pass and two tube passes and it cools down from 293 deg C to 80 deg C. MP steam driven single stage ejector is provided to create a vacuum of 0.1 Kg/cm2. Its normal consumption is 107 Kg/Hr MP steam. The ejector condenser system is designed to handle 402 Kg/Hr (328 Kg/Hr steam, 74 Kg/Hr air).

9.5.4 LUBE OIL SYSTEM: The lube oil system essentially a closed loop designated to provide the compressor bearings and steam turbine bearings with an un-interrupted supply of cooled and filtered oil at the proper pressure. If oil pressure drops to pre-determined pressure the compressor end driver will automatically shutdown. The lube oil system consists of an oil console, LO pumps, coolers, filters, and pressure regulating valves. Lube oil system normal flow is 9 m3/Hr.The console has a charge capacity of 4.39 m3, retention capacity of 1.97 m3, rundown capacity of 2.20 m3, working capacity of 0.75 m3, normal operating range of 0.22 m3. the reservoir has a sloping bottom to drain, clean out manholes, oil fill connection with strainer, oil level guage and vent connection. A steam heater has been provided under the reservoir for heating the oil before starting the pumps. The lube oil circulation is established by LO (screw type) pumps LO-PA-01 A/B main LO pump Lo-PA-01A is turbine driven and in case of its failure stand-by pump LO-PA-01B (motor driven) will take auto start. These pumps have a normal capacity of 12 m3/Hr and an additional emergency pump LO-PA-02 has been provided. It has a normal flow of 5.1m3/Hr and discharge pressure of 5 Kg/cm2. The LO pumps are Kosaka make three spindle screw pump which is a positive displacement rotary pump. Its principal part is composed of a power rotor, two idler rotors engaging closely with the power rotor and the casing in which the three rotors are enclosed. The power rotor, is driven by a motor and the idle rotors rotate in the reverse direction to the power rotor, to move the oil in the grooves of the screws in the axial direction continuously.

CCRU OPERATING MANUAL

MISC- 09- 08

PART-H

The turbine drive of the LO pump is a single stage, MP steam driven with inlet steam pressure of 12 Kg/cm2g (normal)/13.0 Kg/cm2g (max)/10Kg/cm2g (min) & exhaust steam pressure is 4.0 Kg/cm2g (nor)/4.5 (max)/3.0 (min).

The turbine drive of the LO pump has a normal operating speed of 2900 rpm, min, allowable speed of 2400 rpm, max, continuous speed of 3150 rpm, trip speed of 3630 rpm. Two nos. of Lo coolers (LO-EE-01 A/B) have been provided to cool LO from 65 deg C to 49 deg C. These are conventional shell and tube heat exchangers. They are standard outside packed, floating head with removable tube bundles. LO temp control valve is furnished to maintain the supply oil temperature at 43 – 49 deg C. This control valve is pneumatic three-way control valve. It has four tube passes and one shell pass with a duty of 60,000 Kcal/Hr. Twin set of LO filters (K-01A/B) each of capacity 9.24 m3/Hr (at opening temp of 49 deg C) has been provided. Filters are sized for maximum pressure drop of 0.35 Kg/cm2 when clean and passing oil at design temperature. One LO filter has been provided for emergency oil. It has a capacity of 5.1 m3/Hr (at operating temp of 64.9 deg C). It has clean pressure drop of 0.21 Kg/cm2. The filtering elements should be replaced when pressure drop reaches approximately 1.4 Kg/cm2. The above filters have a degree of filtration of 10 microns. Filters are supplied by TAIYO-TECHNICO. Filters elements are of pleated paper type supplied by HILCO cartridges. Continuous flow transfer valves for smooth change over of running filter/ Lo cooler to the corresponding stand-by equipment have been provided. These valves are two-way, six ported valves of TAIYO TECHNO make. Bladder accumulators (2 nos.) of 0.16 m3 capacity each and total usable capacity of 0.25 m3 have been provided. The bladders are pressurized with nitrogen upto pre-charge pressures of 3.9 Kg/cm2 g. These accumulators are located in the controlled pressure header to maintain adequate oil pressure in the system while the stand-by oil pump is coming to speed. An overhead tank of 0.75 m3 capacity has been provided for run down oil supply for about 7 minutes in case of LO circulation failure. A portable centrifuge of capacity of 0.6 m3/Hr of ALPHA-LAVAL make is provided for console oil clarification.

CCRU OPERATING MANUAL PART-H

9.5.5 LUBE OIL SPECIFICATIONS: Basic requirements of LO are:

MISC- 09- 09



Flash Point above 185 deg C



Viscosity at 40 deg C, 27.8-32.0 cst / at 100 deg C, 5.0-5.3 cst



Viscosity index – above 90

9.5.6 ELECTROSTATIC LIQUID CLEANER MACHINES (ELC) PRINCIPLE OF OPERATION : Electrostatic Liquid Cleaner (ELC) machine is a mobile compact unit used for removing solid suspended particulate contamination from mineral oils up to a level of 1 micron and below.The ELC system uses the principle of electrostatics to collect fluid contaminants. FERROCARE ELC's unique design permits it to take advantage of the natural charge of each contaminant. Oil is made to Pass through an electric field. Contaminants that have a positive charge are drawn towards the negative electrode plate and those with a negative charge are drawn towards the positive plate. During their movement to the opposite electrodes the contaminants are trapped on the collector papers inserted between the

electrodes. Neutral

contaminants are drawn and deposited by gradient force to the edge of the collectors where the intensity of the deformed electric field is the strongest. As the fluid flows freely through the system, the ELC removes contaminants – sub micronic particles even smaller than 1 micron, dust, dirt and products of oxidation such as tars or sludge and varnishes. Contaminants are trapped on cellulose collectors for easy disposal. The ELC does not affect soluble additives. APPLICATION The Electrostatic Liquid Cleaner "ELC" unit can be used for cleaning hydraulic and lubricating oils of the following general specifications. Temperature - below 100 degrees C and Moisture - below 500 ppm The ELC unit cannot be used for cleaning of: a) Oils with moisture in excess of 500 ppm b) Oils with detergent dispersant additives c) Some synthetic oils d) Conductive oils

9.6

TURBINE GOVERNOR:

Woodward 505 digital governor is provided for turbine control. It is a micro processor based control. It can be easily configured as per requirement. The 505 control has two operating modes – the program mode and the run mode. Using the program mode, the control of the turbine is configured. Once completed, normally there is no need of re-using the program mode. Run mode is used for turbine operation right from start-up through shut-down. Following are some of the main features of the 505 control: Speed control: A “PID” speed control w.r.t a speed reference set point is achieved using this feature. Valve limiter: it limits the actuator output signal or valve position to aid in starting or shutting the turbine. It limits the maximum valve position. Critical speed avoidance: During programming, up to two critical speed ranges can be selected. Within a critical speed the 505 moves the speed reference at critical speed rate programmed and does not allow the reference speed to stop within the critical speed range.

9.7

COMPRESSOR ANTI-SURGE CONTROL:

9.7.1 COMPRESSOR SURGE: During process start-up or during continuous operation, a variation in the system resistance or and increase in system pressure may fore the compressor in to an unstable region of operation. This results in surge. Surge is a normal characteristic of centrifugal compressor occurs whenever flow through compressor is throttled, either at an inlet or at discharge, beyond a certain point or specifically when the design compression ratio across compressor is exceeded.

CCRU OPERATING MANUAL

MISC- 09- 10

PART-H

As flow velocity and angle are reduced in the radial diffuser passage, the resultant velocity pressure drops off to the extent where static (reservoir) pressure is no longer held in balance and flow suddenly reverses. In some cases, there is no audible evidence of operating in this region. The principle reason for avoiding surge is to safe guard equipment. Operation in the surge region can result in mechanical failure depending on the energy level involved. 15K1 is equipped with anti-surge control system designed by COMPRESSOR CONTROLS CORPORATION. For surge protection gas is recycle from discharge to suction via reformer gas cooler through anti-surge control valve UV-4301.

The control system consists of one series 3 plus anti-surge controller UIC-4301 which monitors relative distance “d” between the operating point of the compressor and its surge control line and provides for the following actions:

1. Proportional and integral response (PI response) to prevent this distance “d” from decreasing below set point “b” 2. Increasing the margin of safety when the operating point of the compressor rapidly approaches the surge control line & slow decreasing when operating point moves away from the surge control line 3. Recycle trip open loop control response, which prevents the operating point from crossing the surge limit line. 4. Safety on response which adds extra static margin of safety to the surge control line thus reducing the possibility of future surge cycles and counts the actual number of surge cycles the compressor has experienced since the controller was last manually reset. The controller can be configured to transmit and receive signals to computers via serial communication. The controller UIC-4301 has six analog inputs:

1. Discharge flow measuring transmitter D.P 2. Discharge pressure of compressor 3. Suction pressure of compressor

CCRU OPERATING MANUAL

MISC- 09- 11

PART-H

4. Speed of compressor 5. Discharge temperature of the compressor 6. Suction temperature of the compressor

Operator can intervene in the AUTO operation of the controller by forcing open the recycle valve UV-4301. This is achieved by providing additional analog input signal from an AUTO-MANUAL station HIC (through I/P transformer). The controller will select the largest of:

1. The internally calculated position of the valve 2. Analog input signal from the above HIC 3. Controllers internal low clamps parameter This allows the HIC to set minimum recycle rate, without comprising the controller’s ability to increase it as needed to protect the compressor. The recycle valve UV-4301 is positioned by output OUT1 of controller UIC-4301, through I/P converter UY-4301.

9.8

GUIDELINES FOR START-UP:

For general routine operation of the unit, following instructions are to be followed: 1. Check oil reservoir to see that it is filled to proper level 2. Dry out steam ahead of throttle valve by opening drain in it. Thoroughly warm-up the steam piping ahead of the turbine. 3. Select AUTO position of selector switch of local control panel. Open the IDLE/RATED governor external contact to the Woodward governor (select IDLE). The IDLE/RATED governor external should be used only on a turbine hot start situation – that is when turbine has been running on load for a considerable time & there was an emergency S/D for a short duration only. 4. Start auxiliary oil pump to circulate oil & to insure the system is working properly. Make sure that the oil temperature is minimum 21 deg C. 5. Drain any intermediate casing drains, and drain under throttle valve seat just before starting and exhaust line. 6. Put any pressure regulators connected to control apparatus in operative position. CCRU OPERATING MANUAL

MISC- 09-12

PART-H

7. Open exhaust steam valve 8. The following operations are to be carried out as nearly simultaneous as possible.



Push “RUN” and open throttle valve wide, but do not jam it. To prevent jamming, back off the throttle valve approx. half a turn.



Put gland condenser and its steam ejector in operation



NOTE: During low speed warm up period, exhaust steam should be to atmosphere with back-pressure increased gradually to exhaust line pressure before loading.

9. Listen for any unusual noises and feel all bearing housing, oil lines, etc. for any signs of abnormal heating or vibration. If undue heating, vibration or noise is detected, slow down until it disappears. If it still persists, shut down and locate and correct the cause before restarting. 10. When turbine is uniformly warmed up and operating at 1000 rpm satisfactorily, increase speed slowly to design speed according to turbine start-up. Bearing temperature may indicate it is time to put water through oil cooler. Make sure the turbine is not held in critical speed range (critical speeds are: 3400-3500 (compressor) & 4100 (turbine)). 11. Ensure that main oil pump has picked up and that auxiliary pump has been shutdown, 12. After the turbine has been found satisfactory at the normal operating speed, the loading of the compressor can be taken up & can be brought on line into normal operating conditions. 

NOTE: the load should be applied as gradually as time and nature of the driven machine will permit to avoid rapid temperature changes in the turbine and to allow the exhaust end to assure its normal temperature.

13. Check oil pressures and temperatures to be sure they are at design. 14. Frequently observe oil level in reservoir, oil piping for leaks, oil pressures and slight indicators, bearing temperatures, shaft packing, and valve stem packing for steam leaks.

CCRU OPERATING MANUAL

MISC- 09- 13

PART-H

9.9

GUIDELINES FOR SHUTDOWN:

For normal routine shutting down of the compressor, proceed as follows:

1. Gradually reduce load to zero 2. Trip the throttle valve by carefully over-speeding the turbine and observe tripping speed and action of mechanism. Alternately push EXTERNAL

STOP switch of local control panel. In case of emergency, the turbine may be tripped by hand. 3. Close the valves between supply header and throttle valve and open the drain ahead of throttle valve. Close exhaust valve as soon as unit comes to rest. 4. Open casing drains. Be sure no steam can enter the turbine from any source when idle 

CAUTION: Do not leave the exhaust valve open while turbine is at rest. The temperature in the exhaust line can be sufficient to bow the turbine shaft when rotor is stationary.

5. After turbine has completely stopped, continue to operate the auxiliary oil pump for several hours to prevent overheating of bearing from hot rotor. Do not shut off C.W. to oil cooler until pump is stopped. 6. Shut off the compressor suction and discharge valve 7. Open compressor drains and drain off any liquid present. 

NOTE: If an unusual amount of liquid is drained from compressor, it should be analysed to determine the source. Steps should be taken immediately to prevent the liquid from entering the compressor.

CCRU OPERATING MANUAL

MISC- 09- 14

PART-H

10.0 HANDING OVER AND TAKING OVER PROCEDURES 10.1 PUMPS Following steps are to be followed for taking over of pump: 1. Check the pump motor, the switch and terminal boxes connection. Then energise the motor.

2. Check that the motor of the pump is properly earthen to prevent electrical shock. 3. Ensure that protective covers are placed over exposed rotary parts of the pump such as pump coupling etc. 4. Check that bearing housing has adequate oil level of proper grade. Change oil if it is dirty / contaminated. 5. Confirm whether cooling water lines are connected properly and there is sufficient flow of water and drive out air from casing through the vent. 6. Open water / steam quench to the mechanical seal as per provision. 7. Rotate the, pump shaft by hand to ensure that it, is free and coupling is secure. 8. Ensure that all blinds have been removed from the suction and discharge line of the pump. Proper pressure gauge should be available on the discharge line. 9. Check whether all bleeder valves have been closed on suction and discharge lines of the pump. Now, open suction valve. CBD valves are to be kept closed and flange blinded. 10. Start the pump and check the direction of rotation. Rectify the direction of rotation if it is not right. 11. If the pump is in hot oil service, it should be gradually warmed up to a temperature close to that of handled fluid. This is absolutely essential, otherwise the pump casing, impeller etc may get damaged due to thermal shock. Hot pumps are normally provided with a bypass across the check valve to keep the idle pump hot. 12. Crack open NRV bypass valve. Do not open NRV bypass valve more else pump will rotate in reverse direction. 13. Pump is to be slowly heated to an operating temperature (not more than 2 0 C / minute).

CCRU OPERATING MANUAL

MISC- 10- 01

PART-H

Following steps are to be followed for handing over of pump: 1. Close the valve in the bypass line across the discharge valve and check valve (wherever provided). 2. Ensure that seal flushing oil (wherever provided externally) are shut off when pump cools down. 3. Shut off pump suction valve.

4. Stop cooling water, when pump cools down. 5. Slowly open the CBD valve and drain liquid from pump. If liquid is very hot, allow sufficient time for cooling before draining is started. Ensure that there is no pressure in the pump. Also keep pump casing vent valve open for complete draining. 6. De-energize / isolate the motor electrically. 7. Get the pump isolated by installing blinds at suction and discharge nozzle flanges.

10.2 HEAT EXCHANGERS Following steps are to be followed for taking over of a Heat exchanger: 1. Heat exchangers are hydraulically tested and certified as fit for operation before being handed over for operation. 2. While taking over a heat exchanger check the followings: a. All nuts and bolts are in position and tight. b. All drains are capped/blinded. c. Thermo-wells, if any, are in position. d. Thermal insulation, if any, is provided. e. Blinds from the inlet and outlet of both shell and tube side is removed. f. Block valves, if any, in the tube and shell side lines and there are by- pass valves are lined-up g. PG’s/TG’s on the tube side and shell side are in place and lined-up and their drains are capped. h. Water from tube and shell are drained and are completely dried before capping/blinding drains

CCRU OPERATING MANUAL

MISC- 10- 02

PART-H

Following steps are to be followed for handing over of a Heat exchanger: 1. Ensure that inlet and outlet valves of tube and shell sides and their by-pass valves are closed. 2. Drain out shell and tube side when the material is still fluid but below 100 oC. 3. In case flushing oil connections are provided flush the exchanger and displace heavy oil to CBD drum. Before flushing, check ullage in CBD drum. 4. Steam the heavy oil heat exchangers after flushing with gas oil.

5. Fill the light oil heat exchangers with water from bottom and displace product from the top through hose to OWS. 6. Get the exchanger positively isolated by installing blinds at inlet and outlet nozzle flanges of both shell & tube side.

10.3 VESSELS Following steps are to be followed for takeover of a Vessel: 1. Check that the vessel is boxed up. 2. Check that inlet and outlet valves are closed. 3. Inlet and outlet flanges are in de-blinded condition. 4. PSV is de-blinded. 5. CBD is blinded. 6. All instrument tapings are connected and bleeders are capped.

Following steps are to be followed for handing over of a vessel: 1. Close the all the Inlet valve of the vessels (if it has more than one inlet). 2. Close all the outlet valves of the vessel (if it has more than one outlet). 3. Isolate the PSV (both inlet and outlet valves). 4. Slowly drain out the left over liquid and release the gases to flare. 5. Deblind the steam out line. 6. Deblind the top vent line. 7. Put steam into the vessel at slow rate and release the gases to flare.

CCRU OPERATING MANUAL PART-H

MISC- 10- 03

8. Open the vent valve (when flare line is hot due to steaming). 9. Continue the steaming for 4 hours, open the bleeders of all instrument tapings of the vessel. 10. Stop the steaming, keep the vent and drain valve open. 11. Get the vessel isolated by installing blinds at inlet and outlet nozzle flanges of the vessel, PSV inlet isolation valve upstream flange and PSV bypass valve upstream flange. 12. Again do the steaming for four hrs, keeping the vent and drain valve open. 13. Stop the steaming and allow it cool. 14. Blind the steam out line.

10.4 COLUMNS Following steps are to be followed for taking over of a Column: 1. All the manholes of the column are boxed up. 2. All the inlet and outlet nozzles and vents of the column are deblinded. 3. PSV is in de-blinded condition. 4. All the instrument tapings are connected and bleeders are capped. 5. CBD is in blinded condition.

Following steps are to be followed for handing over of column: 1. Close the valves on all the inlet lines to column (i.e. CR return to column). 2. Isolate the PSV (both inlet and outlet valves). 3. Slowly drain out the left over liquid and release the gases to flare. 4. Deblind the steam out line. 5. Deblind the top vent line. 6. Put steam into the column at slow rate and release the gases to flare through overhead circuit. 7. Open the vent valve (when condensate is accumulated in overhead receiver). 8. Continue the steaming for 8 hours; drain the condensate from the draw headers and the column bottom.

CCRU OPERATING MANUAL PART-H

MISC- 10- 04

9. Open the bleeders of all instrument tapings of the column during steaming. 10. Stop the steaming, keep the vent and drain valve open. 11. Get the column inlet nozzles isolated, by installing blinds at the inlet flanges of the column, PSV inlet isolation valve upstream flange and PSV bypass valve upstream flange 12. Again start the steaming and continue it for four hrs, put water through the top reflux line with the steaming on. Continue the hot water washing till the hot water at the column bottom is clear. Stop the steaming and continue the water washing till water through the column drain is at ambient temperature. 13. Allow the column to cool. 14. Blind the steam out line.

CCRU OPERATING MANUAL PART-H

MISC-10- 05

11.0 CHECK-LISTS: 11.1

S.N O

1

2

3

4

5

INITIAL FURNACE START-UP:

DESCRIPTION

STATUS

DATE/TIME

CHECKED BY

Have all the thermocouples e.g. skin, box, coil outlet been checked and made okay by Inst. Maintenance. Is there any foreign material inside the furnace and oil soaked insulation, combustible material etc. in the furnace premises? Has the man entry clearance been withdrawn? Has the furnace been boxed up? Are all peepholes, explosion door, manholes etc. closed? Are the Flue gas Main Stack Damper and individual furnace dampers (in case of non IFP heaters) in open position?

6

Are ID & FD fans energized and ready for start-up?

7

Have all the burners been handed over after maintenance and are boxed-up?

8

Is the fuel gas control valve boxed-up in the right direction?

9

Have the instrument connections to the fuel gas control valve been given?

10

Has the stroke check for the FG C/V been done?

CCRU OPERATING MANUAL PART-H

MISC-11- 01

11

Are the pass flows healthy?

12

Has the Furnace interlock been checked?

13

Has the damper operation been checked?

14

15

Are the individual isolation block valves of each burner and its corresponding pilot isolated? Are the fuel gas and pilot gas headers upto PCs steamed for air removal ?

16

Have condensate been drained from FG and Pilot gas headers ?

17

Are the individual burner air resistors closed?

18

Is the igniter in working condition?

19

Is the FG strainer in line and clean?

20

Has box-purging line been deblinded?

21

Has the FG line been deblinded?

22

Are the furnace dampers wide open?

23

Has box purging been done?

CCRU OPERATING MANUAL PART-H

MISC-11- 02

24

Is the tracer to FG and Pilot gas manifold charged?

25

Are the Fuel oil low-pressure trip switch and other interlocks bypassed to start with?

26

Has FD fan been started? (Not required for IFP furnaces)

27

Is the FD fan discharge flow OK? (Not required for IFP furnaces)

28

Are the isolation block valves in the FG and Pilot gas manifold open?

29

Is the furnace draft gauge showing healthy?

30

Is the fuel gas/pilot gas lowpressure trip switch bypassed?

11.2

FURNACE LIGHT-UP:

S.N O

DESCRIPTION

1

Ensure FD fan is running with healthy discharge flow (Required for 09-F-1 and 15-F4 only).

2

Ensure that BFW pump is running with healthy discharge flow

3

Ensure that APH is bypassed.

4

Ensure that individual burner lines and tips are purged.

CCRU OPERATING MANUAL PART-H

STATUS

DATE/TIME

CHECKED BY

MISC-11- 03

5

Ensure flow through each pass of furnace coils. Do ascertain that equal flow distribution is obtained at each pass.

6

Ensure that the FG line is free of condensate

7

8

9

10

11

12

13

14

15

Check / adjust draft and light up pilot burners. Use igniter for lighting Pilot gas burner whenever facility exists. In case of no provision of igniter, insert a lighted torch in front of Pilot and then open valve in Pilot gas line. Ensure that all the pilot gas burners are on line one by one. Is the FG pressure control valve open and FG header pressure healthy Ensure that all the main burners are lighted one by one by opening the individual FG valves slowly Ensure all the individual FG valves are open enough to give a steady flame Ensure air to individual burners are open sufficiently and there are no smoky flames Ensure that the furnace draft is healthy after adjusting furnace stack damper and individual air resistors for healthy flame Ensure that there is no flame impingement on the furnace tubes or walls Ensure that the outlet temperature/skin temp from each pass is well within the limit during initial stage of operation.

CCRU OPERATING MANUAL PART-H

MISC-11- 04

16

17

18

Ensure uniform flow through each pass and then increase firing gradually @ 30 Deg C /hr to required COT. Ensure that there is no flame impingement at regular intervals till required COT is achieved Ensure that box is not pressurized. Commission APH when furnace conditions are normalized.

11.3 CRITICAL EQUIPMENTS HANDING OVER/TAKING OVER CHECK LIST: 11.3.1 COMPRESSOR HANDING OVER CHECK LIST: S.N O

DESCRIPTION

1

Has the compressor been unloaded and stopped from the local control panel and the stand-by started with proper co-ordination with control room

2

3

STATUS

DATE/TIME

CHECKED BY

Have the lube oil pump and cooling water pumps been stopped after sufficient cooling time Has the compressor and its lube oil pump been deenergized

4

Have the compressor suction and discharge block valves been isolated and blinded

5

Has the compressor casing been de-pressurized to flare

6

Have the suction and discharge bottles been drained to CBD

CCRU OPERATING MANUAL PART-H

MISC-11- 05

7

8

Does the compressor local control panel pressure gauges for suction and discharge show zero Has the compressor casing been pressure purged with nitrogen at least twice

9

Have the compressor vent lines to flare and rod packing lines to flare been isolated

10

Have the distance piece nitrogen lines been isolated

11

12

13

Have the compressor suction and discharge PSV ‘s and their by-pass lines been isolated Are the compressor suction/discharge drain lines to CBD/OWS isolated and CBD line blinded Has work order been issued to maintenance department to carry out jobs

11.3.2 COMPRESSOR TAKING OVER CHECK LIST: S.N O

DESCRIPTION

1

Has the compressor been boxed-up and handed over by maintenance

2

Has the compressor suction/discharge bottles and casing leak tested with nitrogen

3

Have the leaks been identified and attended by maintenance

4

Have the compressor gear box and crank case lube oils been replaced

CCRU OPERATING MANUAL PART-H

STATUS

DATE/TIME

CHECKED BY

MISC-11- 06

5

6

7

Are the compressor suction/discharge bottle drains to CBD blinded and OWS isolated Are the suction/discharge pressure and temperature gauges and flow meters lined– up and in working condition Have the suction and discharge lines been deblinded

8

Have the suction and discharge lines been lined-up slowly

9

Have the compressor main motor and its AOP motor been energized

10

Is the lube oil pump running with healthy discharge pressure

11

12

13

14

15

Have the rod packing to flare line and casing vent to flare line lined-up Have the suction and discharge PSV ’s been linedup and their respective bypass b/v ’s isolated Has the nitrogen to distance piece been charged and flow established Has the direction of rotation been checked and compressor trial been taken Take the compressor in line with proper co-ordination with control room and ensure healthy flow before stopping the other

CCRU OPERATING MANUAL PART-H

11.3.3 PUMP HANDING OVER CHECK LIST:

MISC-11- 07

S.N O

DESCRIPTION

1

Has the pump been stopped and the stand-by pump taken in line

2

Has the pump motor been deenergised

3

Has the pump suction and discharge b/v s been isolated and blinded

4

Has the casing warm-up valve been isolated (for hot pumps)

5

Has the pump casing drain line to CBD been de-blinded

6

Has the pump casing material been drained to CBD after sufficient cooling (in case of hot pumps)

7

Have the pump seal pot vent lines to flare been isolated

8

Have the cooling water inlet b/v to the bearings and jacket been isolated

9

Has clearance been issued to maintenance department to carry out jobs

STATUS

DATE/TIME

CHECKED BY

DATE/TIME

CHECKED BY

11.3.4 PUMP TAKING OVER CHECK LIST: S.N O

DESCRIPTION

1

Has the pump been handed over by maintenance after jobs

2

Have the pump in-board and out-board bearing oils been replaced

CCRU OPERATING MANUAL PART-H

STATUS

MISC-11- 08

3

Are the lube oil cups holding enough lube oil

4

Have the seal pot oil been changed/ topped up

5

Has the cooling water to bearing, seal pot and casing been established

6

Have the pump suction and discharge lines been deblinded

7

Has the seal pot vent line to flare been lined-up

8

Has the pump casing drain to CBD been blinded and OWS been isolated

9

Has the pump been put in warm up condition

10

Have the suction been lined up after sufficient warm-up

11

Is the coupling free to rotate with hand

12

Has the pump motor been energised

13

Has the trial been taken to check rotation

14

Change over the pump with proper co-ordination with control room and ensure healthy flow

CCRU OPERATING MANUAL

MISC-11- 09

PART-H

11.3.5 FURNACE HANDING OVER CHECK LIST:

S.N O

DESCRIPTION

1

Has the furnace been put-off and all individual FG and pilot vales been isolated

2

Has the main fuel gas and pilot gas line and box-purging lines been positively isolated

3

Has the furnace stack damper bee opened fully

4

Have the process fluid lines to the furnace coils been purged and positively isolated

5

Have the convection coil process fluid lines been purged and positively isolated

6

Has the furnace cooled down to ambient temperature

7

Has the furnace damper sluice gate been closed (In case of Non-IFP furnaces)

8

9

Have the furnace man holes been opened and sufficient time given for air circulation Has oxygen content been checked with explosive-meter and found ok

10

Has the man-entry permit been made and duly signed

11

Have enough lighting arrangements been made to facilitate man entry

STATUS

DATE/TIME

CHECKED BY

12

Hand over furnace to maintenance department for jobs

CCRU OPERATING MANUAL

MISC-11- 10

PART-H

11.3.6 FURNACE TAKING OVER CHECK LIST:

S.NO

DESCRIPTION

1

Has the furnace been handed over after maintenance

2

Has the man-entry been withdrawn

3

Have all the foreign material been removed from the furnace

4

Have the furnace man-holes been boxed-up

5

Are all the main burners and pilot burners been boxed-up

6

7

8

STATUS

permit

Have the convection zone process lines and main process fluid lines been deblinded Has the stack damper sluice gate been opened (in case of Non-IFP heaters) Has the fuel gas main line and pilot gas line to the furnace been de-blinded

DATE/TIME

CHECKED BY

9

Has the clearance been taken back after de-blinding duly signed

Note: Please follow the furnace light up check-list in section 11.1 for further procedures

CCRU OPERATING MANUAL

MISC-11- 11

PART-H

11.4 START UP / SHUT DOWN CHECK LIST 11.4.1 SHUT DOWN CHECK LIST Steps

Time in Hours

1

0000

Description

 

2

0100

 

3

0200

 

4

0300

 

5

0400



6

0500



Reduce CRU T’put to 48 MT/hr and reactor temperatures to 495 / 512 / 512 oC. Reduce HTU T’put to 48 MT/hr, maintaining same feed ratio. Reactor temperature will remain unchanged at 300 oC. Reduce CRU T’put to 46 MT/hr and reactor temperatures to 490 / 504 / 504 oC. Reduce HTU T’put to 46 MT/hr, maintaining same feed ratio. Reactor temperature will remain unchanged at 300 oC. Reduce CRU T’put to 44 MT/hr and reactor temperatures to 485 / 496 / 496 oC. Reduce HTU T’put to 44 MT/hr, maintaining same feed ratio. Reactor temperature will remain unchanged at 300 oC. Reduce CRU T’put to 42 MT/hr and reactor temperatures to 480 / 488 / 488 oC. Reduce HTU T’put to 42 MT/hr, maintaining same feed ratio. Reactor temperature will remain unchanged at 300 oC. Reduce CRU reactor temperatures to 475 / 480 / 480 oC, maintain T’put @ 42 MT/hr. Reduce CRU reactor temperatures to 470 / 472 / 472 oC, maintain T’put @ 42 MT/hr.

Action By

Panel

Panel

Panel

Panel + field

Panel

Actual time

Sign

7

8

0600

0630

       

Maintain CRU T’put @ 42 MT/hr and reactor temperatures 470 oC in each reactor. Reduce HTU reactor temperature to 290 oC. Maintain 15-V-1 pressure around 3.4 Kg/cm2g. Stop HTU cold feed pump of OM&S. Start bringing down 14-V-1 level to 40%. Inform HGU and stop rich gas to HGU. Stop Ammonia refrigeration system. Stop C2Cl4 injection pump.

CCRU OPERATING MANUAL

Panel + field Field Panel Panel Field field

MISC-11- 12

PART-H

Step s

Time in Hour s

9

0700

Description

    

 

10

0730

  

11

0800



12

0900



Action By

Stop hot feed to HTU. Cut off HTU feed and stop the feed pump. Cut off CRU Feed at 42 MT/hr T’put and 470 o C reactor temperature. Cut off firing of 14-F-2, continue to run 14-P-4 till 14-C-1 bottom cools down. Maintain 14-C1 level around 60%. Line up CRU with Hydrogen bullet through the inter bullet transfer line, so that separate bullets are lined up for HGU and CRU. Ensure no bleeding of Hydrogen through the CRU and HTU system. Reduce CRU reactor temperature to 400 oC in two hours (@ 35 oC/hr) continue Sweeping of CRU reactors with Hydrogen. Reduce HTU reactor temperature to 260 oC in two hours (@ 15 oC/hr); continue sweeping of HTU reactors with hydrogen.

Panel Field Panel field Field panel

Isolate 15-G-1 A/B and 15FC1501 and 1502. Stop 14-P-2 when 14-V-2 level comes down to 20%. Stop 15-P-1, 15-P-2 when 15-V-1 and 15-V-2 level comes down to 20%. Give clearance to blind FG to 14-F-2.

Field

Continue sweeping of CRU reactors with hydrogen maintaining reactor temperatures at

Field

Field Field

Field field PNE+ M/M Panel

Actual time

Sign



13

1300





14

1400

 

400 oC. Continue sweeping of HTU reactors with hydrogen maintaining reactor temperature at 260 oC. Cut off 14-F-1, 15-F-1, 2 and 3. Continue sweeping of all the reactors with hydrogen till the reactors temperature comes down to 100 o C. Vent off the steam to atmosphere. Continue to run 15-P-15 till the SG-1/2 coils get cooled down. Give clearance to blind the FG of 14-F-1, 15F-1, 2 and 3. Give clearance to blind box purging steam to IFP heaters.

CCRU OPERATING MANUAL PART-H

+ field

Field + panel field + panel PNE+ M/M

MISC-11- 13

Step s

Time in Hour s

15

2300

       

16

0100





17

0300

Action By

Description





Stop 14-K-2A. Isolate it and purge with nitrogen. Stop 14-K-1 when HTU system pressure drops to 14 Kg/cm2g. Isolate the compressor. Isolate hydrogen lines. Depressurize HTU reaction section through 14-V-2 to FG / Flare. Stop 15-K-1. Isolate steam header, continue lube oil circulation for eight hours. Depressurize CRU reaction section to flare through 15-PC-05. Close 15-K-1 discharge valve. Give clearance to deblind 15-PC-05 to atmosphere. On depressurization of CRU reaction section, Close 15-PC-05. Charge nitrogen from the d/s of 15-K-1 discharge valve and raise 15-V-1 pressure upto 1.5 Kg/cm2g, close the nitrogen valve and release the gases to flare through 15-PC-05. On depressurization of HTU reaction section, close 14-V-2 depressurization line. Charge nitrogen from the d/s of 14-K-1 discharge valve and raise 14-V-2 pressure upto 1.5 Kg/cm2g, Close the nitrogen valve and release the gases to flare. On depressurization of CRU reaction section, Close 15-PC-05 and Raise the pressure upto 1.5 Kg/cm2g with nitrogen. Close the nitrogen valve and release the gases to atmosphere through 15-PC-05, repeat this exercise for 3 times. On depressurization of HTU reaction section, close 14-V-2 depressurization line. Charge nitrogen from the d/s of 14-K-1 discharge valve and raise 14-V-2 pressure upto 1.5 Kg/cm2g, Close the nitrogen valve and release the gases to atmosphere, repeat this exercise for 3 times.

CCRU OPERATING MANUAL PART-H

Actual time

Field Field Field Field Field Panel Field PNE Panel + Field

Field + Panel

Panel + field

Panel + field

MISC-11- 14

Sign

Step s

Time in Hour s

18

0800

19

20

21 22 23

Action By

Description



Now raise the pressure of both HTU and CRU reaction section upto 1.5 Kg/cm2g, close the nitrogen valve, send the gas sample to laboratory for hydrocarbon content. Release the gases to atmosphere. 1100  If the hydrocarbon content in the gases is equal to or below 0.2 %, Raise the reaction section pressure upto 1.5 Kg/cm 2g, close the nitrogen valve and release the gases to atmosphere and go for blinding in the reaction section as per the blind list. 1100  If the hydrocarbon content in the gases is equal to or below 0.2 %, Raise the reaction section pressure upto 1.5 Kg/cm 2g, close the nitrogen valve and release the gases to atmosphere and go for blinding in the reaction section as per the blind list. If the hydrocarbon content in the gases is above 0.2 %, repeat the steps 17 to 20. 1400 Second check sample 1600 Third check sample (after 2 purges) 1800 Fourth check sample (after 2 purges)

CCRU OPERATING MANUAL PART-H

Actual time

field

field

Field

PNE+ M/M Field Field Field

MISC-11- 15

Sign

11.4.2

START UP CHECK LIST Time in Hours

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Description

Action By

Actual time

0600  14-K-2 discharge at 14-E-1F is deblinded. to  14-K-2 discharge at 14-AC-1 is blinded. M/M 0900  14-K-2 discharge at 14-E-1C is deblinded & kept M/M closed  14-K-1 discharge at 14-E-1F is isolated and kept M/M blinded.  14-R-2 bypass is isolated and blinded. M/M Field  14-R-2 I/L for sulphiding is isolated and blinded. +  14-R-2 O/L for sulphiding is isolated and blinded. M/M  14-K-1 discharge at 14-E-1C is kept deblinded.  14-E-1D s/s O/L is deblinded and lined up to 14- M/M R-2. Field  14-R-2 O/L is deblinded and lined up. + M/M  14-R-2 O/L PCV is lined up. M/M + Field  14-R-1 I/L is deblinded and lined up. Field  14-R-1 O/L is deblinded and lined up. M/M  14-R-2 PSV is lined up. M/M  14-K-2A/B discharge PSV is lined up. Field Field  Line up TC1443 A/B and TC1444 A/B  14-P-1 A/B discharge line PSV is lined up. Field 0900  Charge Nitrogen at the 14-K-1 discharge line and raise system pressure upto 5.0 Kg/cm2g keeping Field 14PC08 open. 1000  Hold the pressure at 5.0 Kg/cm2g and check all the flanges for leakages. dj 1600  On completion of leak test close the nitrogen valve and depressurize to flare using 14-K-1 Field suction to flare. 1700  Charge Nitrogen at the 14-K-1 discharge line and raise system pressure upto 2.0 Kg/cm2g keeping Field 14PC08 open. Close the nitrogen valve. 1800  Depressurize the system to flare using 14-K-1 suction to flare. 1900  Repeat step 21 and 22. Field 2100  Repeat step 21 and send the gas sample to laboratory for O2 content. Also check O2 using Field explosive meter.

Sign

CCRU OPERATING MANUAL

MISC-11- 16

PART-H

Time in Hours

25

26 26

27 28

29 30 31

32 33

34

Actual Time

Description

2100  Inform HGU for the consumption of Hydrogen from the network. Confirm the availability of H2 and its quantity. Expected time of consumption 2300 hrs. 2300  If the O2 content is less than or equal to 0.2 % in the gas, then proceed to Step 27. Otherwise repeat step 22 and 24. 0100  Close 14PC08.  Inform HGU for drawing Hydrogen.  Slowly open Hydrogen network battery limit valve keeping self-actuating PCV in line. The rate of drawing must be under close coordination with HGU. 0200  Depressurize HTU reaction section to flare. 0300  On depressurization open 14PC08 slowly under close coordination with HGU and raise pressure upto 15.0 Kg/cm2g. Hold at this pressure and do the leak test. 0630  Start 14-C-1 bottom circulation. 0700  Light up 14-F-2. Raise COT @30 oC/hr.  Observe the skin temperatures of 14-F-2 and keep them below the operating range. 0730  Inform OM&S to start feed pump ex Tank-106.  Start 14-P-1 and take feed into 14-C-1 bypassing reactor, feed rate to be maintained @35 MT/hr. HTU R/D will go to Tank-106. 0800  Start 14-K-1 and establish circulation. 0900  Start 14-K-2 in presence of DR’s representative and raise 14-R-2 O/L pressure to 25.0 Kg/cm2g keeping PCV in line. While raising 14-R-2 pressure inform HGU. 1000  Inject feed to 14-E-1F s/s at a slow rate upto 35 MT/hr. Maintain 14-R-2 O/L pressure at 25.0 Kg/cm2g and 14V-2 pressure at 17.0 Kg/cm2g, if required keep the bleeding thru 14FC06 and 14K2 loading at 50%. Temperature control circuit will be on SOR mode and TIC 1433 value to be kept at 160 oC.

CCRU OPERATING MANUAL

Sign.

PNE

Field Panel Field

Field

Field

PNE Field Field Panel

Panel

MISC-11- 17

PART-H

Time in Hours

35

36 37

Actual Time

Description

1100  Light up 14-F-1 and start raising COT @30 oC/hr.  Observe the skin temperatures of 14-F-1 and keep them below the operating range. 1500  Stabilize 14-C-1 and keep sufficient bleeding. 1900  Give clearance for hot bolting of 14-R-1 I/L and O/L flanges, 14-R-2 I/L and O/L flanges (which were deblinded),

CCRU OPERATING MANUAL PART-H

Sign.

Field Panel

PNE M/M

MISC-11- 18

12.0

MATERIAL SAFETY DATA SHEET

12.1 AHURALAN (CORROSION INHIBITOR): AHURALAN ESK 50

CHEMICAL IDENTITY Chemical Name

Corrosion Inhibitor

Synonym s

Corrosion Inhibitor

Formula

R1NHR2NHR3RH4

Regulated Identification

Chemical Classificatio n

Long chain fatty amine derivative

Trade Name C.A.S. NO.

Shipping Name

5285-60-9

Ahuralan ESK 50 UN NO.

Ahuralan ESK 50

Codes/Label Hazardous waste I.D. No. Hazchem Code HAZARDOUS INGREDIENTS

C.A.S. NO.

1. Ahuralan ESK 50

5285-60-9

HAZARDOUS INGREDIENTS

C.A.S. NO.

PHYSICAL AND CHEMICAL DATA Boiling Point/ Range oC

150 300

Melting/ Freezing Point oC

10 ppm Exposure Limit

ppm 30 (Skin) mg/m 3 mg/m 3

TLV (ACGIH) ppm

30 (Skin) mg/m3

5 (Skin) ppm 125 mg/m3

NFPA Hazard Signals Reactivity/Stability Special

Odour

Health 3

STEL

20

Flammability 0

0 PREVENTIVE MEASURES Personal Protective Avoid contact with liquid or vapours. Equipment. Provide PVC or rubber hand gloves, air supplied mask, safety goggles, organic vapour canister with full-face masks, rubber apron and shoes. Handling and Storage from heat. Precautions

Store in a cool, well ventilated, dry area way

CCRU OPERATING MANUAL

MISC-12- 12

PART-H

EMERGENCY AND FIRST AID MEASURES FIRE Fire Extinguishing Media

Not Flammable.

Special Procedure Keep the containers cool by spraying water if exposed to heat or flame. Unusual Hazards Poisonous and irritating gases are produced. EXPOSURE First Aid Measures Inhalation : Remove the victim to fresh air area, Give artificial respiration. Ingestion : Induce vomiting, give plenty of water to drink. Eyes & Skin : Wash the affected area with plenty of water. Seek medical aid immediately. Antidotes/Dosages

Not available.

SPILL Steps to be taken Shut off leaks if without risk. Absorb on sand or earth. Waste Disposal Method Seal all the waste in vapour-tight plastic bags for eventual disposal. ADDITIONAL INFORMATION/REFERENCES A suspected human carcinogen. Violent or explosive reaction on contact with fluorine. Potentially explosive reaction on contact with boranes. Potentially dangerous reaction with dimethylene formamide, 1,2,3,4,5,6 - hexachlorocyclohexane or dimethylacetamide, when iron is present as catalyst. This has narcotic action similar to that of chloroform though not as strong. Concentration of the order of 1000-1500 ppm is sufficient to cause symptoms if exposure continues for several hours. Repeated daily exposure to such concentrations may result in poisoning. CC14 has caused explosions when used as fire extinguisher on a wax fires and uranium fires. MANUFACTURER/SUPPLIERS DATA Name of firm : Mailing Address :

CCRU OPERATING MANUAL

MISC-12- 13

PART-H

12.4 DI-METHYL DI-SULPHIDE (DMDS): DI-METHYL DI-SULPHIDE

CHEMICAL IDENTITY Chemical Name

Di-methyl Di-sulphide

Synonym s

2,3-Dithiabutane

Formula

CH3-S-S-CH3

Regulated Identification

Chemical Classificatio n

Organic compound

Trade Name C.A.S. NO.

Shipping Name

Di-methyl DiSulphide UN NO.

2381

DMDS

Codes/Label Hazardous waste I.D. No. Hazchem Code HAZARDOUS INGREDIENTS

C.A.S. NO.

HAZARDOUS INGREDIENTS

C.A.S. NO.

Di-Methyl –di-sulphide PHYSICAL AND CHEMICAL DATA Boiling Point/ Range oC

109.7

Melting/ Freezing Point oC Vapour Density (Air = 1)

3.24

Physical State

liquid

Appearance

Vapour pressure @ 35 oC, mm Hg

Odour

Solubility in water @ 30 oC

Solubility in others

CCRU OPERATING MANUAL PART-H

Highly odourou s

MISC-12- 14

Specific 1.0569 pH Gravity (Water = 1) FIRE AND EXPLOSION HAZARD DATA Flammability Moderat LEL (%V) e TDG UEL (%V) Flammability 3

Flash Point (OC) oC Flash Point, (CC) oC

Auto ignition Temperature oC Explosion Sensitivity to Impact Explosion Sensitivity to Static Electricity SO2, CO Hazardous Combustion products

Does not occur

Hazardous Polymerization Combustible Yes Explosive Liquid Material Flammable Yes Oxidiser Material Pyrophoric No Organic Material Peroxide REACTIVITY DATA Chemical Stability Stable Incompatibility with other material Reactivity

No No

Corrrosive Material Others

No

Oxydising materials

Hazardous Reaction Products HEALTH HAZARD DATA Routes of Entry Effects of Exposure/ Symptoms

Emergency Treatment

May cause hemolytic anemia. It also produces allergic dermatitis. Remove victim to fresh air. Remove contaminated clothing and wash affected part with soap and water. In case of eye contact flush with copious amount of water.

CCRU OPERATING MANUAL PART-H

MISC-12- 15

LD50 (Oral-Rat), mg/kg

LD50 , mg/kg

Permissible mg/kg Exposure Limit ppm

Odor Threshold, ppm

TLV (ACGIH) ppm

STEL, ppm

mg/kg

mg/kg

mg/kg

NFPA Hazard Signals

Health

PREVENTIVE MEASURES Personal Protective

Flammability

Reactivity/Stabilit y

Special

Splash proof goggles, rubber gloves and rubber boots.

Handling and Storage Precautions EMERGENCY AND FIRST AID MEASURES FIRE Fire Extinguishing Foam, CO2, DCP, Water spray Media Special Procedure Unusual Hazards EXPOSUR E

First Aid Measures

Remove victim to fresh air. Remove contaminated clothing and wash affected part with soap and water. In case of eye contact flush with copious amount of water.

Antidotes/ Dosage SPILLS

Steps to be taken

Waste Disposal Method ADDITIONAL INFORMATION/ REFERENCES MANUFACTURER/ SUPPLIERS DATA Name of firm : Mailing Address :

CCRU OPERATING MANUAL PART-H

12.5 TRISODIUM TRIPHOSPHATE:

MISC-12- 16

CHEMICAL IDENTITY Chemical Name: Tri Sodium Orthophosphate Chemical Classification : Inorganic compound Synonyms: Sodium Phosphate Trade Name: Sodium Phosphate Formula: Na3PO4.12H2O UN. NO. NA9148 Regulated Identification

C.A.S.NO.

Shipping Name : Sodium Phosphate Codes/Label

:

Hazardous waste I.D. No: Hazchem Code : HAZARDOUS INGREDIENTS C.A.S.NO. INGREDIENTS C.A.S.NO.

HAZARDOUS

1. Tri Sodium Orthophosphate PHYSICAL AND CHEMICAL DATA Boiling Point/Range oC Decomposes : 73 – 77 oC Physical State : Solid Appearance : Colourless Melting / Freezing Odour: Odourless Point

o

C

Vapour pressure @ 35 oC

mm Hg

________________________________________________________________ __________________________________ Solubility in water @ 15 oC

Vapour Density Others: (Air = 1)

28.3 g/100 ml

CCRU OPERATING MANUAL PART-H

MISC-12- 17

Specific Gravity pH: (Water = 1)

1.062 at 20oC

FIRE AND EXPLOSION HAZARD DATA Flammability Not flammable o C (OC) TDG Flammability o C (CC) Autoignition Temperature oC

LEL

Flash Point

UEL

Flash Point

Explosion Sensitivity to Impact Explosion Sensitivity to Static Electricity Hazardous Combustion products Hazardous Polymerization Combustible Liquid : No Corrosive Material : No Flammable Material : Others: Nil

Explosive Material :

No

Pyrophoric Material REACTIVITY DATA Chemical Stability

No

Oxidiser

No

Organic Peroxide

No No

Stable.

Incompatibility with Other material Reactivity

Reacts violently with magnesium.

Hazardous Reaction POx fumes. Products

High temperature degradation gives off toxic

CCRU OPERATING MANUAL PART-H

HEALTH HAZARD DATA

MISC-12- 18

Routes of Entry Effects of Exposure/ Inhalation : Nose, eyes and throat irritation; sneezing, difficulty breathing, coughing.. Symptoms Ingestion: Burning sensation in mouth, pain in swallowing, stomach cramps. Contact: Skin – itching, burning sensation, inflammation; Eyes – Irritation and burning. MODERATELY TOXIC BY INGESTION AND INHALATION. Emergency Treatment: Obtain medical assistance. Inhalation: Remove victim to fresh air; give artificial respiration, if breathing has stopped. Give artificial respiration. If laboured, give oxygen. Ingestion : Give plenty of water to conscious victim to drink. Induce vomiting immediately. Contact : Remove contaminated clothing and flush immediately with plenty of water Eyes : Flush with water. L.D50 (Oral-Rat) 7400 mg/kg L.D 50 Permissible ppm mg/mg3 Exposure Limit TLV (ACGIH) ppm

ppm

ppm

mg/m 3

mg/m3

Odour Threshold

STEL

mg/m3

NFPA Hazard Signals Reactivity Special

Health

Flammability

PREVENTIVE MEASURES Personal Protective Rubber gloves/rubber boots. Safety goggles, face shields, dust mask. Self contained breathing Equipment apparatus in case of fires. Handling and Storage Precautions

CCRU OPERATING MANUAL

MISC-12- 19

PART-H

EMERGENCY AND FIRST AID MEASURES FIRE Fire Extinguishing Media : Most fire extinguishing medium may be

used in fire involving this chemical.

EXPOSURE First Aid Measures: Obtain medical assistance. Move victim to fresh air. If breathing has stopped, give artificial respiration. Give water to conscious victim to drink and induce vomiting. Remove contaminated clothing and flush immediately with plenty of water. Flush with plenty of water for eyes.

SPILLS Steps to be taken Waste Disposal Method ADDITIONAL INFORMATION/REFERENCES

MANUFACTURER/SUPPLIERS DATA Name of firm : Mailing Address : DISCLAIMER Information contained in this material safety data sheet is believed to be reliable but no representation, guarantee or warranties of any kind are made as to its accuracy, suitability for a particular application or results to be obtained from them.

CCRU OPERATING MANUAL

MISC-12- 20

PART-H

12.6 HYDROGEN CHEMICAL IDENTITY

HYDROGEN

Chemical Name Synonym s

Hydrogen

Chemical Classificatio n

Liquid Hydrogen, Para Hydrogen, Hydrogen (compressed)

Formula

H2

Regulated Identification

C.A.S. NO.

Inorganic Gas

Trade Name 1333-74-0

Hydrogen

UN NO.

Shipping Name

Hydrogen, Compressed gas

Codes/Label

Flammable Gas, Class 2

Hazardous waste I.D. No.

17

1049

2 SE Hazchem Code HAZARDOUS INGREDIENTS

C.A.S. NO.

1. Hydrogen

1333-74-0

HAZARDOUS INGREDIENTS

C.A.S. NO.

PHYSICAL AND CHEMICAL DATA Boiling Point/ Range oC

-252.8

Physical State

Gas

Appearance

-259.18

Vapour pressure @ 35 oC, mm Hg

N.A

Odour

Solubility in water @ 30 oC

Slightly soluble

Melting/ Freezing Point oC Vapour Density (Air = 1)

0.069

CCRU OPERATING MANUAL PART-H

Colourl ess Odourle ss

Solubility in others

MISC-12- 21

Specific 0.0899 pH Not Pertinent Gravity (Water = 1) FIRE AND EXPLOSION HAZARD DATA Flammability Yes LEL (%V) 4.1 Flash Point (OC) oC

NP

Flash Point, (CC) oC

NP

TDG 2 UEL (%V) Flammability Auto ignition Temperature oC 400 Explosion Sensitivity to Impact

74.2

Stable Explodes

Explosion Sensitivity to Static Electricity None Hazardous Combustion products

Does not occur

Hazardous Polymerization Combustible No Explosive Liquid Material Flammable Yes Oxidiser Material Pyrophoric No Organic Material Peroxide REACTIVITY DATA Chemical Stability

Yes No

Corrosive Material Others

No

No

Stable

Incompatibility with other material Reactivity

Reacts vigorously with oxidising materials (Bromine, Chlorine etc.) No chemical reaction with common materials but low temperature causes most materials to become very brittle. Violent reaction on ignition with air + catalyst (platinum etc.) Bromine, Iodine, Di-oxame + Nickel, Lithium, Nitrogen Tri-fluoride, Nickel + Oxygen, Oxygen Di-fluoride, Pet. + Isopropyl Alcohol

Hazardous Reaction Products It forms sensitive explosive mixtures with Bromine, Chlorine, Iodine Hepta-fluoride, Chlorine Dioxide.

CCRU OPERATING MANUAL PART-H

HEALTH HAZARD DATA

MISC-12- 22

Routes of Entry

Skin, Inhalation

Effects of Exposure/ Symptoms

If atmosphere does not contain enough oxygen, inhalation causes dizziness, unconsciousness or even death. Contact with eyes or skin or liquid H2 causes freezing similar to burn.

Emergency Treatment Inhalation

If victim is unconscious (due to deficiencies), move him to fresh air area. And apply resuscitation method. Eyes and skin : Treat for frostbite. Soak the skin in Lukewarm water. Seek medical aid. Not listed LD50 , mg/kg

Contact LD50 (Oral-Rat), mg/kg Permissible mg/kg Exposure Limit ppm

Odor Threshold, ppm

TLV (ACGIH) ppm

STEL, ppm

mg/kg

mg/kg

Odourle ss

mg/kg

NFPA Hazard Signals

Health 0

PREVENTIVE MEASURES Personal Protective Equipment

Handling and Storage Precautions

Flammability 4

Not listed

Reactivity/Stabilit y 0

Special

Avoid contact with liquid or gas Provide safety goggles, face shied, insulated gloves and long sleeves, trousers Worn over high top shoes to shed spilled liquid, selfcontained breathing apparatus containing air (never use oxygen). Store in a cool, fire-proof, with ventilated area, separated from other cylinders, preferably in open air.

CCRU OPERATING MANUAL PART-H

EMERGENCY AND FIRST AID MEASURES

MISC-12- 23

FIRE

EXPOSURE

Fire Extinguishing Media

Stop flow of gas, let fire burn under control.

Special Procedure

Keep the containers cool by spraying water if exposed to heat or flame.

Unusual Hazards

Flash back along vapour trail may occur.

First Aid Measures

Antidotes/ Dosage SPILLS

Steps to be taken Waste Disposal Method

Inhalation : If victim is unconscious (due to O2 deficiency), move him to fresh air area and apply resuscitation method. Eyes & Skin : Treat for frostbite, soak the skin in Lukewarm water. Seek medical aid. Not available Shut off leaks if without risk. Explosion hazard. To be burnt under control condition

ADDITIONAL INFORMATION/ REFERENCES Practically no toxicity, except that it is an asphyxiant. Highly dangerous fire and severe explosion hazard when exposed to heat and flame and oxidisers. Flammable and explosive when mixed with air, O 2, Cl2. Vigorous exothermic reactions with Benzene + Nickel Catalyst, metals (like Strontium, Potassium, Barium-above 300oC) ventilate at highest points.

MANUFACTURER/ SUPPLIERS DATA Name of firm : Mailing Address : DISCLAIMER Information contained in this material safety data sheet is believed to be reliable but no representation, guarantee or warranties of any kind are made as to its accuracy, suitability for a particular application or results to be obtained from them.

CCRU OPERATING MANUAL PART-H

MISC-12- 24

12.7 ANTI-POLYMERISATION AGENT (APA): KEROBIT BPD

CHEMICAL IDENTITY Chemical Name

Anti polymerization agent

Synonyms APA

Formula

Trade Name

KEROBIT BPD

N1N’-di-sec-butyl-p-phenylenediamine

Regulated Identification

Shipping Name

Kerobit BPD

Codes/Label Hazardous waste I.D. No. Hazchem Code

PHYSICAL AND CHEMICAL DATA Density (20 0.942 C) g/cm3 Physical State

Liquid

Viscosity (20 deg C)

30.9 mm2/s

Flash point

>100 deg C

Crystallisatio n point

14 deg C

Solubility in water @ 30 oC

Pour point