Reliance Industries Limited

Crude Complex Refinery Division Crude Distillers

Jamnagar

FOREWORD

Refinery complex in Jamnagar is the largest grass root refinery in the

world . This complex is well integrated / interconnected within the
refinery complex and with downstream petrochemical complexes . All
the units of the refinery have been commissioned smoothly with
envious success with the well formulated procedures laid down in
operating manuals .

Now it has become essential that all the learning from the past years of
operation & the various modifications carried is well documented to
make the present and future operation safer , efficient , reliable and
trouble free .

Procedures contained in this manual are updated version of the original

procedures where all the experiences gathered since commissioning
have been incorporated suitably. All the modifications carried out in the
past and the operational changes required on account of such
modifications have been incorporated suitably .

Date: S.S.Saini

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Operating Manual Issue : 02
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Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Amendment Control Sheet

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

List Of Manuals

Volume I : Operating Manual

Volume II : PFD,P&ID,Cause & Effect Diagram and Process Safeguarding

Flow schemes
Volume III : Precommisioning/Commisioning procedures Manual

Volume IV : Standard Operating procedures Manual

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Volume – I

Table of Contents
Sl NO Description Total Pages

Foreword
Amendment Control Sheet
List of Manual
Table of contents
Distribution List
Document and Data control
Glossary and Abbreviations

1. Introduction
Refinery and Petrochemical complex
Crude Distillers
2. Design Basis
Capacity
Material Balance of Crude and Vacuum units
Material balance of Saturated Gas concentration Unit
Turndown ratio
Feed/Product Specifications
Battery Limit conditions for Feed and product
3. Plant description
Brief process description

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Detailed process description

Process Variables
Desalter Operating Variables
Crude Column Operating Variables
Side cut product strippers
Vacuum Column operating variables
Process variable for Sat gas concentration unit
Simplified Flow diagram
Utilities description
Utilities specification and requirement
Auxiliary system
Storm water system
Flare system
Closed blow down system

Interconnectivity

Normal Operating Conditions and

Control

Normal Operating Conditions

Operation and Control Strategies

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Start Up Procedures

General
Notification to other departments/Start up Co-ordination
Pre start up/Start up activities
Start up Details
Normal Shut down

General
Notification to Other Departments
Details of Normal Shutdown

Emergency Procedures

Power Dip
Total Power failure
Cooling water failure
Steam load shedding
Total Steam Failure
Instrument air failure
Loss of feed from RTF
Crude Heater Failure
Vacuum Heater failure
Crude Column bottom pump failure

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Vacuum Column bottom pump failure

Crude Column Reflux pump failure
HVGO pump failure
Ejector condensate receiver water pump failure
Net gas compressor failure
Process control System failure

Special Operations

Desalter Desludging Operation

A-05 Bundle Isolation and Hand Over
Soot blowing operation
Online chemical cleaning procedure
De- greasing and passivation of Cooling water
exchangers APH water wash
Blinding
Shifting of S-08
Shifting of S-08 U/S of Desalter
Shifting of S-08 D/S of Desalter
Handing over /Taking over of S13/513 for cleaning
Handing over /Taking over of S14/514 for cleaning
Handing over /Taking over of S15/515 for cleaning

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Major Equipments

Desalters
Net Gas Compressor
Crude and Vacuum heater
General description
Detailed Description
Process Loop
Combustion Air/Flue gas loop
Burners
Fuel and Steam system
Special Control loops
Columns & Vessels
Vacuum Ejector system
Description
Utility requirement
Design condition
Start up of Ejector System
Shut down of Ejector system
Change over of Ejector system
Trouble shooting
Pumps & Turbines
Heat Exchangers
Sat Gas Concentration Unit Equipments
HP receiver
Primary absorber

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Sponge absorber
Lean gas Knock out drum
Stripper
Stabiliser

Instrumentation
DCS Description
Data flow
DCS Graphics
ESD System Graphics
Work Station Access
Alarm manger and Alarm displays
Alarm message contents
Scanning and data updation
HISTORIAN
AIM * HISTORIAN
Hard wired alarms

Trouble shooting
Desalter
Heater
Crude Column
Net gas Compressor
Ejector System
Centrifugal pump

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Positive displacement pump

Sat gas Con unit

Electrical System and Emergency power

requirement
Power distribution
Emergency power
U.P.S

Unit Safe guarding system

ROVs
Pressure relief valves
ESDs
Lock Open valves
SG for pumps
SG for Fin fan coolers
SG for Heaters

Catalyst and Chemicals

Laboratory Sampling
General
Testing methods

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Fire and Safety

Loss prevention and safety philosophy
Intro on HAZOP & HAZAN Analysis
Taming of Hazards
Fire Induction and fire fighting
Active fire protection
Different Fire fighting equipments
MSDS
Crude Oil
LPG
Naptha
Kerosene
Diesel
Vacuum Residue
Fuel Oil
Caustic

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Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Chapter – 1

Introduction

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

1. Introduction :

1.1 Reliance Refinery and Petrochemical Complex

Reliance’s Jamnagar manufacturing complex is the first fully integrated manufacturing

complex in the world to house a petroleum refinery complex, petrochemical complex, a
power generation complex, a port & terminal complex and pipeline network. The
refinery having processing capacity of 650,000 BPSD of Crude is the world’s largest
grass root refinery.

The site is located at latitude 22° 22' N, longitude 69° 51' E adjacent to the town of Jamnagar in
Gujarat State alongside the Gulf of Kutch approximately 480 km north of Bombay on India's West
Coast. The refinery site is located just to the south of the State Highway No.25 to Jamnagar. Total
area of this complex is 7500 acres..

This Refinery is basically intended to provide backward integration to Reliance’s own

petrochemical plants by producing feed stock for PX/ LAB/PP and other basic
petrochemical products like Benzene, Propylene etc. besides producing LPG / Diesel to
meet the ever-growing demand of these products in the country. Location of this grass root
refinery at Jamnagar in West Coast is basically to process crude oil supplied from Middle
East and to cater the maximum demand of petroleum products in Northwest India.

The Refinery complex besides having the primary processing units CDU/VDU, includes secondary
processing units like Fluidized Catalytic Cracker, Coker and a number of treating units like
Hydrotreaters, Sulfur Recovery plant to meet environment stipulation

Crude complex of the Refinery has two identical trains, each designed to process 325,000 BPSD of
Crude oil. All refinery process units except Coker, Hydrogen and Sulfur Recovery unit are designed
based on UOP technology. Coker is designed by Foster wheeler (USA), Hydrogen plant by Linde
(Germany) and Sulfur Recovery Unit by Pritchard (USA). Crude unit produces streams of LPG, Full

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

range Naphtha, Light and Heavy Kerosene, Diesel, Vacuum gas oil and Vacuum residue which are
sent either for further treatment/blending or for secondary processing. Each train of crude complex
consists of Crude distillation Unit (CDU/VDU-311/312), Saturate gas concentration unit (321/322),
Diesel hydrotreater unit (DHT-351/352), Vacuum gas Oil Hydrotreater unit (VGOHT-361/362).

1.2 Crude Distillers Unit :

The Crude Distillers units consists of two similar trains i.e Unit –311/321 & Unit –312/322 .Each
train is designed to process 325,000 BPSD of Crude oil. The design Crude blend is 48% Arab light
,32% Arab heavy and 20% Maya . However there is a flexibility to process verities of Crude blends.

The Crude Distillers consist Crude and Vacuum distillation units –311/312 and Sat gas
Concentration units –321/322.

The Crude Unit is the mother unit in any Petroleum Refinery. The feedstock for the Crude Unit is
Crude Oil.

Crude oil is received through the ships at SPM’s( Single Point Mooring ), off-loaded in Crude Tanks
at the Marine Tank farm (MTF)via the sub sea pipe line. Crude is transferred from MTF to RTF by
pipelines. The crude oil from the RTF crude tanks is then fed to the Crude Units by a combination
of the booster & main crude oil charge pump in the RTF area.

The Saturate Gas concentration unit also receives Unstabilized Naphtha and off gases from the
different Unionfining units and platformer unit as a feed.

The objectives of the Crude Distiller Units are to separate Crude Oil into various fractions as
given below:

 Off-gas which is used as refinery fuel/HMU feed(Hydrogen Manufacturing Unit) after

treatment in ATU (Amine Treating Unit).

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Crude Complex Refinery Division Crude Distillers
Jamnagar

 LPG which is a feedstock for LPG Merox Unit.

 Stabilized Full Range Naphtha which is the feedstock for the HNUU (i.e. Heavy Naphtha
Union fining Unit) of the Aromatics Complex for the production of PCN,PX, OX, Benzene
etc.

 Light & Heavy Kerosene which is a feedstock for LAB production, SKO or ATF Product or
Diesel blending component.

 Diesel which is feedstock for Diesel union finer or a component for diesel blending system.

 HAGO, LVGO & HVGO together form the feedstock for Vacuum Gas Oil union finer. VGO
Union finer in turn prepares the feedstock for FCCU.

 LVGO is also Diesel blending component depending on business needs

 Vacuum Residue which is a feedstock for DCU (Delayed Cocker Unit)

The Key features of the unit are as follows:

 The original Crude Distillers were designed based on UOP technology having capacity of 450
KBPSD ( 2x225 ).

 During the original design and engineering stage the unit capacity was de bottlenecked to 540
KBPSD ( 2x270 ).

 The Units were gradually de bottlenecked up to 590 KBPSD ( 2x295 ) by in house development.

 As a part of Quality & Yield Improvement ( QYI ) project the units were further de bottlenecked
to 650 KBPSD ( 2x325 ) based on Shell know how.

 The design Crude blend is 48% AL, 32%AH and 20% Maya as feed stock.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

 Two similar and independent trains ensure continuous operation of the refinery even if one
train is shutdown.

 Valve trays selected in atmospheric column and side strippers for low turn down
considerations. Potential for future revamps with packing to increase unit capacity. ( This has
already been accomplished for HAGO section during QYI ).

 Two parallel train of two stage desalters to reduce salt content from 43 PTB to less than 1 PTB.

 Highly heat integrated Crude Unit with Vacuum and Saturated gas concentration unit by
transfer of intermediate products at highest possible temperature between units.

 Two kerosene draw-off flexibility to meet changing market and product specifications (ATF,
Dual purpose Kerosene (DPK), SKO, LAB plant feed stock).

 Heavy atmospheric gas oil (HAGO) draw off minimizes load on Vacuum Heater & Vacuum
column.

 The original design envisaged total draw off trays (chimney trays) selected for all column side
draw-off streams, to facilitate measurement of internal refluxes and aid in advance process
control effort. However this facility was sacrificed for naphtha IR during QYI for reliability
purpose.

 Over flash facility provided in atmospheric and vacuum column as part of advance process
control. Over flash provides reflux to trays immediately above flash zone.

 Net Gas Compressor in the crude overhead system allows Crude column operation at lower
pressure (i.e. closer to atmospheric pressure), reduces overall energy and enhances LPG
recovery.

 Crude column diameter is 9.6 meter height is 62.7 meter. The column was having originally
multi pass valve trays. During revamp packed bed in HAGO section introduced replacing
previous 44 to 49 trays.

 Vacuum column is 11m Dia and 36.6m Height. The vacuum column consists of three zones
with structured packing above flash zone & 6 nos. sieve trays below flash zone acting as
stripper.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

 Two trains of two-cell fired charge heaters, two transfer’s lines from fired heater outlet to
Crude Column flash zone.

 Air preheaters in each fired heater to achieve the peak thermal efficiencies. Steam air heater
upstream of air preheaters to prevent sulfur condensation and associated corrosion in the cold
end of the air preheaters.

 Sponge Absorber and Primary Absorber in saturated gas concentration units to achieve >96%
recovery of C 3 /C 4 .

 Most modern low-pressure drop structured packings (Mellapak plus 252Y) for Vacuum Column
internals reduces load on fired heater , minimizes cracking / cocking tendencies in vacuum
heater passes and thereby reduces load on ejectors.

 Additional packing beds were provided to upgrade LVGO to diesel blend component.

 “DAMP” vacuum (i.e. condition between wet & dry vacuum) unit with minimum steam stripping
(25% of wet vacuum unit) combines advantages of both wet and dry technologies.

 In the Damp design, pre-condenser which is necessary on overhead vacuum system of a wet
design is dispensed with.

 However, provision for future conversion to “Deep Cut HVGO” is retained with damp vacuum
(not feasible with dry vacuum).

 In HVGO, metal contents is < 0.5 PPM is achieved by the efficient slop wax section,
this would avoid catalyst de-activation in VGO Union finer and FCCU.

 Superior MOC changes in 312 unit to process High Acid Crudes

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Chapter – 2

Design Basis

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

2.0 Design Basis :

2.1 Capacity :

The Crude Distiller Units are designed to process 650,000 BPSD Crude Oil. The Unit consists of
two similar trains Unit-311/321 and 312/322 each having capacity to process 325,000 BPSD
Crude oil.

The Sat Gas Concentration Units are designed to process feed generated based on 650,000 BPSD
of Crude processing and following quantities of external feed directed from various Hydrotreaters
and Platformer unit.

Stream TPH

Diesel HT off gases - 3.7

Diesel HT Naphtha - 16.0

VGO HT Off gases - 5.9

VGO HT Naphtha - 10

LNUU Off gases - 1.5

LNUU Liquid - 3.6

Platformer Off gases - 7.0

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

The units are designed to feed hot streams of FR Naphtha, Diesel, Vacuum Gas Oil & Vacuum
Residue to downstream Heavy Naphtha Unionfiner, Diesel Unionfiner, VGO Unionfiner & Delayed
Coker Unit respectively.

The provision has been made for cooling & storing FR Naphtha, Diesel, VGO & vacuum Residue
streams in intermediate storage tanks.

The LPG from Sat Gas Concentration Unit is cooled in a trim cooler & fed to Sat LPG Merox Unit
(U-331). The provision exists to route LPG to Unsat LPG Merox Unit (U-415) during Sat LPG Merox
Unit turnaround.

The Light Kerosene Stream from CDU/VDU exchanges heat with Crude and then further cooled in
fin-fan cooler / trim cooler & fed to Kerosene Merox Unit (U-341) or Superior Kerosene tankages.
The Provision also exist to route Light Kerosene to HSD pool or Diesel Hydrotreater.

The Heavy Kerosene Stream from CDU/VDU is cooled in finfan cooler and then routed to HSD pool.
The provision also exist to route Heavy Kerosene stream to SKO pool . Also the provision exist to
route Heavy Kerosene stream hot to Diesel HT.

The Lean gases from Sat Gas Concentration unit is fed to ATU .

The sour water from CDU/VDU is routed to WWSU in Sulfur Block.

The unit equipment are designed for a minimum temperature of 7.5 0C. All the fin fan coolers on
the rundown streams are designed for cooling the streams up to 55 0C (except for gas oil fin fan
0
cooler 311-A-07 which is designed for run down temperature of 80 C due to pour point
consideration & LP condensate return fin fan cooler A-09 designed for outlet temperature of 103
0
C).

All product trim coolers are designed for product stream rundown temperatures of 40 0C.

The pumps in critical services are provided with turbine drives i.e. RCO / VR / LP Flare KOD / HP
Flare KOD & Net Gas Compressor Lube Oil Pumps. The ram pump for flushing oil is having Steam
Engine Drive.

Each crude train is expected to require shutdown for maintenance after an operating period of 4 to
6 years.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

The expected duration of maintenance shutdown is 4 weeks.

At no time both the trains would be under turnaround to facilitate un interrupted operations of the
downstream units.

During Delayed Coker unit turnaround sufficient VR intermediate storage tankage has been

provided to allow one Crude Train to run at 100% capacity.

2.2 Unit Material Balance :

The material balance of the unit is given in the following table for 325,000 BPSD X 2 Design Crude
processing.

Feed Product
Flow Yields
Component Flow tons/hr Component
tons/hr wt%
Crude 1889.6 Lean Gas 13.6 0.70
Diesel HT Naphtha 16.0 LPG 27.3 1.40
Diesel HT Off gases 3.7 Naphtha 257.3 13.28
VGO HT Naphtha 10.0 LK 254.3 13.12
VGO HT Off gases 5.9 HK 30.0 1.54
LNUU liquid 3.6 Diesel 339.7 17.53
LNUU Off gases 1.5 HAGO 61.8 3.19
Platformer Off gases 7.0 LVGO 57.6 2.97
HVGO 400.4 20.66
VR 490.8 25.33
HC Oil from Vac 2.9 0.14
overhead
Off gases Vac Overhead 1.6 0.08

Total 1937.3 Total 1937.3 100

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

2.3 Turn Down Ratio :

The Crude Distiller Units were originally designed for 50% turn down ratio. The units thereafter
revamped for higher capacity , present turndown ratio is about 45 %

2.4 Feed and Product Specifications :

The Crude Distillers Units are designed based on following Crude blend:

Crude Percent Volume in Blend

Arab light - 48%

Arab Heavy - 32%

Maya - 20%

Crude TBP and Specific Gravity for the above Crude blend is as follow:
Specific gravity kg/m3 -0.8786
Degree API 29.5
TBP Degc
IBP -27
5%Vol 61
10%Vol 99
30%Vol 226
50%Vol 350
70%Vol 491
90%Vol 696
95%Vol 806
FBP 1214

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Crude Complex Refinery Division Crude Distillers
Jamnagar

In addition to above design Crude blend simulations for three Check cases Crude blends one light
and two heavy were been performed by the designer and stream tables have been generated.
Also Product cut point flexibility – Flexi cases in order to change product yields and
qualities to meet market requirement has been checked in design and flexibility provided to
vary TBP cut point of LK in the range of 245 –260 degc , HK TBP cut point in the range of
280-300 degc and Diesel-95% in the range of 360-370 degc.

However, in actual operations Crude blends will vary depending upon different scenarios following
Crude blend specification had been agreed upon.

Crude Feed Specifications:

Parameter UOM Specification Target Remark
1 Gravity API 27 to 32 27.5 Indicates light or heavy
Crude blend. Heavy
Crudes – difficulty in
desalter operations
2 Density gm/cc 0.86 to 0.895 -Do-
3 Sulfur Wt %, Max 2.7 2.3 Higher values increases
high temp sulfur
corrosion.
4 Total Salts PTB, Max 43 Higher values increases
conventional chloride
corrosions in Crude
overhead sections
5 Filterable Solids PPM,Max 100 Higher value increases
in Crude fouling of heat
exchangers
6 K. viscosity @ 40 CSt, Max 18 17 Higher value increases
o
C desalting difficulties
7 Potential H2S in PPM , Max 200 Increases H2s Health
Crude hazard
8 UOP K Max 11.78 11.68
9 TAN in unit 311 Mg KOH/g, Max 0.50 Higher value increases
Naphthenic acid corrosion
TAN in unit 312 Mg KOH/g, Max 1.50 -Do-

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Crude Complex Refinery Division Crude Distillers
Jamnagar

Parameter UOM Specification Target Remark

10 VGO Metal Ppm, Max 4.5 4.35 Affects VGO HT catalyst
(Ni+V) activity

11 % LPG Wt % 1.3 Overloads Crude column

overhead section
12 %LPG+Naphtha Wt% , Max 14.5 -Do-

113 % VR (565+) Wt % 27 25 VR evacuation limitations

Note : The above specifications are periodically reviewed jointly with CES/CTS/EPS and revised.
This revised specifications document is generally called as “ Crude Window ”. Please refer to ISO
document for the latest revision.

Product Specifications:

S.No. Product Parameter UOM Specification Remarks

1 Lean Gas %C3 Wt % 13
o
2 LPG Weathering C 2.0 Max.

H2S ppm (wt) 50000 Max,

3 Stabilised RVP Kpa 40 Max.

Naphtha o
Distillation C 165 FBP, Max.
o
4 LK ( ATF ) Flash point C 42 Min.

Sulfur Wt % 0.24 Max. or As

required by EPS
5 LK Color Sa.bt. +10 Min.
Product o
(SKO) Flash point C 38 Min.

Sulfur Wt % 0.27 Max. or as

required by EPS /
RTF
o
6 HK Flash point C 55 Min.
Product
(SKO) Color Sa.bt +10 Min.
o
Distillation C 300 FBP, Max.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

S.No. Product Parameter UOM Specification Remarks

7 Diesel Ex- o 95 %, Max. in
Distillation C 375
CDU R/D
Flash o
C 66 Min.
8 LVGO ASTM Distillation o
C 500 95 %, Max.
9 HVGO ASTM Distillation o
C 600 95 %, Max.
CCR % Wt % 1.2 Max.

Metals (Ni+V) Wt % 5.0 Max.

10 LVGO ASTM Distillation o
C 410 95 %, Max.
Diesel Grade
o
11 VR Flash point C 180 Min

Sodium ppm 20 Max.

o
12 Slop Wax Flash point C 150 Min.

Note : The above specifications are periodically reviewed jointly with Downstream units HOD /EPS
and revised. Please refer to ISO document for the latest revision.

2.5 Battery Limit Conditions :

Normal Normal Design Normal Design Remarks

Stream Flow pressure Pressure Temp. Temp.
Kg/hr Kg/cm2g Kg/cm2g 0
C 0
C
Crude from 1889583 32 43 25 80
Tankages
Phenolic stripped 74454 2.2 13.3 58 131
water from unit
441
Non-phenolic NNF 2.2 13.3 58 131
stripped water
from unit 441
Vent gas from 502 0.035 4.2 47 150
units
331&415
Net overhead NNF 4.87 8.9 52 143 Two

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Crude Complex Refinery Division Crude Distillers
Jamnagar

liquid phase
From unit 221
Off gas from 18100 14.8 21 55 150
units
231,351,361&47
1
Unstabilized 26000 15 29 52 150 Two phase
Naphtha from Alt. normal
Pr=2kg/cm
unionfining units 2

Stabilized NNF 8 37 21.5 65 Unit

Naphtha inventory
From tankage at start-
up
LPG from storage NNF 15 31 37 65 Unit
inventory
at start-
up
LK to unit Merox 254667 16.8 27.3 40 83
Kero to SKO 254667 16.8 27.3 40 83
tankage
Kero to LAB 254667 16.8 27.3 40 83
Feed stock
tankage
Desalter effluent 174189 4.2 11 55 80
To unit 763
H. K/Diesel to 388116 8.3 21.7 246 274
DHT
Stream Normal Normal Design Normal Design Remarks
Flow pressure Pressure Temp. Temp.
Kg/hr Kg/cm2g Kg/cm2g 0
C 0
C
HK/Diesel to 339749 5.5 21.7 55 200
unionfiner feed
tankage
HAGO/LVGO/ 462233 7.8 17.1 267 424
HVGO to unit
VGO

HAGO/LVGO/HV 462233 7.8 17.1 80 424

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Crude Complex Refinery Division Crude Distillers
Jamnagar

GO to unionfiner
feed tankage
Vacuum residue 491849 11.76 17.90 260 281
to Coker
Vacuum residue 491849 11.76 17.9 190 281
to tankage
Non-phenolic 51814 11 39 56 84
water to unit 414
Non-phenolic 35472 9 39 56 84
water to unit 441
Lean gas to unit 13699 8.7 16.3 50.2 70
ATU
Naphtha to unit 257333 6 16.3 146 190
HNUU
Naphtha to 257333 2.76 18.7 40 140
heavy Naphtha
Unionfiner feed
tankage
LPG to unit 331 27316 15.8 28.6 42 89
Heavy NNF 6.3 17.9 80 281
hydrocarbon to
heavy slop
tankage
Light NNF 4.2 15.6 40 150
hydrocarbon to
light straight run
slop tankage
LK/HK/Diesel to NNF 5.1 27.3 55 200
Diesel blending.

Note: NNF = Normally no flow

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Chapter – 3

Process Description

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Crude Complex Refinery Division Crude Distillers
Jamnagar

3.0 Process Description :

3.1 Brief Process Description:

[Refer Simplified Process Flow Diagram attached after this section.]

Crude oil is pumped from Refinery tank farm to the Crude Distillation units. Crude enters the unit at
25 degc temperature and 32-35 Kg/cm2g pressure. The Crude is then equally split and pre-heated
up to 140-150 degc temperature in two parallel heat-exchanger-trains before being routed to two
parallel trains of two-stage Desalter system. This heat exchangers train is called as Cold preheat
train.

The Desalter system is designed to remove 99% salt contained in the incoming crude. The Desalter
are the first line of defense against Hydrochloric Acid corrosion in the Crude column overhead
system. The desalter also removes the In organic sediments present in the suspension form in the
Crude and reduces fouling in the heat exchangers. The specialty Chemicals like De-emulsifier and
Wetting agents are added in the Desalter for effective performance.

The Desalted Crude flow is equally split and further pre-heated up to 170-180 degc temperature in
two parallel heat exchanger trains before flashed in Flash drum. This heat exchangers train is called
as Warm preheat train. The diluted Caustic solution is injected in the desalted crude for
suppressing hydrolysis of the carried salts. Also the Anti-foulants are added to reduce the fouling
rates of the heat exchangers.

In the Flash Drum water and lighter components of the Desalted Crude oil are flashed-off and
flashed vapors are routed directly to flash zone of Crude Column.

The Flashed Crude oil is pumped and further heated up to 250 degc temperature in two parallel
heat exchanger trains before fed to the Crude Heaters .This heat exchangers train is called as Hot
preheat train.
In Crude heaters it is further heated up to 380 –385 degc temperature before fed to the Flash zone
of Crude Distillation column. There are two Crude heaters each divided in two firing zones and

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common convection section. The Crude flow to each heater is split in to 10 separate passes. The
Crude heaters are fired on Fuel gas, Fuel oil or Combination of both.
The heated up Crude from Crude heaters gets fractionated in various cuts in Crude column at 1.2
Kg/cm2 g Pressure . The Crude column consists of total 43 Valve trays , One Packed bed section
and 6 stripping trays.
The Naphtha minus vapors leaves from Crude column top and are partially condensed in fin fan
coolers provided in Crude column overhead and routed to Crude column overhead receiver.
The Neutralizers like NH3 and/or Neutralizing amines are injected in Crude column overhead to
neutralize Hydrochloric acid. The corrosion inhibitor is also injected in overhead section for
protection against corrosion. The wash water is also injected to wash out resultant neutralization
salts. The sour water is separated in overhead receiver boot and routed to Non phenolic waste
water stripping unit.
The non condensed vapors are compressed to 3.5 Kg/Cm2 g pressure in Net Gas Compressor and
re contacted in fin fan coolers with condensed Naphtha and directed to Re Contact drum.
The one phase mixture of Naphtha minus vapors are pumped to HP receiver of the Sat Gas
concentration unit after cooling down to 40 degc in trim cooler. Also the off gases and un stabilized
Naphtha of the Hydrotreaters and Platformers are fed in HP receiver. The Pressure of the HP
receiver is maintained at 11-12 Kg/cm2 g.
The Naphtha minus vapors mixtures is then pumped to stripper where C1 , C2 and H2S are

stripped off . The stripped vapors passes through Primary Absorber and Sponge Absorber to
recover C3 + Components from the stream. After passing through Absorber section C3 minus
stream is Knocked down in Knockout drum and then is diverted as a Lean Gas stream to Amine
treating Unit. The Absorbers operates at 11-12 Kg/cm2 g pressure.
The Stripper bottom liquid is fed by pressure differential to Stabilizer to separate out LPG and
Naphtha.
The LPG from Stabilizer overhead is routed to Sat LPG Merox unit after cooling down to 40 degc in
a trim cooler.
The Stabilized Full range Naphtha from bottom of the Stabilizer is routed to Heavy Naphtha Union
Fining Unit after exchanging its heat to Stripper re boiler and Stripper feed exchanger at 100 Degc.
The Stabilizer pressure is maintained at 10.2 Kg/cm2 g.

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In the top section of Crude column the Naphtha stream collected on Naphtha partial draw off tray
is circulated through Crude preheat exchangers to maximize the heat recovery and off load Crude
column over head condensers.

The Light Kerosene cut collected on LK total draw off tray of Crude column is stripped in LK
stripper for Flash correction. The stripped LK is routed to SKO tankages / LK Merox Unit as per
requirement after recovering heat in Crude preheat exchanger and then cooling down in fin fan
cooler –trim cooler to 40 degc.
The Heavy Kerosene cut collected on HK total draw off tray of Crude column is stripped in HK
stripper for Flash correction and then routed to Diesel pool after cooling to 55 degc in fin fan
coolers.
The Diesel cut collected on Diesel total draw of tray is stripped in Diesel stripper for Flash
correction in Diesel stripper and then routed to Diesel Hydrotreaters.
The Heavy Atmospheric Gas Oil cut collected on HAGO total draw off tray is stripped in HAGO
stripper for Flash correction and then routed to VGO Hydrotreater.
The refluxes in different sections of Crude Column are provided by pumping down Part of the liquid
collected on draw off tray as a Internal reflux.
The part of the liquid collected on draw off trays are circulated through different Crude Preheat
exchangers or different re boilers to remove required amount of heat for the desired fractionation.
The left over Crude after fractionation in Crude column is called as Reduced Crude (RCO ) is
stripped out in Crude Column bottom by Superheated Low pressure steam to reduce Diesel
component in the RCO.
The RCO from Crude column bottom is pumped to Vacuum heater at 370 degc temp. The RCO is
further heated to 392 degc temp in Vacuum heater. The RCO flow to Vacuum heater is split in ten
equal passes. The Medium Pressure steam is introduced in each passes to increase velocities for
avoiding cracking of the RCO.
The RCO from vacuum heater is fed to Vacuum column for the separation of the different cuts
under 20mmHg A pressure. The Vacuum column consists of 4 Packed bed sections and 6 stripping
trays.
The three stage Steam ejectors and condensers are installed on Vacuum column overhead for
maintaining desired vacuum in the Vacuum Column.

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The cracked non condensable gases leaves the ejector hot well and are diverted to Crude heaters
as a Fuel.
The Cracked Condensable Hydrocarbon liquids are separated in Ejectors hot well from condensed
water and are routed to Diesel Union fining feed tank.
The Separated sour water is routed to Non Phenolic Waste Water Stripping Unit.
The Light Vacuum Gas Oil Cut is collected from LVGO total draw off tray and is routed to Vacuum
Gas Oil Hydro treating Unit. The Part of the liquid from the total draw off tray is cooled in Fin fan
coolers ,followed by a trim cooler and returned back to vacuum column top as a reflux.
The Heavy Vacuum Gas Oil cut is collected from HVGO total draw off tray and is routed to Vacuum
Gas Oil Hydro treating Unit. The Part of the liquid from the total draw off tray is circulated through
Crude preheat exchangers to remove required amount of heat and returned back to Vacuum
column on the top of HVGO section Packed bed.
Also the part of the liquid collected on HVGO tray is pumped down as a Internal Reflux to Slop wax
section.
The Slop wax collected on double decker tray of the Vacuum column is transferred to Slop wax
quench drum and then routed back to Vacuum heater. The recycle of the Slop wax to the Vacuum
heater maximizes the HVGO yield. Also the part of the liquid collected in Slop wax drum is
circulated to Crude preheat exchanger to quench the Slop wax drum to 330 degc temp to avoid
cocking up.
The left over Crude after fractionation in Vacuum column is called as Vacuum residue (VR). The VR
is stripped out with superheated Low pressure steam to reduce Gas oil contents in the VR.
The Stripped VR is routed to Coker unit after recovering heat in Crude preheat exchangers at 230
degc and Part of the VR is routed to VR tankages at 190 degc.
The Vacuum column bottom temp is controlled to maximum 360 Degc to avoid cocking by
quenching with cooled run down VR.

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3.2 Detailed Process Description:

3.2.1 Crude Receipt and Blending in Tank Farms :

The Crude oil from different sources are received in Ships and are unloaded in Marine Tank farms
through two SPM (Single Point Mooring System).

SPM is a system of a circular floating buoy secured by 6 anchors. Ships are tied and have freedom
of movement in all directions. Ship pumps through floating hoses attached to buoys and connected
to pipelines laid on seabed. The two SPM’s are separated by 3.1 KM and made at a distance of 15
KM from MTF. The SPM’s are designed to receive very large vessels carrying parcel of 250000MT
of Crude oil. The SPM’s are connected to MTF by two 48” pipelines which is capable to pump out at
12,000 MT/hr rate. The two SPM have been configured to maintain low demurrage cost even at the
30 MMTPA of Crude consumption and to have a backup in the case of non availability of one.

The EPS Mumbai group plans procurement and scheduling of different Crude based on Market
requirement, Units Operating Window and Economy of the operations by the help of PIMS (Process
Industries Modeling and Simulation) and MIP (Mix Integral Programming ) software.

The EPS Jamnagar group plans Crude blend based on the scheduling of different Crude and advises
MTF group for unloading in different tanks as per the properties of the particular Crude oil like API,
Viscosity , Total Sulfur content and Total Acid Numbers etc.

The MTF have total 12 tanks ( MT-MM811- 1 to 12) of capacity 123596 M3 each for the storage of
Crude oil. On the receipt of Crude the tanks are to be prepared for feeding to RTF by settling and
draining out free water. The tanks are normally allowed to settle for 24 hrs and then drained for
free water and sludge. The settling and draining the water normally takes about 48 hrs. After
completion of free water draining three side bottom mixers of the tanks are started to homogenize
the tank content. Once the mixers are started the tanks are ready for feeding to RTF.

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The High TAN Crude are normally stored in different tanks. As a standard all the Crude are required
to be settled and drained off for free water before feeding to RTF, but it has been allowed to
transfer unsettled if its impacting any ullage issue after consent of Crude operation group.

The EPS Jamnagar group plans Crude blends to be processed and issues Instruction for lining up
of different tanks ratios in the blend. ( A typical Crude Instruction sheet is given after this page)

As per EPS Crude Instruction MTF lines up different tanks at a specified ratios and starts pumping
to the RTF tanks MT-RW-611-01 & 02 through two 30” headers from MTF to RTF. The MTF have
10 pumps associated to different tanks of the capacity 1876 m3/hr each and two smaller pumps of
capacity 800 m3/hr. The smaller pumps have been added recently on to have the flexibility to
process if required very small quantities of tough / High Acid Crude in the blend.

The NMR (Nuclear Magnetic Resonance) spectroscopy analyzer is installed in MTF for predicting
different Physical and Chemical properties of the Crude blend pumped to the Units. The NMR
predicts API Gravity, Sulfur, Aromaticity and ASTM distillation with respect to Crude blending.
The predictions of the NMR analyzer are the inputs to the CBSS (Crude Blending Supervisory
System) automation package. The CBSS also have inputs of economy factors and Operating
windows. Based on these inputs CBSS varies tank ratios in the blend to have a consistent blend
stretched up to the maximum possible benefit levels.

The RTF receives Crude from header-1 in MT-611-01 and from header-2 in MT-611-02 Crude
intermediate storage tanks of capacity 72000 M3 each. The CTM (Custody Transfer Meters) are
installed in each header to measure the quantity received. The each CTM is having separate
densitometer to measure density of the Crude. As a standard practice CTM meters are proved
weekly for accuracy.
The flexibility exist to line up two more tanks MT-611-18 & 19 of capacity each 82000 M3 for Crude
receipt and feeding to units.
The Crude tanks in the RTF are equipped with two bottom side mixers which are kept on
continuously to homogenize the tank contents.

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The received Crude oil in the RTF Crude tanks are pumped to Crude Distiller –1 & 2 by the
combination of Booster and Charge Pumps. There are four booster pumps ( P01 A/B/C/G for Crude-
1 and P01 D/E/F/H for Crude-2) of capacity 857 M3/hr each takes suction from respective tanks
and are capable of developing pressure up to 7-8 Kg/cm2 g. There are four charge pumps ( P04
A/B/C/G for Crude-1 and P04 D/E/F/H for Crude-2) of capacity 857 M3/hr each takes suction from
respective booster pumps and are capable of developing pressure up to 40 Kg/cm2 g. The normal
discharge pressure of the pumps remain about 30 to 34 kg/cm2 g based on pumping rate. There is
a spill back flow control valve which protects the pump against the operation below minimum
stable flow. Normally the Crude from Tank-01 is fed to Crude Distiller-1 and Crude from Tank-02 is
fed to Crude Distiller-2.
The above set up of different headers and pumping system provides very much required flexibility
to process different Crude blends in Crude Distiller-1 and 2.

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3.2.2 Crude Preheating and Desalting :

The Crude oil is the name applied to degassed raw petroleum that has been removed from the
ground. Crude oil is believed to be a product of the decomposition of the certain type of plant or
animal and is an organic substance. All organic compounds are composed of hydrogen and carbon
and have general name hydrocarbon. Based on the general molecular structure hydrocarbon are
divided in four classes Paraffin, Olefin, Naphthene and Aromatic. In addition to these hydrocarbon
Crude oil contains a small amount of materials which are classified as impurities with respect to
Crude Refining. These impurities are listed below:
1. Salts – These are predominantly chloride salts such as Sodium Chloride , Magnesium
Chloride and Calcium Chloride. These salts may break up chemically at the temperatures of
Crude refining to form acids and corrode the steel in the top and overhead section of the
Crude column. Practically all Crude oil contain salt water together with sediment depending
upon the area from which Crude is produced as well as the manner it is handled prior to
the time it reaches to Refinery storage tanks. The salt content is normally reported as
Pounds of Salt per thousand barrels of oil ( PTB ). The salt is normally measured as Sodium
chloride.
2. Sulfur Compounds –Sulfur compounds comprises the largest portion of the impurities found
in the Crude oil. If the sulfur content of the Crude is high it is called a “Sour Crude”. The
number and type of sulfur compound found in the Crude is numerous. The lightest sulfur
compound is Hydrogen Sulfide ( H2S ) which along with being very corrosive is also a
deadly gas. Utmost care is to be taken while handling the Crude having high potential of
H2S. The other Sulfur compounds presence in the Crude oil are Mercaptans , Thiophene ,
Sulfide and Disulfide.
3. Metals – The common metal found in the Crude oil are Arsenic, Lead , Vanadium , Nickel
and Iron. Most of the metals in the Crude oil will exit the unit through Vacuum Residue.
Arsenic and Lead are the bad poisons to the Catalytic reforming catalyst while the
Vanadium , Nickel and Iron will deactivate Catalytic cracking catalysts.
4. Sand and Water – These compounds are in suspension in the Crude oil and are normally
reported as “ Base Sediment and Water ” (BS&W). The numbers will normally be less than
0.5 wt% of the total Crude. These sediments leads to fouling in the heat exchangers.
Out of the impurities listed above Salt and BS&W are removed by Desalting before performing
Crude Distillation.
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The Crude received at the Battery Limit of the Crude Distiller Unit is required to be preheated from
25 degc to 145-150 degc temperature to reduce the Crude Viscosity for efficient desalting
operation. Also this preheating helps to maximize heat recovery from the low temperature streams.
The Crude Flow from the battery limit is split equally in two parallel trains of exchangers. The One
stream enters shell side of S01 A/B exchanger and other stream enters to shell side of S04 A/B
exchangers. The distribution of flow will vary based on the pressure drop across the entire
exchanger train. The equal distribution is ensured by providing split range ratio controller FIC 091 A
& B which governs opening of the FV091A/B control valves. One of the Control valve out of FV-91
A/B will be wide open (of the exchanger train which exerts more pressure drop) and other’s
opening will get adjusted to maintain same flow as of other train. The low and high flow values will
be alarmed by FAL/FAH-091A and FAL/FAH-091B.
The Crude is preheated in S01 A/B and S04 A/B by circulating Naphtha drawn from the Crude
column Naphtha accumulator tray through tube sides of S01 and S04.The Naphtha flow to S01 and
S04 is controlled by FIC-006 and FIC-007. The Naphtha outlet stream from these exchangers is
routed back on Crude column top tray. The flow of the Naphtha through these exchangers are
always maximized to maximize the heat recovery.
The PSV’s 451 A/B/C and 452 A/B/C are provided on Crude side outlet’s of these exchangers for
safeguarding.
The provision exist for Isolating/ Bypassing S01 A/B and S04 A/B for maintenance job during
normal operation of the unit.
The Crude outlet stream from S01A/B shell side enters the shell side of S02 where it is preheated
by Circulating Heavy kerosene stream on tube side. The heavy kerosene stream returns back to
Crude column.
The Crude outlet stream from S04 A/B shell side enters the shell side of S05 A/B where it is
preheated by Light Kerosene Product rundown stream.
The provision exist for Isolating/ Bypassing S05 A/B for maintenance job during normal operation
of the unit.
The Crude outlet stream from S02 shell side is further split in two streams. One stream enters
tube side of exchanger S25 A/B where it picks up heat from rundown Vacuum residue stream. The
Crude flow to S25 is controlled by FIC-453. The other stream enters the shell side of exchanger
S03. The flow of Crude to S03 is regulated by PDV-607 which controls delta P across S02 Crude
outlet and S03 Crude outlet and measured by FI-452.The Crude is preheated in S03 by Medium
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Pressure Steam on the tube side. The generated condensate stream is routed to MP condensate
header on Flow control FIC-008.The Crude outlet from S25 and S03 recombines again.
The S25 exchanger was added in the QYI project to reduce VR rundown temperature to VR tanks
to 190 degc and to maximize the Crude preheat temperatures.
The Crude outlet from S05 A/B enters the shell side of S08B where it gets preheated by circulating
Diesel stream on tube side leaving S08A. The Crude outlet from S08B recombines to common
outlet line of S03/S25 and routed to Desalter at about 145-150 degc temperature.
As per original design of 450 KBPSD for the AL/AH Crude the designed desalter temp was 130
degc. The processing of heavy Crude need higher desalting temp about 145-150 degc and hence to
have a flexibility to process heavy Crude the flexibility to shift S08 A/B in the Cold preheat train
was added. But subsequently it was observed that the entire shift of S08A/B was shifting more heat
duty to cold preheat train leading to under utilization of S03 and reduction in net Crude preheat.
Based on these inputs in Crude Distiller-2 the split of S08 A and B was carried out in QYI-2
shutdown to post S08B in cold preheat train and A in the Warm preheat train. The flexibility to shift
entire S08A/B to Cold or warm preheat train is also retained. The same configuration will be carried
out in Crude Distiller-1 in next turnaround.
The following table explains temperature profile of crude in Cold preheat train for the design case
operation.
SR.NO Stream Temperature Degc
01. Crude at B/L 25
02. Crude outlet from S01A/B 74
03. Crude outlet from S04 A/B 74
04. Crude outlet from S02 80
05. Crude outlet from S25 112
06. Crude outlet from S03 145
07. Combine stream of S03 & S25 128
08. Crude outlet from S05 A/B 112
09. Crude outlet from S08B 175
10. Combined stream going to Desalter 152

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The preheated Crude up to 145-150 degc temperature in Cold preheat train is routed to Desalter
for desalting.

The salts present in the Crude oil are normally in the form of highly concentrated brine droplets
dispersed throughout the Crude. These droplets are extremely small and widely dispersed. It is
impossible or uneconomical to remove it by ordinary gravity settling. The Crude oil also contains
varying amount of solid materials such as Slit, Iron oxides , Sand and Crystalline salts etc.

The desalting process is divided in two steps –

1. Emulsification of Fresh water with the Crude Oil

2. De emulsification of Crude-Water emulsion

In the first step Fresh water is injected in the Crude oil and emulsified to disperse the water
throughout the Crude and obtain intimate contact with the brine droplets. The dispersed fresh
water in Crude dilutes brine and reduces concentration of the salts present. The Crude and water is
emulsified by passing through Mixing valve and Static mixture. The degree of mixing will depend on
pressure drop across mixing valve. Higher the pressure drop, higher will be the degree of mixing.
In the second step the Crude-water emulsion is passed through a high voltage electric field
maintained between the pairs of metal electrodes in the Desalter. The electric forces causes water
droplets to coalesce with each other to form a larger droplets. The larger droplets have sufficient
mass to fall through the oil phase to the water phase maintained at the bottom of the vessel.
The coalescence effect is expressed by the formula –
F = K E2 a6 / d4
Where
F = Attractive force between two water droplets a = Diameter of the droplet E = Voltage
K = Proportional factor d = Distance between two water droplets

The rate of settling of water droplets can be expressed by the Stokes Law formula as follow –
V = K a2 ( D1 – D2 ) g / Z
Where
V = superficial velocity of falling water droplets a = Diameter of the water droplets
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D1 = Density of water at desalting temp D2 = Density of Crude at desalting temp

Z = Viscosity of the Crude g = Gravitational constant K = Proportional factor
The water concentrated in salts normally called brine leaves the Desalter from bottom. A liquid
level controller controls the interphase level.
After flowing through the electrodes, the Desalted Crude flows upwards and leaves from top of the
Desalter.
The salt content in desalted Crude is analyzed to work out desalting efficiency. The water content
in the desalted Crude is also analyzed to work out De hydration efficiency.
The desalting efficiency achieved by single stage desalting is about 90 %. To increase the desalting
efficiency up to 99% normally two stage desalting system are installed, where Crude and Water
moves in counter current manner.
The dehydration efficiencies are normally maximized by addition of De emulsifier in the Crude. The
de emulsifier is required to be dispersed well in the Crude before it enters the Desalter. The de
emulsifier is added at Crude battery limit.
The Crude Distillers –1 & 2 were having two stage desalting system for 450 KBPSD operation
supplied by M/S Petrolite. The Desalter V02 is the First stage Desalter and V02 is the second stage
Desalter.
One more two stage desalting system parallel to V02-V03 supplied by M/S How Baker was added
subsequently during revamp of units for 590 KBPSD operation. The Desalter V33 is the first stage
Desalter and V34 is the second stage Desalter.
The preheated Crude is normally split in the ratio of 40:60 for desalting in V02/V03 and V33/V34.
The Crude flow to V33 is measured by FT-802A and the flow towards V02 is computed based on
FI005 Crude B/L flow after temperature compensation. The flow split to V02 and V33 is controlled
by ratio controller by governing outputs of FV-802 A installed in V34 Crude outlet line and FV802B
installed in V03 Crude outlet line.
The water requirement for desalting is managed by following four sources –
1. Phenolic water
2. Non Phenolic water
3. Cold condensate
4. LP condensate

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The Phenolic water is received from Phenolic waste water stripping unit and the flow to V01 is
controlled by FV019.
The Cold condensate is received from Utilities and the flow to V01 is controlled by FV-018.
The Non phenolic water is received from Non-phenolic waste water stripping unit and the flow to
V01 is controlled by FV020.
The level controller of V01 LIC004 is cascaded with FV018 or FV20 for level control of V01.
The provision to use LP condensate as a desalting water is being done under PCO.
To avoid phenols release to atmosphere from V01 on the account of use of phenolic water the vent
line of the V01 is connected to Crude column overhead receiver V12.

The water received in V01 is pumped by P02 A/B/C/D pumps to Crude Inlet lines of second stage
desalters V03 and V34 after preheating water from 60 degc to about 90 degc in S07 and S27
respectively. The fresh water flows through shell side of the exchangers and picks up the heat from
the brine leaving the first stage desalters V02 and V33. The preheating is required to avoid
quenching of Crude in the desalters as V01 water temp is only about 60 degc. This also helps in
recovering heat from outgoing brine and to offload the brine coolers. Flow of the wash water to
V03 is controlled by FIC016 and to V34 is controlled by FIC808. Wash water ratio controllers are
also provided to adjust wash water flows based on variations in Crude flow to desalters. Normally
wash water rates are kept around 5-7%vol based on Crude flow.

The provision exist to route part of wash water after preheating in S07 A/B to Crude inlet line to
S01A/B and S04A/B in case of requirement during processing of high salt content Crude.
The provision also exist to route part of the P02 discharge water to A05 Crude column overhead
condensers for regular wash water requirement.
Based on expansion projects to meet the increased requirements of water P02D pump were added
and the motors of P02 A/B/C were resized. Also two new pumps P36 A/B were added to V01 for
supplying wash water to A05.

The water from second stage desalters V03 and V34 are pumped to Crude Inlet line of first stage
desalters V02 and V33 by P03 A/B/C and P40 A/B pumps respectively on the interphase level
control of V03 and V34. The V03 interphase level is controlled by LIC002 and V34 level is controlled
by LIC805A.
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Crude Complex Refinery Division Crude Distillers
Jamnagar

The Crude and water mixture is passed through PDV100 and PDV808 for V02 and V33 respectively
for emulsifying Crude and water. The pressure drop across up stream and downstream of these
PDV’s are measured and adjusted for the required degree of mixing depending upon desalting
efficiency. The emulsified Crude and water is fed to V02 and V33 from bottom through distributor
header inside the desalter just below the electric grid.
The electrostatic field in the V02/V03 is generated by applying high voltages to grids installed
inside the desalters. The high voltages is applied by the single step up transformer of 120KVA for
each desalter. The voltage level can be varied at three levels 16000, 17600 and 19200 volts as per
the requirements.
The electrostatic field in V33 /V34 is generated by applying high voltages to grids installed inside
the desalters. The high voltages is applied by the three step up transformers of 200KVA for each
desalter. The voltage level can be varied at three levels 12000,16000,20000 volts as per the
requirement.
For changing the voltage tap level transformer is required to be switched off.
The de emulsifier required for enhancing Crude water separation is injected at the Crude line at
the B/L for proper dispersement by the three metering pump P34 A/B/C. The facility to inject de
emulsifier near to desalters is also exist. The normal dosage level of de emulsifier is about 3-5 wt
ppm of Crude.
The Crude water emulsion passes vertically through electric grids and water oil separation takes
place.
The dehydrated Crude leaves V02 and V33 from top through collector header and proceeds for the
second stage desalting in V03 and V34. The fresh desalting water is injected in the Crude outlet
lines from V02 and V33 by flow controllers FIC016 and FIC808 respectively. The Crude and water
mixture is again passed through PDV101 and PDV809 for V03 and V34 respectively for emulsifying
Crude and water. The pressure drop across up stream and downstream of these PDV’s are
measured and adjusted for the required degree of mixing depending upon desalting efficiency. The
emulsified Crude and water is fed to V03 and V34 from bottom through distributor header inside
the desalter just below the electric grid.
The electrostatic field in the V03/V34 is generated by applying high voltages to grids installed
inside the desalters. The Crude water emulsion passes vertically through electric grids and water
oil separation takes place. The dehydrated Crude leaves V03 and V34 from top through collector

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Crude Complex Refinery Division Crude Distillers
Jamnagar

header and recombines after individual flow control valves FV802A and B for further preheating
warm preheat train.
The salt concentrated water normally called as brine accumulated in V02 and V33 bottom is
withdrawn and transferred to ETP (Effluent Treatment Plant) on interphase level control after
recovering maximum possible heat in S07 and S27 and then cooling in fin fan coolers A02-A12
followed by trim cooler (Plate type) Y08 at < 60 degc temperature. The V02 level is controlled by
LIC001 and of V33 by LIC804A. The transfer of brine to ETP is on pressure difference. The
provision exist to route A02/12 out let to heavy slop header in case of pumping out of the desalters
in shutdown or during high oil carry over along with brine.
The fin fan cooler A12 and trim cooler Y08 was added later on as per the expansion need to
maintain brine temperature <60 degc.
The brine PH varies from acidic to alkaline range depending upon the Crude processed. To protect
the brine transfer line against the acid attack the brine PH is maintained in the range of 5.5 to 6.5
by addition of diluted Caustic solution to P03/P40 suction by the help of dozing pumps P37/38.The
corrosion probe is also provided at the outlet of Y08 to monitor the corrosion rate.
Maintaining the proper interphase level in the desalters is of utmost important to avoid sudden
carry over of water along with Crude and of Crude along with brine. Sudden drastic increment in
water carry over from desalter is termed as “ Water Shot” . The sever water shot will suddenly
increase the flash drum pressure and Crude column prssure. There also the possibility exist for
blowing off of the Crude column internals. Also during water shot desalter Amperages will increase
and voltages will drop down. The desalters are provided with additional High interphase level
switch which will generate high and high high interphase level alarm and will trip the transformer of
the desalter in case of attaining high high value to prtotect the transformer. The obvious action in
case of sever water shot is to stop the Wash water to desalter.
In the same line oil slippage along with brine is termed as oil under carry over and is serious
concern for the operation of the Effluent treatment plant. The desalters are provided with
additional low interphase level switch which will generate low and low low interphase level alarm
and will close the Automatic operated Isolation valve ( XV) provided in the brine circuit before
entering to fin fan coolers.
To counter check the desalter water level physically, 5nos try lines are provided. Normally bottom
two lines should have clear water, middle one should have mixture of crude and water, and top
two lines should have crude.
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Crude Complex Refinery Division Crude Distillers
Jamnagar

Apart from desalting desalter also removes majority of the solids carried along with Crude. The de
emusifier and wetting agents helps to keep these solids in the water phase and are normally
discarded through brine. Some of the solids settles down in the bottom portion of the desalter and
are required to be removed regularly by desludging operation. In the desludgging operation the
water is jetted separately towards the bottom walls of the desalters by separate nozzles provided in
the desalters. The desludgging operation for each desalter is carried out normally once in a day. If
the brine contains lots of solids the frequency of the desludgging operation is required to be
increased to avoid any built of solids in the desalter. Excessive built of solids in the desalters will
affect the oil water separation and may call for the outage of desalter. In every turn around
desalters are opened up and sludge is removed manually.
The desalters performance are normally monitored and controlled to achieve following targets-
1. Salts in V03/V34 outlet Crude < 0.8 PTB
2. BS&W in V03/V34 outlet Crude < 0.5 %
3. Solid removal efficiency > 85%
4. Brine PH- 5.5 to 6.5

Addition to above Chloride levels in the Crude column overhead receiver V12 boot water is also
monitored and are targeted < 20 ppm.
The diluted Caustic solution is injected normally in the range of 3 to 4 PPM of Crude to neutralize
liberated HCL in the down stream circuits of the desalters. The Caustic solution of 3.0 wt% is
prepared in the tank V-31 and is pumped by P37/38 pumps and injected through quill to slip
stream taken out from desalted Crude line . The Caustic added is mixed thoroughly by passing the
slip stream through static mixer and is then pumped by P48 pumps and is injected through quills
to Crude entering S09 and S11. The rate of Caustic injection is varied based on the V12 boot water
Chloride levels.
The target is always to achieve V12 Chloride less then 20 PPM without injection of caustic to avoid
fouling issues arising out of Caustic injection. The Sodium levels in the Vacuum residue stream are
also monitored and controlled less then 20 ppm to protect Coker furnaces tubes against Na
imbrittlement .
The Agar probes system have been installed in the desalter later on to stretch the desalters
performance up to maximum possible levels and to optimize de emulsifier dozing rates.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

The principle of operation of the Agar probe is absorption of the microwave energy. The water
absorbs much more energy than oil. The Agar system uses this fact to measure water/oil ratio in
the range of 0-100%. The transmitters sends through the probe body a 1-watt electromagnetic
signal to the antenna which it radiates. The amount of electromagnetic energy absorbed is directly
proportional to the concentration of water surrounding the antenna. When the antenna is
surrounded by dry Crude the absorption is minimum and transmitter output is 4 mA. On the
contrary when the antenna is surrounded by water absorption is maximum and transmitter output
is 20 mA. The 4 mA represents 0% water in the oil and 20 mA represents 100% water.
The desalters V33/V34 are equipped with 3 Agar probes located one in oil phase , one in water
phase and one in interphase. The interphase Agar probe controls the interphase level of these
desalters. The Agar probe placed in oil phase indicates water carry over along with Crude and Agar
probe placed in Water phase indicates oil or solids in the water phase.
The desalters V02/V03 are equipped with 2 Agar probes located one in oil phase and one in water
phase.
The provisions are available to isolate and bypass any desalter as per the requirement.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

3.2.3 Warm Preheating and Flashing :

The Desalted crude from V03 & V34 is split in two trains of exchanger to further preheat Crude up
to 170degc temperature and then to flash the Crude from 21.0 kg/cm2 a pressure to 6.0 Kg/cm2 a
pressure in the Flash drum. The flashing of Crude results in about 3 wt% vaporization of water and
lighter hydrocarbons of Crude feed to the flash drum. The flashed vapors are directed to Flash zone
of Crude column. This off loads Crude heaters and eliminates vaporization in heater coils. The
preheating before flashing the Crude in the Flash drum is required to maximize the vaporization of
lighters.
In the one train the Desalted Crude is heated in the shell sides of S08A with the circulating Diesel
stream leaving Stabilizer re boilers on the tube side. The Crude outlet from S08A enters the tube
side of S09 where it is heated up by HAGO circulating stream leaving S14/514 on the shell side.
The Crude outlet from S09 enters the Tube side of S10 where it is heated up by VR rundown
stream leaving S15/515. The crude outlet from S10 is fed to flash drum through flow control valve
FV022. The flow through this train is measured by FE022 installed at Crude inlet to S09 and
controlled by FV022.
In the other train the Crude enters the shell side of S11A/B where it is heated by circulating Heavy
Kerosene stream on the tube side. The Crude outlet from S11 A/B enters tube side of S12 A/B and
C/D where it is heated up by circulating HVGO stream. The crude outlet from S12 A/B and C/D
recombines and fed to flash drum through flow control valve FV021. The flow through this train is
measured by FE021 installed at Crude inlet line to S11 and controlled by FV021. The temperature
profile of the warm preheat train is given in the following table.
SR.NO Stream Temperature Deg
01. Crude outlet from Desalters 145
02. Crude outlet from S08A
03. Crude outlet from S09
04. Crude outlet from S10
05. Crude outlet from S11
06. Crude outlet from S12A/B/C/D
07. Flash Drum bottom temperature 169

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

The Crude from FV021 and 22 are fed to flash drum through two different nozzles via special feed
distributors schoepentoetor.
The flow through the down stream piping of FV21 and FV22 are two phase and vibrations in the
area are required to be monitored.
The liquid level in the flash drum is maintained around 50% by the level controller LIC005 which is
cascaded with FIC021 and 22.
The flash drum pressure is controlled by PIC002 by governing the output of pressure control valve
PV002 located in the vapor outlet line going to Crude column flash zone. The opening of PV02 is
normally tracked to judge the water carry over from the desalters. The sudden increase in the
controller output must be addressed immediately.
The two PSV 127 A/B are installed on flash drum for safeguarding against the over pressurization.
The out let line of PSV joins the down stream line of PV002. Subsequently the header is divided in
two sub headers and enters the Crude column flash zone separately. This change was carried out
to resize the vapor outlet line as per expansion need.

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Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

3.2.4 Hot Preheating and Final heating in the Crude Furnaces:

The flashed Crude form the flash drum is pumped by P04A/B/C pumps and is split in the two trains
of exchangers for further heating it up to 250 degc temperature before feeding to Crude furnaces.
In the one train the flashed Crude enters tube side of S13A/B exchanger where it is heated up by
circulating HVGO stream on shell side coming from the discharge of the HVGO circulating pump
P20 A/B. The Crude outlet from S13A/B enters the tube side of S14A/B where it is heated up by
circulating HAGO stream on shell side leaving exchangers S16/S18. The Crude outlet from S14 A/B
enters the tube side of S28 where it is heated up of circulating slop wax stream on the shell side
coming from discharge of slopwax pumps P19A/B. The Crude outlet from S28 enters the tube side
of S15 where it is heated up by VR rundown stream on shell side coming from discharge of VR
pumps P18 A/B. The heated Crude up to 260 degc from S15 outlet is fed to Crude furnace F01 for
final heating up.
In the other train the flashed Crude enters the tube side of S513A/B exchangers where it is heated
up by Circulating HVGO stream on shell side coming from the discharge of the HVGO circulating
pump P20 A/B. The Crude outlet from S513 enters the tube side of S514A/B where it is heated up
by circulating HAGO stream on the shell side leaving exchangers S16/S18. the Crude outlet from
S514A/B enters the tube side of S515 where it is heated up by VR rundown stream on shell side
coming from discharge of VR pumps P18A/B. The heated Crude up to 256 degc from S515 is fed to
Crude furnace F51 for final heating up.
The flashed Crude pumps P04A/B/C ‘s motors have been resized from 790KW to 1050 KW for
expansion need. Also the impellers have been resized from 450mm to 473mm. The present rated
flow of the pump is 1240m3/hr each. The PSV 535 is installed in the common discharge header of
P04 pump is for the fire case thermal relief protection and outlet of it is routed to Crude column
flash zone. Normally two pumps of P04 are required to be run during normal operation. The
discharge flow of pumps is measured by FT116 and 117. The minimum stable flow of the pump is
350 m3/hr each and can be maintained by governing output of spillback control valve FV117. The
PT’s 531 A/B/C are installed on the common discharge header of the P04 A/B/C pumps and
generates high pressure alarm at 29 Kg/cm2g. The provision of tripping P04A/B/C on high high
discharge pressure at 31 Kg/cm2 exist to protect downstream exchangers. While reducing unit

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

charge rates during emergencies it is important to keep the watch on the pressure and to be
regulated by opening spill back control valve FV117.
The P04 A/B/C pumps and motors have MCMS ( Machine Condition Monitoring System) for
continuous monitoring of its condition. The vibrations and temperatures are monitored and alarms
are generated at alert levels. The provision also exist to trip the pumps at the given high high
limits.
The facility to isolate and bypass these hot preheat train exchangers were added later to clean the
exchangers on the fouling. Also it is planned to install a parallel single hot preheat train exchangers
( S 713/714/715) as standby to avoid slowdowns during cleaning of the exchangers.
The fouling rate of exchangers have got increased considerably on the account of tough Crude
processing and to combat the fouling in these exchangers Antifoulant dozing has been started. The
Antifoulant chemicals are injected in the Crude inlet line to S10 exchanger.
The temperature profile of Hot preheat train is given in the following table-

SR.NO Stream Temperature Degc

01. Crude outlet from Flash Drum 145
02. Crude outlet from S13 A/B
03. Crude outlet from S14A/B
04. Crude outlet from S28
05. Crude outlet from S15
06. Crude outlet from S513
07. Crude outlet from S514 169
08. Crude outlet from S515

The preheated Crude from S15 outlet is routed to Crude Furnace F01 and from S515 is routed to
Crude furnace F51 for further heating up to 380-385 degc temperature required for the distillation
in the Crude column.
The Crude Furnaces F01 and F51 are twin cells heaters with vertical tube arrangement in the
radiant section and the horizontal tubes in the convection section. The one furnace have two firing
zones and one common convection section. The process heat is provided by firing fuel gas ,fuel oil
or combination of both through fourteen burners in each cell located on the furnace floor. The

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Crude Complex Refinery Division Crude Distillers
Jamnagar

cracked gas from Vac column overhead is also fired in the furnaces through these burners. The air
is provided to the burners by two combustion air fans one running ,one in spare. The flue gas is
extracted by one Induced draft fan (No spare). Combustion air is successively heated through a
steam air heater up to 115 degc temperature and an air pre heater recuperative type located at
side of the heater upto 260 degc temperature. The furnace is provided with two rows of soot
blowers retractable type for cleaning of the convection tubes.
The fired duty of each Crude heater has been increased to 110 MMKcal/hr from 90MMKcal/hr to
meet the expansion need of the unit. Increment has been achieved by converting LP steam
superheating coils in the convection section to process coils and resizing the burners for higher
firing duty.
The Crude flow to the each furnace is split in the ten equal passes. The flow of the each pass is
measured by Flow transmitter and controlled by a flow control valve before entering to the
convection section. The one more flow transmitter is installed in each pass to have increased
reliability and for independent signals to Emergency Shutdown Management System. The pressure
gauge is installed in the downstream of each pass flow control valve to indicate the backpressure in
the particular pass. Keeping a track of this backpressure is of up most important to judge any
coking up or flow restriction in the pass flow.
The Crude divided in ten passes enters the convection section of heater and gets heated up by flue
gases leaving the radiation section. The pass 1 to 5 enters in the convection section from one side
and pass 6 to 10 enters from the other side. The convection section have total 17 raw of horizontal
tubes. The top 14 raw tubes are extended surface studed tubes and bottom 3 raw tubes are the
bare tubes. The Crude outlet from convection section of Pass-1 to 5 enters the radiation section in
zone-1 and of Pass-6 to10 enters the radiation section in zone-2. In the radiation section tubes
arrangement is vertical and each pass have 22 tubes. The Skin thermocouples are mounted on 7th
,12th.17th and 22nd tubes of each pass at about 7 meter height from furnace floor for measuring the
skin temperature of the tubes. In the radiation section the Crude is further heated up to 390-395
degc temperature by firing of Fuel gas ,Fuel oil or combination of both. The heated up Crude leaves
the radiation section from the top. The temperature of the each pass outlet from radiation section
is measured and is normally termed as Individual outlet temperature. The high temperature alarm
for individual coil outlet temperature is generated at 410 degc.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

The material of construction of all the convection and radiation section tubes is 9 Cr ( P9 Material –
9% Chromium / 1% Molybdenum / 1.5 % Mangense and rest Iron ). The MOC of the studs of the
Convection section tubes is of Carbon steel.
The Crude inlet to convection section and outlet from radiation section line size of each pass is 6”.
The each pass line size gets expanded to 10” afterwards. The pass outlets 1 to 5 joins and makes
the header of 24” and pass 6 to 10 joins and makes the other header of 24”. The temperature of
this two 24” header is measured and is termed as common outlet temperature ( COT ). The COT
of pass-1 to 5 header controls the Fuel firing of heater zone-1 and the COT of pass-6 to 10
controls the fuel firing of heater zone-2. The two 24” outlet headers of zone-1 and zone-2
combines and makes the header of 36”. The 36” header normally called as Crude transfer line is
connected to Crude column flash zone.
The two transfer lines of 36” of F01 and F51 each are connected to Crude column flash zone
separately. The heated up Crude is fed to Crude column through special feed distributor
schopenteator.
The set point to the Crude furnaces pass flow controllers decides the Crude unit throughput. The
pass flows are required to be varied to vary the unit throughput. The total pass flow to each zone
i.e F01- Z-1 , Z-2 and F51 Z-1,Z-2 are normally kept equal unless any firing constraint in the
particular zone. The flow of the each pass of the particular zone are varied by pass flow balancing
scheme in order to have uniform individual outlet temperature. The uniform individual outlet
temperatures of the passes ensures uniform thermal loading in spite of non uniform firing pattern
like combination firing of fuel gas and oil.
The low flow alarm is generated at 45m3/hr flow and low low alarm is generated at 28m3/hr. The
emergency shutdown system trips the fuel firing in the furnace if two pass flows out of ten pass
flows of the furnaces goes down below low low value.
The common outlet temperature ( COT) of two zones of the furnace is controlled in the range of
380 to 385 degc temperature. The COT of the individual zones are controlled by lead lag control
system for fuel firing which always ensures adequate excess combustion air is available for the
complete combustion. The lead lag control systems safeguards the furnace against the dangers of
the incomplete combustion. The flexibility exist to cascade Fuel gas or Fuel oil firing with COT
controller.
The tube skin temperatures are required to be monitored closely. The tube skin temperature is a
function of heat firing duty and heat absorbed by the process fluid. Normally the skin temperatures
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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

of the tubes will remain in the range of 500 to 550 degc. The high alarm for the Skin temperature
is given at 600 degc temperature. It is important to trend the skin temperature values and
observing it for any continuous increment rather then looking as absolute value. The sudden
increment of 20-30 degc temperature indicates flame impingement on the tubes and must be
addressed immediately by adjusting furnace firing. The lower pass flow could also be the reason for
higher skin temperature. The continuous high skin temperatures may result in coking of the tube
leading to hot spot and premature failure of the tube.
The connection of the Medium pressure steam is given to each passes of the furnace at the inlet of
the convection section for the emergency purging. It is of up most important to ensure the
emergency steam header is charged and is condensate free.
The connection of the Low pressure steam is given in the bottom of the fire box of each zone for
the use as a snuffing steam. It is of up most important to ensure the emergency steam header is
charged and is condensate free.
The temperature, pressure and vaporization profile across the furnace is given in the following
table.

Sr. Stream Temperature Pressure Liquid Flow Vapor Flow %age

No Degc Kg/cm2g Tons/hr Tons/hr Vaporization
01 Crude Inlet to Convection
252 13.97 920.880 0 0
section
02 Crude Inlet to Radiation
302 9.68 854.64 66.24 7.19
section
03 Crude outlet from
386 3.41 543.24 377.64 41.0
Radiation section
04 Crude Inlet to Transfer
383 1.835 493.56 427.32 46.44
line
05 Crude feed to Crude
382.4 1.52 482.40 438.48 47.61
column Flash zone

The above data are only indicative and will vary according to Crude TBP, Flash drum temperature
and pressure, Heater inlet temperature and Heater outlet temperature.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

3.2.5 Crude Distillation in the Crude column:

The Crude outlet from the Crude furnaces and vapors from the flash drum are fed to the flash zone
of the Crude column C05. The Crude distillation column C05 is 9.60 meter in diameter and 62.7
meter in height. The various column sections are described below –
1. Flash zone
2. HAGO section
3. Diesel Section
4. HK Section
5. LK Section
6. Circulating Naphtha section
7. Crude Overhead section
8. RCO section

Flash zone -
The flash zone is the section between 6 bottom stripping trays and packed bed for RCO – HAGO
separation. The vapors travels upward and liquid travels travels downward from the flash zone. The
special feed distributor called schoepentoeter reduces entrainment of the liquid along with vapors
rising up from the flash zone.
The common relief header of 18” of different hydrocarbon services PSVs is also connected to the
flash zone.
The flash zone pressure and temperature is required to be monitored closely. The flash zone
pressure is the indicative of the vapor load to the column. The flash zone temperature is the
function of the Crude furnaces COT and Crude TBP range. The flash zone temperature is the
indicative of composition of the vapors. Lower the temperature more will be the low boilings and
higher the temperature more will be the higher boiling. The flash zone temperature is also affected
by quenching by the vapors from the flash drum. More vapors from the flash drum will quench the
flash zone. Excessive water carry over from the desalters will quench the flash zone temperature
drastically. Also the sudden drop in the flash zone temperature indicates release through relief
header to flash zone.

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Crude Complex Refinery Division Crude Distillers
Jamnagar

The Flash zone temperature and pressure will be normally respectively.

HAGO Section -
The HAGO section in Crude column is devided in the two parts RCO- HAGO separation section and
the HAGO pump around section.
The RCO- HAGO separation section is consists of Packed bed of 1.855 meter height between the
Flash zone and HAGO draw off tray. The packing are structured Mellapak 250Y type. The packed
bed is equivalent to six conventional separation trays.
Gas, LPG and Naphtha cut ranging upto 165 oC is taken out from the top vapour line at temp 113
o
C and cooled to 55 oC in crude column condenser (air fin cooler) A05. Air fin cooler has 12 bays
and each bay has two bundles. There are total 24 fans with motors. Two bays can be isolated at a
time. On the overhead vapour line 12 nos. safety valves (including one spare) PSV
130A/B/C/D/E/F/G/H/J/K/L/M are located to release pressure to low pressure flare. Corrosion
inhibitor from pumps discharge P25A/B after dilution with top reflux part stream is injected on the
top vapour line to form protective film to avoid corrosion. The dosing rate will be 6 PPM on
overhead vapor load. Spillback line from net gas compressor joins at U/S of fin coolers. Outlet of
A05 is sent to crude column receiver V12. Outlet temp of A05 can be measured by TI-075. Naphtha
from Heavy Naphtha Unionfiner feed pumps also joins V12 inlet line. In V12, naphtha and water
are separated. Water from boot is pumped by pumps P15A/B under level control LV-012 of water
boot to Non Phenolic wastewater Header. Minimum circulation line is also provided and flow is
regulated by FV-123. Part of the discharge is sent as wash water to all bundles of air fin cooler A05
to avoid plugging /washing and flow is controlled by FV-813. Water from P02A/B discharge is also
injected. Flow through each bundle is regulated through restriction orifices.

All 24 nos. fans have High Vibration Alarms with shutdown switches on high vibration VAH/VSH-011
to 030 & 091 to 094. All motors have local start/stop switches.

V12 has two safety valves PSV-133A/B discharging to LP flare. Top outlet vapours are then
compressed in NET GAS COMPRESSOR MC-RD311-C01. Naphtha is pumped by pumps P16A/B and
discharge is partly sent as reflux to column top tray. The flow is controlled by FV-036 cascaded
with column top temp TIC-053 for top temp control having high and low temp alarms TAH/TAL-
053. Additional temp monitor TI-052 is also available. At the reflux line, unstabilised net overhead
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liquid from HNUU and circulating naphtha streams from S01/S04 also join. Reflux temp can be
measured by TI-054. Other part of naphtha is sent to Recontact drum via air fin cooler A06 under
level control LIC-013 and LV-013. Flow can be measured by FI-098. High/low level alarms are
available LAH/LAL-013. High high level alarm LAHH-079 is connected with emergency shutdown
system and will trip compressor. Fuel gas connection is provided at top for start up/shutdown
required. Three pressure transmitters PT-437A/B/C are provided on top line. High pressure in two
out of any three will activate emergency shutdown system and will trip heaters F01/F051 and close
stripping steam line XV-065/FV-035.

Column top pressure is controlled by PIC-005 or PIC-005A on split range control valves PV-
005A/B/C. PT-05A is located at V-12 & PT-05 is on overhead vapor line. The selector switch is
provided to select pressure control on either PIC-005 or PIC-005A mode. PV-005A is the fuel gas
make up, PV-005B is to flare and PV-005C is on compressor spill back line. In case of low pressure,
PV-005A will open first and then PV-005C. In case of high pressure PV-005B will open. Discharge
from compressor enters recontact drum cooler (air fin cooler) A06. Details of compressor are
covered in later section.

Naphtha and gas are cooled in A06. Air cooler has two motors. High vibration alarm for fans with
shutdown of motors has been provided VAH/VSH-033/034. Stream is cooled to 55 oC measured by
TI-142 and enters recontact drum V13. Two safety valves PSV-135A/B has been provided on top of
V13.

Top pressure of V12 is controlled by PIC-010 on split range control valves PV-010A & PV-010B for
fuel gas in and flare respectively. Boot water under level control LV-014 is sent back to V12. High
level alarm and low level alarm on LIC-014 are provided. Naphtha from bottom is pumped by
pumps P17A/B and sent to saturated gas concentration unit as feed. Level of V13 hydrocarbon is
controlled by LIC-015 under flow control valve FV-048. Minimum circulation line is provided for
P17A/B and flow is controlled by FV-122. Temp can be monitored by TI-041. Emergency shutdown
of P17A/B and FV-048 will occur in case of Gas Con Unit depressurization.

 NAPHTHA CIRCULATING CIRCUIT (REFER P&ID NO:311/312- 05,16,23)

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Naphtha is drawn from partial draw off tray between 3rd & 4th tray of column at temp. of 129 oC
and is measured by TI-046. Column 4th tray temp is measured by TI-055 with high temp alarm
TAH-055. Naphtha is pumped by pumps P05A/B/C & discharge is routed in parallel to tube sides of
S01/S04. Flow through S01 &S04 are controlled by FV-006&FV-007. Return temp at 81 oC can be
controlled by TIC-753 for S01 and TIC-752 for S04. Return stream joins top reflux stream. Low
PDI across P05A/B/C can be measured by PDI-434, 435, 436. Motors have local ON/OFF switches.

 LIGHT KEROSENE CIRCUIT (REFER P&ID:311/312- 23,26,06,07)

Light kerosene is drawn from total draw off tray between trays 14 & 15 at temp 188 oC measured
by TI-047. Column 15th tray temp can be measured by TI-056. One part is sent to suction of
P06A/B and discharge as hot internal reflux by FV-024 above 15th tray and controlling tray level by
LIC-026. Another stream from P06 discharge is return back to suction line & is controlled by FV-
471. Other part is sent to Light kerosene Stripper C09 under level control LIC-010 of stripper and
LV-010 located on inlet line of Light kerosene Stripper C09. Reboiler S18 is a thermosyphon type
reboiler to heatup bottoms. New steam connection is provided from upstream of FV-37 to shell side
outlet CCPP of S18 reboiler. Heating medium on tube side is Heavy Atmospheric Gas Oil; flow is
measured by FV-040 located on the tube outlet. Stripped vapours leave from top and return to top
of Light KERO draw-off tray. Bottom outlet temp can be measured by TI-065, which will be about
213 oC. Outlet temp from reboiler is measured by TI-064 and will be app. 226 oC. Bottom of
stripper is then pumped by P12A/B/C. Minimum circulation flow back to stripper bottom will be
controlled by FV-100. Discharge from pumps is routed to tube side of S05A/B and after cooling to
102 oC is sent to light kerosene product cooler (Air fin cooler) A01 and light kerosene product
cooler S06 to cool it to 40 oC. A01 has four bundles and two bays. Two motors and fans are
provided. VAH/VSH are provided in case of high fan vibration and subsequent trip of fan motors.
Two PSV-450A/B are located at the outlet of A01 and discharge to D/S of stripper inlet line. Light
kerosene can be sent to;
Feed to kerosene merox unit/light slop header under flow valve FV-011
Blending LAB feedstock tank under FV-010
Blending kerosene to kerosene/diesel blending under FV-009.
For SKO tankage under FV-11B

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Jamnagar

 HEAVY KEROSENE CIRCUIT (REFER P&ID:311/312-

06,11,17,23,28,29,31)

Heavy kerosene is drawn from total draw off tray between 26th & 27th tray of
column at temp 231 oC measured at TI-048. Column 27th tray temp can be
measured by TI-057 with TIH-057 provision. One Part is sent to suction of
pumps P07A/B with discharge back to column above tray no.27 as hot internal
reflux under flow valve FV-026 and controlling tray level LIC-027. Other
discharge is sent to tube side of S11A/B, S02 and return as reflux above tray 24
at temp 148 oC. Flow can be controlled by FV-025 located at outlet of S02 shell.
Temperature is controlled by split range using TV-006A/B on Heavy Kero CR
outlet and bypass of S02.

Other part from column is sent to Heavy Kerosene Stripper C07 at the top tray.
Stripper has 6 nos. of trays. Level controller LIC-008 is controlling the level of the
stripper C/V LV-008 located at inlet line of stripper. Reboiler S16 is used to strip-
off lighters. Stripped vapourare sent back to colum on 24t tray.
¤hermosy hon reboiler S16 heats up bottom and heating medium is circulating
HAGO. Flow through tube side is controlled by FV-039. Bottom outlet and reboiler
return temps are monitored by TI-063 & TI-062, which will be around 291 oC &
294 oC. Stripped HK is then pumped by pumps P13A/B/C. FV-121 controls flow
through minimum circulation line from the pump discharge back to stripper. Part of
hot HK is sent under flow control FV-044 to Diesel Unionfining Unit as feed &
joins at d/s of FV-042B (diesel C/V) or sent through Diesel air fin cooler A04. It is
also send to Heavy Kerosene Product Cooler A03 for further cooling to 55 oC. The
provision made to sent P13 discharged to A13 and outlet from A13 join back to
A03 outlet. After cooling it is either routed to SKO/DIESEL blending via C/V FV-
045 or LAB blending via C/V FV-046. FIC-046/044/045 will receive signals
from LAB/SKO/DIESEL blending systems. Off spec HK can be sent to off-spec and
start up header. At suctions of P13A/B Shutdown Valves XV-050, 051, 096 are
located. Purpose of these valves is to close in case of emergency. Valves
open/close indication is available in control panel by XZL-050/051/096. Valves
reset push buttons are available near the valves XHS-050A/051A/096A. Valves
open/close push buttons XHS-50B/51B/096B are located at least 15 meters
away form the pump but in line ofsight of pump. Pump motors will not start until
SDV is minimum 80% open and motors will trip if valve closes below 20% .

 DIESEL CIRCUIT (REFER P&ID:311/312-24,17,27,29,321-015)

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Jamnagar

Diesel stream is drawn from total draw off tray between 34th & 35th tray of column
at temp 276 oC measured by TI-049. 35th tray temp can be measured by TI-058
with high temp alarm TIH-058. Part of stream is pumped by pumps P08A/B and
returned back on 35th tray as an internal reflux for advance control purpose under
flow control FV-027 and cascaded with LIC-028 of tray. Pumps P08A/B have
shutdown valves XV-044 & XV-045 at suction to close in case of emergency.
These valves OPEN/CLOSE status can be seen in control panel by XZL-044/045.
Valve reset buttons XHS-044A/045A are available at the valves. Valve
open/close push buttons XHS-044B & XHS-045 are located at minimum
distance of 15 meter from pumps but in line ofsight of pump. Pump motors can
not be started unless SDV are 80% open or motors will stop if valves are less than
80% close.

(REFER P&ID NO: 321/322-015,08,09)

Part of P08A/B discharge is sent as circulating stream to reboiler 321/322-S09

& 321/322-S10 of stabiliser column in SAT GAS CON UNIT. Flow through
321/322-S09 is controlled by FV-019 located at tube outlet of 321/322-S09
and flow through tube side of 321/322-S10 is controlled by FV-013 located at
outlet. Total diesel circulating flow is maintained by FV-014 located on common
bypass line. In case of Stabiliser overpressure or SAT Gas Conc. Unit
Depressurisation, FV-019 & 013 will close and FV-014 will remain open to
maintain flow.
Diesel is then sent to tube side of S08A/B and returns to column as reflux on 32
nd
tray. Return temp is controlled by split range control valves TV-018A/B located
around tube side of S08. Return temp would be 184 oC. Part of diesel stream is
used as lean sponge oil routed through tube side of 321/322-S03, Air fin cooler
321/322-A01, water cooler 321/322-S04, suction of 321/322-P04 A/B and
to sponge absorber 321/322-C03 under flow control. From bottom of 321/322-
C03, it is heated in shell side of 321/322-S03 and joins diesel circulating reflux
line on 32nd tray of crude column. Flow of rich absorber oil from 321/322-C03 is
measured by 321/322- FT-018 and controlled by 321/322-LV-004.

DIESEL PRODUCT (REFER P&ID: 311/312-17,27 & 29)

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Diesel from column is sent to inlet of diesel stripper C08 at top tray under level
control of stripper LIC-009 and by LV-009. Stripping steam is introduced at
bottom and flow of steam is controlled by FV-041.

Aim of stripping steam is to strip off lighters. Stripped vapours and steam is sent
back to column 32nd tray. Stripped diesel is then pumped by diesel product pumps
P14A/B/C. Minimum circulation line ensures flow through pumps by FV-126
and returns back to bottom of stripper. Part of hot diesel from pump discharge is
routed as HOT FEED TO DIESEL UNIONFINER UNIT under FV-042B and flow
measurement by FT-033. Other part of diesel is cooled in Air fin cooler A04.
Heavy kerosene from P13A/B and Light slops from light slop tank (321/322-
V08) also enters at inlet of A04. Air fin cooler has 3 bays and each bay has two
motors. High vibration alarms and high fan vibration motor trip alarms are
available by VAH/VSH-003, 004, 005, 006, 007, 008. The provision has made
to sent P14 discharge to A13 fin fan cooler and outlet from A13 join back to A04
outlet. Diesel is cooled to 60 oC and outlet is either sent through diesel blending
under flow control FIC-217, to diesel unionfining feed tanks/off spec, start up to
straight run light slop tank under PV-004. Or cold diesel from A04 can be sent to
diesel unionfiner as feed during start up. The flexibility have made to use A04 of
both unit for either of unit when 311 or 312 A04 is in shutdown.

 HEAVY ATMOSPHERIC GAS OIL CIRCUIT

HAGO CIRCULATING REFLUX (REFER P&ID NO: 311/312-

24,18,26,28,14,12)

Heavy Atmospheric Gas Oil is drawn form total draw off tray between 43rd & 44th
tray of column at temp 347 oC measured by TI-050. TI-059 is available to
measure 44th tray temp and high temp alarm TIH-059 also available. PI-083 is
available to monitor pressure above draw off tray.

HAGO stream is divided into two parts as follow:

First part is sent to suction of pumps P09A/B. One part of pump discharge
returns back to column under flow control FV-028 above structured packing. New
HAGO IR filter is provided in revamp to avoid choking of IR nozzles. The pressure
difference across filter is measure by PDG-616. Other part is used for heating in
REBOILERS S16 and S18. In reboiler S18, flow is controlled by FV-040, through
reboiler S16 by FV-039. Total return flow is controlled by FV-038 located on inlet
to outlet line. Further HAGO is sent in parallel to shell sides of S14A/B and

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Crude Complex Refinery Division Crude Distillers
Jamnagar

S514A/B, TV-762 is provided that bypass S14/514 & S09. The shell side of S09
and returns to column on 41st tray as reflux at temp 236 oC.

Temp is controlled by split range TV-22A/B located outlet and bypass of S09.

HAGO PRODUCT (REFER P&ID NO: 311/312-18,25,47,24,25,47)

Second part is sent to top tray of HAGO stripper C06 under level control LIC-007
and LV-007 located on inlet line. LP stripping steam via FV-037 is introduced at
the bottom to strip off lighters. Stripped vapours and steam is returned back to
column on 41st tray. Stripped HAGO is pumped by pumps P11A/B as hot feed to
VGO UNIONFINER joining LVGO & HVGO rundown lines or sent to Gas oil cooler
A07. One stream of HAGO product join HVGO pumparound under flow control
FV-455.

Pumps P11A/B have minimum circulation line and flow is controlled by FV-102,
returning back to stripper bottom. Shutdown valves XV-048 and XV-049 are
located at the suction of P11A/B for isolation, during emergency. Valves
OPEN/CLOSE indication XZL-048 & 049 are available in control panel. Valves can
be reset from field using push buttons XHS-048A & 049A which are located at
minimum 15 meters away from pumps but in line of sight of pump.

 FLASH ZONE (REFER P&ID: 311/312- 24)

Heated crude at 380 oC from both heaters transfer lines enters the flash zone of
column between HAGO IR structured packing & 50th tray. Above flash zone
discharges from following sources enter by 18’’ line
PSV-451A/B/C : CRUDE OUTLET EX S01A/B
PSV-452A/B/C : CRUDE OUTLET EX S04A/B
PSV-124 A/B : DESALTER V03 TOP
PSV-124A/B BYPASS : DESALTER TOP
PSV 121 A/B : CRUDE INLET LINE TO DESALTER V02
PSV 122A/B : DESALTER V02 TOP
PSV 810A/B : DESALTER V33 TOP
PSV 811A/B : DESALTER V34 TOP
PSV 800A/B : S08 SHELL SIDE OUTLET
PSV 614 : LVGO TO DHT
PSV 615 : LVGO TO A-04

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In flash zone, feed inlet lines safety valves PSV-127A/B D/S and PV-002 D/S
OF V04 is also connected.

Flash zone pressure can be measured by PT-082 with high-pressure alarm PAH-
082 and temp by TI-060.

Below flash zone 6 trays are provided for stripping by bottom stripping steam and
flow control by FV-035.

Stripping steam will be cut-off by XV-065 and FV-035 on steam line due to high
high pressure in the column top activated by PT-437A/B/C.

 BOTTOM REDUCED CRUDE OIL (REFER P&ID:311/312-

24,15,43,20,21,46)

Bottom reduced crude oil is pumped at 369 oC and measured by TI-051, by

Pumps P10A/B to Vacuum heater F02. Minimum circulation line back to column
bottom is provided and flow is controlled by FV-120. Pump discharge is connected
to inlets of F01, F51 as start up circulation line. Start up circulation line to gas oil
cooler (A07) inlet is available from pumps discharge. Pump P10A is motor driven
and P10B is turbine driven. Both pumps have XV-041 and 042 at suction to
close during emergency. Valves ON/OFF status XZL-041 & 042 are available in
control panel. Valves can be reset by push buttons XHS-41A & 42A from the field
which are located atleast 15 meters away from pumps.

Motor or turbine will not start or trip if valves are atleast 80% open. Flushing oil
connections have been provided to flush the pumps as well as suction and
discharge lines.

Turbine is driven by medium pressure steam. There is an XV-043 for steam inlet
to turbine and valve open/close status XZL-043 is available. Condensate returning
to condensate header PSV-143 is located on condensate line.

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Bottom level of column is controlled by LIC-006 with LAH/LAL-006 by FV-151

to 160 (F02, heater pass flow C/Vs).

 VACUUM DISTILLATION SECTION:

THIS SECTION IS DIVIDED INTO FOLLOWING PARTS:

 VACUUM HEATER (F02)

 VACUUM COLUMN (C16)

 VACUUM HEATER (REFER P&ID: 311/312-43,15,57):

Vacuum heater is cylindrical furnace having convection and radiation zones. Feed
enters first in the convection zone having tubes in horizontal and then enters
vertically in the radiation zone and finally comes out from top radiation outlet. Soot
blowers are provided for removal of any soot deposition.

Reduced crude oil from RCO Pumps P10A/B at temp 369 oC enters vacuum
heater in ten passes. Flow through each pass is controlled by FV-151 to 160. At
the U/S slop wax from pump discharge P19A/B is recycled back. There are total
12 tubes per pass and turbulising steam is injected at 1st & 11th tube and flow is
controlled by FV-461 to 470 & FV-161 to 170. Turbulising steam is medium
pressure steam and first enters steam separator RD311/312-Y02 for condensate
removal.

Low flow alarm in each pass can be alarmed by FAL-150A to J. Any two pass low
flow will trip the furnace. Emergency coil purging steam is injected at D/S of feed
control valves during emergency shutdown. The valves are located at minimum 15
meters away from heater for safety. Outlet temp from each pass is measured by
TI-284, 289, 294, 299, 304, 309, 314, 319, 324, and 329 having High temp
alarms. All 10 passes outlet join common header and transfer line is 100’’diameter.
Common outlet temp (COT) is measured by TI-111 and TIC-110 controls outlet
temp by adjusting burners firing. Provision is made for decoking of coils. Each pass
has four skin thermocouples located at various locations. These are tagged as
TXE-280 to 283, TXE-285 to 288, TXE-290 to 293, TXE-295 to 298, TXE-
300 to 303, TXE-305 to 308, TXE-310 to 313, TXE-315 to 318, TXE-320
to 323, TXE-325 to 328. The flame side (120o ) of 8” and 10” tubes of each
pass is covered with heat shield.

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TRANSFER LINE TEMP IS ABOUT 392 oC.

Furnace is fired on fuel gas, pilot gas, atomized fuel oil. Furnace is balanced draft
having air preheating system, Induced draft fan and Forced draft fans. Details are
described in later sections.

 VACUUM COLUMN

Vacuum column C16 has top diameter 5.9 meters, middle-11.0 meters and bottom
7.5 meters. Its T/T length is 36.5 meters. Column is having packings and has five
zones as follow:

 TOP OVERHEAD

 LIGHT VACUUM GAS OIL

 HEAVY VACUUM GAS OIL

 SLOP WAX

 VACUUM RESIDUE

 TOP OVERHEAD SYSTEM (REFER P&ID:311/312- 49, 50)

Overhead vapour line is 74’’ in diameter. It has six nos. safety valves PSV-138
A/B/C/D/E/F connected to LP flare. Future provision for ammonia injection in
vapour line is provided. Vapours and steam from column at temp 47 oC is then
sent to First stage two nos. ejectors in parallel. Vapours and steam is then cooled
in water condensers S21A/B. Condensed vapours and steam flows down to
Ejector condensate receiver V17 and temp from S21A/B are monitored by TI-
103 & 109. Uncondensed vapours are further sent from shells side of S21A/B to
second set of ejectors, cooled in condenser S22 and condensate flows down to
V17. Temp from S22 is measured by TI-104. Finally uncondensed vapours pass
through third set of ejectors, cooled in S23 and condensate flows down to V17
and temp from S23 is monitored by TI-105. Uncondensed vapours from S23 are
sent to V17. Part of uncondensed vapours is returned back to inlet of ejectors for
column pressure control by PIC-062. Fuel gas supply is connected at U/S of PV-
062 to break vacuum or for start-up/shutdown purpose. New PV-62A is installed

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in the bypass of PV-62. Both PV-62A and PV-62 are operated in split range by
PIC-062. Medium pressure steam from header enters steam separator Y10,
condensate is removed and steam is sent to ejectors under pressure control PV-
061. Low low steam pressure alarm will sound PALL-104 in case of low steam
pressure. To get steam pressure up to 19.5 Kg/cm2, modification is made to use
low temperature and pressure HP steam for ejectors. HP steam from header under
New PV-61 flows to PRDT where HP BFW is injected. Temperature of steam in
the outlet of Y-21 (PRDT) is controlled by TIC-772. TIC-772 also gives high/
low temperature alarm to panel. PSV-633A/B is given in the outlet of PRDT.
Reduced pressure

Condensate and hydrocarbon are received in ejector condensate receiver V17

where water and hydrocarbon are separated. Hydrocarbon is pumped by Pump
P22A/B to off-spec/start-up header or DUF feed tankage under hydrocarbon level
LI-019. High level will start the pump and low level will automatically stop the
pump. ON/OFF push buttons are also provided locally in field near the pump. Also
selector switch is provided on panel to selected either P-22A or P-22B in auto
mode. High and low level alarms are available for V17 water level. Water is
pumped by pumps P23A/B under level control LIC-018 and sent to NON
PHENOLIC WASTE WATER STRIPPING UNIT. Motors have local START/STOP
switches near the pumps. Minimum circulation line control valve FV-101 assures
minimum flow required for smooth operation of pumps. Provision is also available
to route water from pump discharge to UNSATURATE GAS CONCENTRATION
UNIT.
Vapours from V17 are sent to ejector vapour knockout drum V18 from where
condensate is drained to ejector blow-case V19. V17 outlet line has safety valves
PSV-139A/B connected to LP flare. High level in V18 can be alarmed by LI-017.
Ejector receiver vapours from V18 are then sent to flame arrestors and are
subsequently burnt in heaters F01/F51 or can be diverted to LP flare by hand
switch XHS-028. Manual diversion indication XHL-028 is also available in control
panel. XV-016 is located on vapour line to heaters and XV-018 is located on LP
flare line. In case of heaters trip, vapours can be diverted to flare by activation of
shutdown system. From V19, condensate drained back to V17. Fuel gas
connection is provided at V19. Two safety valves PSV-140A/B are located on top
with discharge to LP flare.

 LIGHT VACUUM GAS OIL (REFER P&ID NO:311/312- 44,47,46,48)

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LVGO is the first top product drawn from top accumulator tray having packings
and top reflux distributor. LVGO at temp 97 oC is pumped by pumps P21A/B. Part
of discharge is sent to Air fin cooler A08, trim cooler S20 and returns to column at
temp 43 oC under flow control FV-074 as top reflux through distributor. Draw off
temp and return temps are measured by TI-129 & 125. A08 has four bays with
two bundles per bay. It has eight motors RD311-MO8-01 to 08 and each fan
has been provided with high vibration alarm, high fan vibration motor trip interlock
VAH/VHS-056 to 063. Manual louvers are provided operating from grade. LP
steam coils are provided to heat up the material in case of requirement. Temp at
outlet of A08 can be measured by TI-123

Second part of pump discharge is sent to inlet of gas oil cooler A07 under flow
control FV-075A and other stream is sent as hot feed to VGO UNIONFINER as
feed under flow control FV-075B. Total flow is measured by FT-075 and both
C/Vs FV-075A/B are split range controlling LVGO tray level by LIC-022 and
having high/low level alarms. Field gauge LG-036 is provided to physically cross
check level of LVGO tray. TI-126 measures temp below draw off tray and PDI-
084 measures DP across top packing bottom and column top. Rest of pump
discharge is return back as a internal reflux to LVGO IR packing through filter.
Pressure difference across LVGO IR filter is measure by PDG-419. IR flow is
controlled by FV-454. The provision is made to put LVGO from P21 to HVGO IR
through flow controller FV-77A. PDI-88B measures DP across LVGO IR packing .
Flushing oil connection is given at suction line of P21A/B and IR filter.

 HEAVY VACUUM GAS OIL (REFER P&ID NO: 311/312-44,57,55,14,46)

HVGO is the second draw from top and drawn at temp 278 oC measured by TI-
130. Above HVGO draw off tray, packings and distributor has been provided.
Temp below HVGO draw off can be measured by TI-127 and PDI-088A
measures DP across HVGO and LVGO IR packing zones. It is then pumped by
pumps P20A/B. Discharge is split into two streams. First stream returns back to
column via filters as internal reflux under flow control FV-077 above slop wax
packing through distributor. The DP across filter is measure by PDG-618. Second
stream is sent to shell sides of S13A/B and S513 A/B in parallel through PV-
610, shell sides of S12A/B and C/D in parallel and returns back as reflux through
filter at temp 198 oC. The pressure difference across HVGO pump around filter is
measure by PDG-617. Flow of reflux is measured by FV-081 located at the shell
outlet of S13A/B and S513 A/B and temp is controlled by split range TV-
020A/B located at the shell side outlets and bypass of S12A/B/C/D. The

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Jamnagar

provision has been made to put HVGO from outlet of S12 to HVGO IR upstream
of FV-77. Part of second stream is sent as HOT FEED TO VGO UNIONFINER UNIT
under flow control FV-086A or can be sent GAS OIL COOLER (A07) under flow
control FV-086B. Total HVGO flow can be measured by FT-086 and controlled by
C/V FV-086A/B on split range and controls HVGO tray level by LIC-023. High
and low level alarms for LIC-023 are provided. Field gauge glass LG-037 is
provided to cross check level physically. Outlet of cooler is sent to GAS OIL
TANKAGE system or to off-spec header as per requirement. Cooler outlet temp can
be measured by TI-074 having high/low alarms.

Inlets to gas oil cooler are hot HVGO from P20A/B, hot LVGO from P21A/B,
from off spec header, start up circulation line from reduced crude pumps P10A/B,
pump out line from VACUUM RESIDUE pumps P18A/B, from HEAVY SLOP DRAIN
TANK PUMPS P29A/B .

Air cooler A07 has six bays and each bay has two bundles. There are 12 motors
ME-RD311/312-A07-01 to 12. Motors have start/stop hand switches. High fan
vibration alarms with high fan vibration trip of motors VAH/VSH-040 TO 051 are
available. Manual louvers are provided to operate from grade.
Pumps P20A/B have emergency shutdown valves XV-057 & 058 on suction
lines. Valves open/close position can be known from panel by XZL-057 & 058.
Valves can be reset by XHS-057A & 058A locally. Valve open/close push buttons
XHS-057B & 058B are located atleast 15 meters away but in line of sight of
pumps. Motors can be stopped from panel by MHS-20A and 20B.

Flushing oil connections are provided at common pump suction, individual

suctions, common discharge and both IR & PA filters.

Vent lines from each pump are given for priming and back to column.

 SLOP WAX (REFER P&ID:311/312- 44,57,42)

Slop wax is the third draw off from top. It has packing and distributor above. Slop
wax tray temp can be measured by TI-128. DP across tray and HVGO packing
bottom can be measured by PDI-086. PIC-070 can be put on pressure control
mode by PV-062 by selector switch PHS-062. Slop wax is drawn to V-44 at
temp 356 oC measured by TI-031 and pumped by P19A/B and sent as recycle to
vacuum heater inlet line. The flow is controlled by FV-076 which controls level of
slop wax tray by LIC-201 having provision of HIGH/LOW level alarms. Low flow

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Jamnagar

recycle to heater can be alarmed by LAL-202. Level of slop wax tray can be
physically checked by LG-202 locally. Total flow through pumps can be
maintained by FV-125. Part of slop wax can be routed to either vacuum R/D as
feed to DELAYED COKER UNIT through FV-76B OR VACUUM RESIDUE TANKS
through flow control FV-76A.
Remaining is routed to slopwax/crude exchanger (S-28) & return back
to inlet line of V-44 as quench stream. Quench flow is conrolled by FV-451 &
temperature is controlled by TIC-751 & FV-451.
Pumps P19A/B have shutdown valves XV-055 & 056 at the suction to close in
case of emergency. Valves reset buttons XHS-55A, 56A are located near the
valves. Emergency push buttons XSH-55B & 56B are located atleast 15 meters
away and in sight of pumps. VALVES ON/OFF position is available in control panel
XZL-55 & 56. Motors can be stopped from control panel by MHS-19A &
19B.Motors will not start if valves are less than 80% open or will stop if valves
close more than 20%. Flushing oil connections have been provided at common
suction of pumps, individual suction of pumps and common discharge. It is also
provided at slop wax line to heater F02 and to vacuum residue product line.
Vent line has been provided for priming pumps and returned to column.

 VACUUM RESIDUE (REFER P&ID:311/312- 44,45,46,15,12,42)

Vacuum residue is the bottom product and pumped by P18A/B. P18A/B pump
discharge can be pumped out to gas oil cooler (A07) during shutdown/start-up.
Circulation line ensures flow through pumps by FV-124 back to column bottom.
Other part of discharge is sent parallel to two sets of exchangers S15A/B,
S515A/B shell side and shell side of S10, S25A/B. Part of S25A/B outlet is
refluxed back to column under flow control FV-072 cascaded with bottom outlet
temp control TIC-133. Other part can be sent to VACUUM RESIDUE TANKS
under flow control FV-082 One stream from S10 outlet sent to DELAYED COKER
as hot feed under level control LIC-031 of column and cascaded with FV-073.
High and low temp alarms can be known by TI-112. Vacuum residue rundown
temperature is controlled by TV-756B which is located at bypass of shell side of
S25..Vacuum Residue can also be diverted to off-spec header and at the inlet of
Gas Oil Cooler (A07) as well as to heavy slop tank. TI-183 measures Vacuum
Residue temp to gas oil cooler with high temp alarm TIH-183.

Pump P18A is motor driven and P18B is turbine driven. Emergency shutdown
valves XV-52 & 53 are provided at suction of pumps. OPEN/CLOSE indication
XZL-052 & 053 are available in control panel. Shutdown valves can be reset

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locally by XHS-52A & 53A. Emergency push buttons for closing are located
atleast 15 meters away from pumps but insight. Motor of pump P18A can be
stoped from panel by MHS-018. Turbine of P18B steam line shut down valve
XV-054 OPEN/CLOSE indication is available in control panel. PSV-144 is located
on condensate return of turbine and vent to atmosphere at safe location.

Super heated LP Steam is passed at bottom and flow is controlled by FV-080.

Following level and temp points are available in the bottom section.

 LT-021 having low and high level alarms, which can be cascaded, to column
level by switch LHS-031.
 Independent level tapping LT-035 (NUCLEONIC LEVEL DETECTOR) to cut off
steam to column with LAHH-035 ALARM.
 LT-020 (NUCLEONIC LEVEL DETECTOR) having low and high level alarms
which can be cascaded to column level by switch LHS-031.
 TI-134, 135 and 136 are provided to monitor temp at various levels.

Flushing oil supply is provided for all the level tapings from flushing oil supply
header and from RAM pump discharge.

Flushing oil connections are provided at common suction, individual suctions and
common discharge lines of P18A/B, shell side inlet of S15A/B, S515A/B, and
shell side of S10. Provision is also made to flush VR lines to heavy slop, gas oil
cooler (A07).

3.2.2 PROCESS DESCRIPTION FOR SGC UNIT

The function of saturated gas concentration unit is to separate feed stream in Lean
gas, Gas, LPG and Stabilized Naptha.

Unit is divided in the following sections

 Feed to Primary Absorber

 Primary Absorber
 Primary Absorber
 Sponge Absorber
 Stripper
 Stabiliser
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 FEED UPTO PRIMARY ABSORBER(REFER P&ID :321/322 004,005)

Feed :
 Unstabilised naphtha from Crude & Vacuum unit
 Unstabilised naphtha from VGO unionfining unit
 Off gas from VGO unionfining unit
 Unstabilised net overhead liquid from DIESEL unionfining unit
 Off gas from DIESEL unionfining unit
 Off gas from Platforming unit
 Off gas from Light naphtha unionfining unit
 Overhead liquid from Light naphtha unionfining unit

All the above feed streams enter shell side of S-01/B after joining with
Unstabilised naphtha (discharge of 311/312-P-17A/B) from crude unit under flow
control 311/312-FV-048, Rich oil from primary absorber rich oil pumps P-
03A/B (flow measurement by FI-003), stripper vapours from Stripper C-05 (flow
control by FIC-009). XV-102 is provided in Unstabilized naphtha from
unionfinning units line & new line with XV-101 for gases from platformer unit are
joining the stream coming from 311/312 P-17 discharge. XV-101 & XV-102
are connected to Unit depressurisation interlock and will close during
depressurization. The jump-over is provided at b/l to route gases from
unionfinning unit directly to PV-004 downstream to ATU line.Feed stream after
cooling in water cooler, enters High Pressure Separator V-01.High pressure
separator is horizontal vessel with water boot.

Three streams gas, liquid hydrocarbon and water are separated in HP receiver
(V01)

Gases containing mostly methane, ethane & traces of LPG are sent to Primary
Absorber (C-02) and flow is measured by FI-002 . Emergency Shutdown Valve
XV-011 is located at inlet line of Primary Absorber with open/close indication in
the control panel. Emergency Shutdown system during depressurisation will close
this valve.

Sour water from the boot is routed as Non Phenolic water to WasteWater Stripping
unit (U-431) under level control LIC-002 having low and high level alarms and C/V
LV-002. Emergency Shutdown Valve XV-003 provided on the water outlet line will
close on low low water boot level LALL-030. XV-003 open/close indication is

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available in the control panel. New C/V LV-002A installed in the bypass of LV-002
that both control valve is in split control with LIC-002.

Unstabilised gasoline is pumped by P-01A/B to the shell side of Stripper Feed

preheat Exchanger S-05. Flow is controlled by FV-001 cascaded with
hydrocarbon level control LIC-001 of vessel. LIC-001 has high and low level
alarms. At the D/S of FV-001 unit pump out line to "LIGHT SLOP TANK” is
provided. Spillback control valve FV-40 is been provided to maintain minimum
flow.

HP receiver (V-01) is provided with pressure indicator PI-001 & high/low pressure
alarms. The vessel is protected by three safety valves PSV-021A/B/C
discharging to HP Flare. XV-008 is provided on V-01 to depressurise HP flare in
case of emergency activated by shut down system. XV has open/close indication in
the control room. Unit depressurisation switch XHS-009 in provided in the panel.
Fuel Gas back up line during start up is also provided.

Pumps P-01A/B have XVs-001 and 002 at the suction . XVs open /close status
XZL-001 and XZL-002 are available in the control panel. XVs reset buttons XHS-
001A & 002A are available in the field. XVs can be closed during emergency by
push buttons XHS-001B & 002B located at least 15 meters away from pumps but
insight. Emergency shutdown system will trip ( ESD-03) the running pump.

 PRIMARY ABSORBER ( REFER P& ID :321/322- 006,007,013)

The function of Primary absorber C-02 is to obtain sharp separation of Propane

,Butane from rich gases Ex V-01 by absorption. Absorption medium used is
Stabilized Naphtha from Stabilizer C-06.

Rich gases from V-01 enter C-02 under bottom most tray no 30. The gases flow
from V-01 is measured by FT-002.

Stabilized naphtha from Stabilizer Bottom Cooler S-08A/B in the shell side
pumped by pumps P-05A/B under flow control FV-011 enters top tray of
column.

Heat of absorption is removed by circulating a stream of rich gasoline from tray no

16 via pumps P-02A/B and inter cooler S-02 to 15th tray of column . Pumps will

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Jamnagar

trip in case of activation of emergency shutdown system of unit depressurization.

Pump around flow can be measured by local FI-005.

Lighter hydrocarbons leaving C-02 top flow to Sponge Absorber C-03. Two safety
valves PSV-22A/B are located at the inlet line of C-03.

Rich gasoline from the bottom of Primary Absorber is pumped by P-03A/B to the
inlet of High Pressure Receiver V-01. Pumps P-03A/B can be stopped from
control panel by MHS-003A/003B. Pump motors are connected to Unit
depressurization shutdown system to trip the motors. (ESD-03)

Bottom level of Primary Absorber can be controlled by LIC-003 and LV-003

located at the discharge of P-03A/B. Flow of rich gasoline can be measured by FI-
003 with low level alarm. Pressure differential across C02 bottom and top can be
measured by PDI-014C.

 SPONGE ABSORBER ( REFER P&ID :321/322-

06,007,008,009,010,015)

The function of sponge absorber c-03 is to recover the valuable lpg components
from the gas, which are not absorbed in primary absorber. The absorption medium
is diesel from crude column.

Sponge Absorber is packed tower. Vapours from Primary Absorber enter at the
bottom of packed bed.

Circulating diesel from crude column at temp of 2760C is cooled in tube side of
Rich/Lean gas oil Exchanger S-03, Air fin cooler A-01,water cooler S-04 to temp
38 0C and pumped by pumps P-04A/B to top of packing. Flow of this stream is
controlled by FV-006.

Pumps can be stopped from control panel by MHS-004A/004B and also by unit
emergency depressurisation shutdown system. (ESD-03)

Air Fin Cooler A-01 has one bay & two bundles with two fans. VAH/VSH-001 & 002
have been provided for vibration alarm for fans and high vibration fan tripping the
motors.

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PSVs 26A/B are located on the shell side inlet of S-04 and discharge connected
to HP flare.

Unabsorbed lean gas from top of C-03 flows to knock out drum (V-04), gases from
V04 are routed to Amine Treating unit under pressure control PV-004 which
controls Sat Gas Concentration Unit Pressure Control. V-04 has level indication LI-
005 having high level alarm. Hydrocarbon condensate is to be drained manually
and routed to Rich Gas Oil from Sponge absorber bottom at outlet of exchanger
S-03.

The Rich Sponge Oil from bottom of C-03 returns to fractionation column after
getting heated from 55 0C to 162 0C in shell side of S-03. Level of C-03 is
controlled by LIC-004 and LV-004. Column has low/high flow alarms. Flow can
be measured by FI-018 and bottom outlet temp by TI-006. Differential pressure
across packing can be monitored by PDI-016C.

 STRIPPER C05 ( REFER P&ID :321/322-012,004,011,014)

The function of this column is to strip off lighter ends( lighter than propane) and
bulk of h2s that is present in the unstabilised gasoline which is coming from hp
receiver v-01.

Unstabilised gasoline from HP receiver is pumped by P-01A/B and after getting

heated in shell side of stripper feed/stabilizer bottom exchanger S-05 from 38 0C
to 56 0C enters top of Stripper Column C-05. The feed temp is controlled by TIC-
010 and controlled by TVs-010A/B located on tube side of S-05.
Bottom reboiling is done by thermosyphon reboilers S-06 and S-07 one above the
other. S-06 has stabilizer bottom and S-07 has MEDIUM PRESSURE STEAM in
tube side as heating medium. Stripping rate from top is controlled by FIC-009
which in turn controls 25th tray temperature by adjusting the flow of MP Steam in
S-07 . Flow of steam is controlled by FV-010 located on the MP condensate line
from S-07. The provision exists to take HP steam in S-07.

Emergency Shutdown Valve XV-004 is located at the tube inlet of S-07. This SDV
will close on interlock due to high column top pressure sensed by PAHH-005.
(ESD-01)

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Reboiler inlet temp. can be measured by TI-012 which will be appox. 128 0C and
reboiler outlet temp appox. 161 0C.

Stripped vapours from top of stripper is routed to inlet of HP cooler S-01A/B. Top
stripped vapour flow and temp can be measured by FT-009 & TI-013. Separate
three pressure tappings (PI-005A/B/C) for pressure sensing for interlock are
provided. Any two voting out of three for high high pressure sensed by PAHH-005
will activate emergency shutdown system and will cut off MP steam to S-07.
Three PSVs 25 A/B/C with discharge connected to HP flare are located at the
top vapour line. PDI-011C will measure differential pressure across C05.

Unstabilised gasoline under system pressure will flow to Stabilizer column C-06. A
level control valve LV-006 located on this line will control stripper bottom level by
cascading with LIC-006 having high and low level alarms.

 STABILIZER C-06 (REFER P&ID:13,14,15,16,17)

The function of this column is to remove mainly butane, propane as overhead

products to produce stabilised full range naphtha of required vapour pressure as
feed stock for heavy naphtha unionfiner unit.

Unstabilised naphtha from stripper column enters on 22nd tray .

Heat to stabiliser is supplied by two parallel reboilers S-09 & S-10. These are
thermosyphon type reboilers. Heating medium is circulating diesel from crude
fractionator. Circulating diesel from pumps 311/312-P-08A/B discharge enters
S-09 on tube side and flow is controlled by FIC-19 & C/V FV-19 located on tube
outlet of S-09. Another circulating diesel stream enters tube side of S-10 and flow
is controlled by FIC-13 & C/V FV-13 located on the tube side outlet of S-10.
Both these C/Vs are having interlock to close in case of high high stabiliser top
pressure activated by emergency shutdown system (ESD-02).
Emergency shutdown valve XV-005 is located at the common inlet of circulating
diesel to S-09&10 which will also close during activation of emergency shutdown
system on stabiliser high high pressure. Total circulating diesel flow will be
measured and controlled by FV-014 located on the bypass of both the reboilers to
maintain steady flow. This C/V will open and control total flow of Diesel in case of
activation of emergency shutdown system.

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Stabiliser bottom reboiler inlet temp will be measured by TI-019. Reboiler inlet
and outlet temps will be appox 199 0C & 211 0C respectively.

Overhead vapours are condensed in Air Fin Coolers A-02. It has three bays and
each bay has two tube bundles. There are six fans and motor nos MO2-
01,02,03,04,05,06. VAH/ VHS -10,11,12,13,14,15 is provided for each fan to
indicate high fan vibration and high fan vibration motor trips. TI-021 measures
condenser outlet temperature. For more cooling new S-13 cooler installed in the
outlet of A-02. The outlet temperature of S-13 is measured by TI-100.
Overhead accumulator V-07 receives condensate and gases.

On the vapour line, three safety valves PSVs 23A/B/C are located discharging to
HP flare.

Three separate pressure tapping PT-07A/B/C are provided and any two voting of
high high pressure will activate emergency shutdown system (ESD-02) to cut off
reboiling medium. TI-016 will measure top vapour temp.

Top pressure of column will be controlled by PV-09 installed on the vapor line,
which has high pressure alarm PAH-009. A constant differential pressure is
maintained between column and accumulator with the help of DIFFERENTIAL
PRESSURE CONTROLLER which resets the control valve PDV-010 located on the
bypass line of air fin coolers. One more control valve installed PV-09A on V-07,
which is controlled by PIC-009. The downstream of PV-09A can be routed to
flare or ATU.

 Fuel gas supply provision is made for start up requirement.

 Hand Control Valve HV-003 has been provided on accumulator (stabiliser
receiver) to route gases to flare during start up period.
 PSVs 24A/B are installed on top of receiver and discharge to flare.
 Provision LPG to meet start up requirement is done.

A part of overhead liquid stream from V-07 is refluxed to column top by Pumps P-
06A/B/C. The flow of reflux is controlled by FV-016 which is reset by TIC-017
controling 6th tray temperature. The flow of reflux is measured by FI-016. TI-
018 is also provided to measure 6th tray temperature. The minimum flow control
valve FV-101 in P-06 discharge is installed during revamp. Also during revamp
boot facility is been provided to V-07. The seperated sour water is sent to

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phenolic waste water stripping unit . LV-081 is given to control boot level and is
controlled by LIC-081. Boot has high and low level alarm. XV-080 is given in
the up stream of LV-081 which get close at low level of boot and get open at high
level (ESD-005).

The remaining liquid LPG is cooled in cooler S-11 and sent to SATURATE LPG
MEROX FOR FURTHER TREATMENT OR UNSAT. LPG MEROX. The flow of LPG is
controlled by FIC-015 which is cascaded with LIC-008 of receiver level and reset
by control valve FV-015 located on the run down LPG line. Receiver has low/high
level alarms.

PSVs 27A/B are located at the LPG inlet line of S-11.

XVs 006,007 and 035 are installed at the suction lines of P-06A/B/C to close in
case of emergency. These valves can be reset locally by XHS-
006A/007A/035A. Emergency Stop buttons XHS-006B/007B/035B are
located at least 15 meters away but insight of pumps. Motors can also be stopped
from control panel by switches MHS-006A/006B/006C. OPEN/CLOSE status of
XVS –006,007 and 035 is provided in control panel.

Pumps can not be started if the XVS-006, 007 and 035 are closed more than
20% or pump will trip if valves get closed more than 20%.

PDI-008 with high differential pressure alarm monitors differential pressure across
the Stabiliser column.

Stabilised naphtha from column bottom under system pressure flows to tube side
of stripper reboiler S-06, tube side of stripper feed preheat exchanger S-05 and
finally split into two parts:

One part is pumped by P-05A/B cooled in water cooler S-08A/B and sent as
recycle to primary absorber C-02 top. Flow of this stream is controlled by FV-
011. Temp indication with high temp alarm is available and can be monitored by
TI-025. Pumps P-05A/B can be stopped from control panel switches MHS-
005A/005B. Running pump will stop in case of activation of emergency
shutdown system of unit depressurisation (ESD-03).

Other part is sent as HOT FEED TO HEAVY NAPHTHA UNION FINER under flow
control FIC-012 cascaded with stabilizer bottom level controller LIC-007 and

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controlled by FV-012 and LV-007 located on rundown line. At low level of

stabilizer FV-12 and LV-007 will get closed (ESD-04). Stabilizer bottom level has
low/high level alarms.
TI-022 will monitor rundown temp of naphtha. Part of naphtha can be cooled in
water cooler S-12A/B and sent to FULL RANGE NAPHTHA STORAGE TANKS OR
OFF SPEC. LIGHT SLOP TANK. Rundown temp ex S-12A/B can be measured by
TI-026 with high temp alarm.

The provision has been made to route 321 stab. Naphtha to 322-S-12A/B & vise
versa (In case of either of unit cooler is in shutdown).

3.3 PROCESS VARIABLES:

3.3.1 DESALTER OPERATING VARIABLES

 WATER INJECTION RATE AND PRESSURE DROP

Water injection should be started only after the crude temperature has reached
specified level of approximately 130 0 C, de-emulsifier injection is started and
power is switched on the grid. Initially injection rate should be limited between 3
to 5 % of crude flow rate
The pressure drop across emulsifying valve (Mixing valve) should be adjusted to
give required degree of desalting. Higher the pressure drop, more efficient will be
the contact between the crude and the desalting water. Too high-pressure drop
will result in excessive emulsification and poor separation of oil and water resulting
in water carry over in the desalted crude (i.e. high BS&W in desalted crude oil). A
pressure drop between 1 to 1.5 kg/cm2g is normally sufficient, can be effected by
PDV-100/ PDV-101 and PDV-808/809.
Optimum water injection rate and pressure drop across mixing valve should be
established to get the desired desalting of crude. Once this is done, the conditions
should be steady and should be varied for changes in feed rate and feed qualities.

 OIL WATER INTERFACE LEVEL

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The oil water interface level should be kept below the centre line of the vessel.
Incorrect operation on the interface level controller can result in water carry over
in desalted crude due to less hold up time available for oil (high interface level)
and more oil carry over in brine water (low water level). Also too high interface
level may put watery mixture up between the electrodes and cause to short out.
Drawing samples through five try-cock-valves provided on the Desalter vessels
should be done to counter check the level indications in the DCS. New desalters
(V33/34) is equipped with Agar Probe which give reliable operation to monitor oil
water interface level.

 Desalter pressure
Desalter design pressure is 43.9kg/cm2g & the operating pressure is between 25 to
26 kg/cm2g. Pressure is not an operating variable except that the pressure should
be high enough to prevent vaporisation of Crude Oil within the Desalter. A
Desalter operating pressure of 1.8 to 3.5 kg/cm2g above the vaporisation pressure
at a given crude oil inlet temperature to the Desalter vessel is normal.

 Desalter temperature
Temperature is another important variable, which affects oil water separation in
Desalter. Most crude oils have an optimum operating temperature range of around
129 oC. Our desalters are designed for maximum operating temperature of 157 0C
(From electrical reliability view it is 150ºC). Lower the temperature, higher the
viscosity of oil, which slows down the oil water separation rate. Also due to high
viscosity of crude oil the mixing between desalting water & crude oil would be poor
& hence the desalting efficiency would be poor.
As conductivity of crude oil increases with temperature, operating temperature
beyond the range will lead to drop in grid voltage due to high amperage, which
imposes limitation on good separations. Excessive amperage will eventually cause
the circuit breaker to open, removing the grid voltage and rendering electrical
system inoperable until the thermal relay is closed. More over very high
temperature may lead to vaporisation of crude in Desalter.

 Demulsifier injection
Stable emulsions can also be broken by use of demulsifying chemicals. The
amount of chemicals required depends on the nature of emulsion, type of crude oil
and other operating conditions like residence time, temperature etc. Tests should
be conducted to ascertain the required chemical injection rate for optimum

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operation of desalting unit. Normally 4 to 5 PPM of crude flow is used,when Crude

diet of high viscosity is processed upto 12 to 16 PPM is used.

 Voltage
The voltage required for good desalting is approximately 3000 volts per inch of
distance
between electrodes. These high voltages are obtained by means of transformers
designed
for the voltage available to the refiner (For details see major equipment chapter).
At voltages above the 3000 volts per inch, the Current flow becomes excessive and
operating costs go up. If the voltage is very low then demulsification becomes
poor or does not occur at all. The voltage is affected by the conductivity of the
fluid, and the operator has no control over the voltage except as these
conductivity changes.
Rapid swings and fluctuations in voltage are usually due to localized changes in
the
concentration of water or emulsion and are generally not serious.

A gradual decline in voltage may indicate vaporization is taking place in which case
the
temperature should be reduced to allow for the voltage to return to normal.

Our old desalters are designed for two stage bi-electric desalting & supplied by
M/s Petrolite.

3.3.2 CRUDE COLUMN OPERATING VARIABLES

 Crude Charge Heater outlet temperature

The first operating variable that we encounter is the flashed crude heater outlet
temperature, sometimes called the '”Transfer line temperature". This temperature
can vary from 315 oC to 425 oC depending on the crude composition and the
endpoint of the heavier side cut products. In order to achieve optimum recovery of
distillates an overflash is required & attained, by keeping the transfer line
temperature slightly high. The over flash could vary between 3 to 6 % liquid
volume on crude charge rate. Our system is designed for 3 %LV over-flash. The
crude heaters supply all the additional heat input required for the column
operation that is not supplied by crude pre-heat exchanger train. Heater outlet

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temperature is controlled by TIC-143 & TIC-155 for F-01. Similarly heater outlet
temperature is controlled by TIC-158 & TIC-169 for F-51. The transfer line
temperature for crude heaters in Design case-1 is appr.385 0C.

 Crude Column Top Temperature:

The second operating variable in the crude column section is the top temperature
of the crude column. This temperature is controlled by TIC-053 at 113 0C
centigrade, by returning some of the condensed naphtha as reflux to the top of
the column. If the crude heater outlet temperatures are increased, then the top
reflux rate must be increased to maintain the same top temperature. This is done
by cascading column top reflux flow control valve FIC-36 with TIC-53. The top
temperature is a good indicator of the naphtha endpoint. Lowering of top
temperature will reduce FBP of naphtha and flash point of side stream product
drawn. Too low a temperature will start steam condensation at the top section of
the column, which may increase corrosion rate (due to chloride attack) at the top
section of the column. Raising of top temperature will increase FBP of naphtha and
flash point of side stream product drawn.

The external reflux which is returned to the top of the column passes downwards
against the rising vapors. The lighter components are revaporized and return to
the top of the column, while the heavier components in the rising vapors are
condensed and begin a downward flow in the column. We have then an internal
reflux stream flowing from the top of the crude fractionator all the way to the flash
zone and becoming heavier as it descends. There may be occasions when the
internal reflux necessary to achieve satisfactory fractionation between the heavier
products is so great that if the only supply were the top reflux, then the upper
trays would flood. Therefore, an "Intermediate Circulating Reflux" solves this
problem.

 Circulating Reflux (Pump Around Stream: PA)

The circulating reflux serves mainly in withdrawal of heat from the column and
reduces the vapor load in the respective section of a distillation column. However
the higher than the required PA stream flow would adversely affect the
fractionating efficiency in that particular zone. Excessive PA stream flows could
also lead to flooding in that zone & the lower section of the column.

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Also it should be noted that the draw-off temperature of a particular tray would
control the endpoint of that particular draw-off stream & thereby affect the IBP of
the next side draw-off just below that section.

There are four circulating reflux streams – Naphtha PA, Heavy Kerosene PA, Diesel
PA and HAGO PA and are controlled by FIC-06 / FIC-07, FIC-25, FIC-14 and FIC-
38 respectively. The return temperature of these refluxes is controlled by TIC-02 /
TIC-05, TIC-06, TIC-18 and TIC-22.

A high naphtha PA flow will result in decrease of overhead reflux flow (FIC—36)
which is cascaded with column top temperature controller TIC-53 and affect the
quality of naphtha (i.e.FBP of naphtha would decrease & this would result in lower
IBP of the LK stream drawn from tray no 14 of crude column C-05). The overhead
condenser (A-05) heat duty will come down, as there will be less overhead
product. The light kerosene cut will be correspondingly lighter (as the tail end of
the naphtha product would form the front end of LK product) & if light kerosene
draw-off temperature is not touched, the LK draw-off rate would have to be
increased.

High light kerosene PA flow will tend to lower the draw-off-tray temperature of
light kerosene and HK draw off tray temperatures, resulting in light products in
these trays. Likewise, high HK PA will tend to lower the draw-off temperature of
diesel and heavy kerosene. High HAGO PA will tend to lower the draw-off
temperature of HAGO and diesel & crude column flash zone temperature.

Increase of PA stream flows could result in higher crude pre-heat temperature by

greater heat recovery in heat exchanger train.

 Column top Pressure:

Although the column pressure is not typically considered process variable, small
changes in pressure will result in large temperature changes at constant
compositions. If the pressure is not held constant and operations are attempting
product quality control based upon tray temperatures, then changes in product
composition will occur with those pressure changes. Frequent pressure swings will
not allow for stable column operations.

The column pressure is maintained by split range pressure controller PIC-005 at

1.2 Kg/cm2g (PIC-005A flares when the column pressure is higher than the set
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point, PIC-005B introduces fuel gas in V-12 & PIC-005C is spill back to V-12 from
the compressor discharge through A-05 when the column pressure is lower than
the set point). A lower pressure aids in greater vaporization at the same
temperature & hence all products will trend to be heavier. Higher than the normal
pressure will have reverse effects.

 Product withdrawal (draw-off) temperature

The withdrawal temperature of the product from the column influences the end
point of product drawn. This is determined by quantity of the product withdrawn
from accumulator trays. An increase in withdrawal rate of one side stream
increases both IBP & END points of side stream below that particular tray in the
column unless withdrawal rate down below in the column is reduced
correspondingly. Otherwise if the draw-off rate of the side stream just below were
kept constant then only IBP would be affected. Similarly reverse action takes place
when withdrawal temperature is lowered by reducing the quantity of withdrawal
from the draw-off tray. The draw-off temperatures for Circulating Naphtha / LK /
HK / Diesel / HAGO trays are indicated by TI-46/47/48/49/50 respectively and
their projected values in Design case-1 are 129/188/231/276/347. (Refer table no
1 in Chapter no.5 for details of draw-off tray temperature in Design case-1).

3.3.3 SIDE-CUT PRODUCT STRIPPERS OPERATING VARIABLE

The side-draw-off products are routed to their concerned side stripper. The only
purpose of these strippers is to strip-off the light vapors dissolved in the product,
which determines the flash of these products. Hence the side draw –off products
are steam stripped in a stripper or reboiled with some heating media.

 Stripping Steam Flow Rate:

The amount of low pressure stripping steam ( superheated by injecting small

amount of MP Steam to LP Steam & temperature controlled by TIC-764 / TIC-765
to 177 0C centigrade) that is introduced into the bottom of each stripper (i.e.
Diesel & HAGO strippers through FIC-41 & FIC-37 respectively) on flow control is a
process variable. Generally only enough steam is used to meet flash point
specifications of diesel & HAGO product streams. While a further increase in the
quantity of stripping steam may raise the IBP of the product slightly, the only way
to substantially increase the IBP of one product is to increase the yield of the next
lighter product (provided of course the crude fractionator has enough internal

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reflux to make a good separation). Thus if the IBP of diesel stream is to be

increased then draw-off rate of HK stream should be increased. Similarly if the IBP
of HAGO stream is to be increased then draw-off rate of diesel stream should be
increased.

Steam injection into the bottom of the strippers, which carries the lighter vapors
out from the stripper.

In LK & HK strippers the circulating hot HAGO stream drawn from the crude
column is used as the heating media. The flow of hot HAGO to LK & HK
thermosyphon reboilers (S-18 / S-16) is controlled by FIC-40 & FIC-39 respectively
& dictated by the flash point correction required. The IBP of the LK & HK side
products would depend upon the FBP of the top naphtha product & LK product
respectively.
 Product Draw Rate:
The second process variable concerning the side-cut strippers is the amount of
product removed from the crude fractionator and passed through the side-cut
stripper. This amount of the side-cut draw determines the Final Boiling Point
(FBP).

Most refiners use the 95% distillation point as the control point because of
accuracy, although some refiners may use the distillation FBP in controlling these
side-cuts. If the side-cut withdrawal rate is increased, the extra product is
material, which was formerly flowing down the fractionator as internal reflux. Since
the internal reflux below the draw-off is reduced, heavier vapors can now rise to
that point and the result is a heavier product.

3.3.4 VACUUM COLUMN OPERATING VARIABLES

 The Vacuum Charge Heater Transfer Line Temperature

The vacuum charge heater supplies the required amount of heat to feed to provide
adequate amount of hydrocarbon flashing when the feed enters the flash zone of
the vacuum column. The primary operating variable is the heater outlet
temperature TIC-110 (projected value 392 0C centigrade in Design case-1), since
this variable controls the flash zone temperature. The vacuum transfer line
temperature determines the ability of the bottom product to meet design

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specifications based on a specific gravity, a "penetration test" % volume recovery

at 524 0C and/or a flash specification.

 Flash Zone Temperature

The flash zone temperature is varied depending upon the crude source to meet
the bottom product or pitch specification. The flash zone temperature is not
directly controlled, but as stated in the previous section, the heater outlet
temperature controls the flash zone temperature. The normal vacuum column
flash zone temperature TI-128 is around 20 to 25 0C centigrade lower than the
vacuum heater transfer line temperature (TI-110 / TI-111).

 Flash Zone Pressure

Although this pressure is not normally varied, if the pressure is decreased, then it
will be easier for some of the heavier vapors to move up the column. The lesser
the flash zone pressure, the lower would be the firing in vacuum heater & hence
lesser would be the hydrocarbon cracking tendency in heater process coils. The
normal vacuum column flash zone pressure (PI-70) is around 35 mmHg absolute.

 Residuum Bottoms Temperature

The first process variable in this section is temperature control of the vacuum
column bottom boot section (at approx. 358 0C). The control of this variable (TIC-
133 cascaded with FIC-72 for VR quench flow to C-16) is accomplished by
returning a slip -stream of vacuum residue from S-25 back to the column boot. If
the vacuum column bottom temperature is not controlled as specified and allowed
to increase then there are chances of thermal cracking in the column bottom
section. Quenching the vacuum column bottom section also aids in avoiding
chances of vacuum column bottom pump cavitation.

 Residence Time

Although the vacuum column bottoms level ( LI-21 DP cell type, LI-20 & LI-35
nucleonic level indication) is normally operated at 50%, if the level is operated at a
higher set point, then the residence time of vacuum residue in C-16 will increase.
This level build up in vacuum column bottom would lead to a higher degree of
thermal cracking resulting in coke formation.

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 Slop Wax Reflux Flow rate

The slop wax section is provided to remove approximately 5% of the existing gas
oil from the vapors rising out of the C-16 flash zone. Along with this 5% VGO,
normally the heavier fraction, is a significantly higher amount of metals and
associated asphaltenes than the lower boiling gas oils contain. The slop wax draw
provides some measure of control of these troublesome metals. These heavy
materials (asphaltenes) and metals are poisons for Unionfining / FCCU catalysts &
hence would have a negative effect on the downstream VGO Unionfiner / FCCU. A
slop wax draw off has been provided which is drawn off from the vacuum column
on level control of the draw-off tray (FIC-76 cascaded with LIC-201) & recycled to
vacuum heater feed inlet line or exported with the vacuum bottom stream. By
varying the slop wax recycle flow, the amount of metals and heavier materials that
pass up the column to the HVGO section can be controlled.

 Heavy Vacuum Gas Oil (HVGO) Reflux Flows

The heavy gas oil section is referred to as the heat removal section in Vacuum
Column. It is here that the major portion of the gas oils are condensed by
circulating the HVGO product through heat recovery exchangers S-13/S-12 and
returning a portion as reflux to the top of this section. In most designs, the heavy
gas oil draw (FIC-86 cascaded with LC-23 on draw-off tray) is 50-80% of the total
gas oil. By drawing both a light and heavy product, the HVGO draw-off
temperature will be considerably higher and thus provide for more efficient heat
recovery.

 "Hot" HVGO Reflux Flow rate:

The process variables for this section are the flow rates of the two HVGO refluxes.
The "hot" HVGO reflux stream is directed back to the column from the discharge of
the HVGO pump, where it enters the column beneath the HVGO accumulator tray.
This stream helps in washing the metals and heavier hydrocarbons from the rising
vapors. At no time in normal operation the hot HVGO reflux flow should be
reduced below the specified limits as this would lead to cocking tendencies in the
section just below. The hot HVGO reflux flow is controlled by FIC-77.

 "Cold" HVGO Reflux Flow rate:

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The "cold" HVGO reflux is directed from the discharge of the reflux pump to the
crude pre-heat exchangers S-13/S-513 & S-12. The flow & temperature of cold
circulating HVGO is controlled by FIC-81 & TIC-20 respectively. After the heat
exchange is completed, the HVGO is returned to the vacuum column at the top of
the HVGO section above the grids or packed sections.

 Light Vacuum Gas Oil (LVGO) Section

The light vacuum gas oil section can be described as the top or final condensing
region. It is here where the LVGO is condensed and separated from the non-
condensable gases going to the ejector jets. The quantity of vapors rising to this
section is considerably less than the section below, hence the vacuum column is
swaged at this point. The LVGO drawn-off from the accumulator tray is split into
two streams. The first cooled in A-08 fin fan cooler followed up by trim cooler S-
20 and then sent on flow control (FIC-74) back to the top of LVGO packed section
as cold reflux. The flow rate of this stream is the process variable for this section.
In varying this flow rate, the composition of the liquid collected on the LVGO
accumulator tray will be changed. If the flow rate is increased, then more of the
lighter vapors will be condensed out and the initial boiling point of the LVGO will
be less. The part of LVGO Draw-off is return back to column as hot reflux. The hot
reflux flow is controlled by FIC-454.

The another stream (i.e. LVGO product to VGO storage or downstream VGO
Unionfiners), flow is controlled by the LVGO draw tray level controller (i.e. FIC-75
cascaded with LC-22).

 Vacuum Overhead Section

The process variable for the overhead section is the pressure (PIC-62, normal
value apprx 20 mmHg absolute) or vacuum being maintained. Although the
vacuum is not varied generally, the MP steam pressure (PIC-61) and temperature
must be maintained near to the design conditions of 16 kg/cm2g & 232 deg
centigrade. Any change in the steam pressure or temperature or the condenser (S-
21A/B, S-22, S-23) cooling water supply temperature (CWS normal value 32 deg
centigrade) & flow (normal value approx 4000 m3/hr) will vary the column
pressure or vacuum, thus varying the operation of the entire column.
1. Steam Pressure:
Steam pressure must be maintained quite close to that for which the equipment
was designed. If the steam pressure greatly exceeds that for which the ejector
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nozzle was designed, the quantity of steam discharging into the diffuser will be
greater than the quantity which can pass through the diffuser and steam will back
into the suction header. Too low a steam pressure will mean a drastic loss in
performance of the ejector. It should be noted that wet steam will cause random
fluctuations in ejector performance and will erode the nozzle / diffuser.

2. Discharge Pressure:
If the discharge pressure rises above design, there is an increasing probability of
reverse flow. An increase in discharge pressure on an ejector discharging to
atmosphere is only possible if the discharge is obstructed. On multi-stage units, an
increase in inter-stage pressure due to high condensate temperatures or failure of
a second-stage or third-stage ejector will immediately affect the performance of
the first-stage unit.

3. Load:
A decrease in the mass flow rate of vapor to the ejector or load will result in a
somewhat higher vacuum. If the load is increased above design the vacuum
obtained will fall off quite suddenly and dramatically. The load could be increased
due to the following reasons a. Excessive thermal cracking in vacuum heater
process coils
b. Improper stripping in Crude column bottom
c. Air leakage in the Vacuum section

4. Water Temperature:
The temperature at which steam is condensed in the condensers will have a
relatively major effect on vacuum obtained. Higher condensate temperatures will
substantially reduce the load at which the ejector system breaks down, since the
discharge pressure increases.
In order to ensure flexibility, an ejector system for a vacuum unit will generally be
constructed using two parallel sets. The minimum combination of equipment,
which will achieve a satisfactory vacuum, is normally used. Vacuum column vapors
to the ejector consists of air from leaks, steam from the bottom of the column,
light hydrocarbons, sulfur and nitrogen compounds from thermal decomposition in
the vacuum heater (F02).

3.3.5 PROCESS VARIABLES FOR SAT. GAS UNIT

The Saturate gas concentration unit has many operating variables which influence
product quality, yields and utility consumption. The process or design specification
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for any unit can only be used as a guide because reduced feed rates, variations in
equipment performance, changes in feed and product specifications and other
factors can and will cause a change in process conditions. The unit operators,
supervisors and the other personnel involved in the startup and subsequent
operation of the unit must make adjustments to operate the unit at optimum yield
pattern and maximum efficiency.

1) ABSORPTION SECTION

 Vapour flow rate :

The stripper pressure & bottom temperature should be adjusted in such a way that
the maximum amount of H 2 S is stripped off from the stripper bottom liquid with
minimum amount of valuable C 3 /C 4 Components in stripper overhead vapor. The
main operating variables are stripper overhead flow controlled by FIC-09 in the
stripper overhead line and 26th tray temperature controlled by TIC-14. There is a
hand selector switch to select either of these two controlling parameters to
control the flow of MP steam condensate from the stripper reboiler (FV-10).
(stripper overhead vapor flow should be adjusted to strip-off maximum H 2 S from
the feed to stabiliser with minimum loss of valuable LPG components (i-e. propane
& butane) in the sponge absorber off gas. It is worth mentioning here that the
more the H2S content in stabiliser feed, more would be the H2S content in LPG
product . This in turn would increase load on ATU Column in LPG Merox Unit (U-
331).

There is a possibility of liquid cycle build up if the stripped vapour flow is kept too
high. For example, if the stripping rate becomes excessive, the stripper vapors will
contain heavier than desired components (i.e. propane / butane / pentane etc)
which would condense in S-01 A/B and end up as a liquid in the high pressure
receiver (V-01). This will increase the feed rate to the stripper increasing the liquid
loading and consequently the pressure drop across the column. Also due to high
liquid level in HP receiver would lead to entrainment of heavier components in
vapor feed to Primary Absorber resulting in high absorption load in it. The heavier
components which escape from primary absorber would be absorbed in sponge
absorber lean oil and get recycled back to crude column in CDU/VDU thus
increasing the liquid load in it.

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The best immediate action to rectify the situation is to reduce the heat input to
the bottom of the stripper by lowering the setting on the stripper vapors flow
controller (or reduce the temperature across tray-26) until the upset condition is
corrected.

 H 2 S rejection :

A sudden increase in the H 2 S level of the LPG stream should not be constructed as
being a result of lower stripping alone. If the sulfur content of the unit charge
increases, the H 2 S content of all the streams will increase roughly in that
proportion. On the other hand, if the H 2 S of the LPG stream is held constant by
changing stripping rate, the propane content of the lean gas may increase.

Since our objective is to maximise recovery of C 3 and minimise the H 2 S content of

LPG stream, let us examine what variables control the H 2 S rejection.

 Lean Oil flow to the absorber :

1. Primary absorber
 Flow of recycled naphtha : Increase in lean oil flow to primary absorber would
increase the recovery of LPG components.
 However, caution must be exercised to prevent liquid flooding at higher
throughputs.

2. Sponge absorber
Increasing sponge oil flow rate will increase absorption efficiency but it will be
more noticeable on the recovery of heavier components i.e. butane, pentane,
hexane etc.

 Absorber temperature :

 Absorption is favoured at low temperatures. The primary absorber intercooler is

provided to remove heat of absorption and should be operated to control the
return stream temperature to column at around approximately 380C. When
starting up a saturate gas concentration unit water should be shut off on the
intercooler until the unit is steady so that the H 2 S rejection is favoured.
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 System pressure :

 System pressure in the Sat Gas Unit is controlled by Lean Gas KOD (V-04)
back pressure controller PIC-04, except for the stabiliser column (C-06)
wherein the pressure is controlled by PIC-9/PDIC-10.
 It can be used to keep the stripper vapour rate in convenient range i.e more
the back pressure controller (PIC-04) set point lesser would be stripped vapor
flow rate and hence higher would be the concentration of H 2 S in stabiliser feed.

 Sometimes it may be desirable to lower system pressure, when unit swings to

high sulfur charge stocks which would lead to following cascading Effects:

i. H 2 S rejection in stripper column will increase

ii. However the lower pressure in stripper, would result in lower operating
pressure in absorption section leading to loss of LPG components in lean gas
and hence, less LPG recovery. However this situation would have to corrected
by increasing the lean oil flow to primary absorber.

Temperature Pressure
HP receiver 27-38 0C Rides on primary absorber
back pressure
Primary absorber <38 0C Rides on sponge absorber
(top and intercooler back pressure
temperature)
Sponge absorber As cool as Continues to give good
economically absorption eff. And hold
feasible correct back pressure on HP
receiver.

2) DISTILLATION PROCESS

 Stripper Column (C-05)

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Overhead vapour rate is the primary control on the Saturate gas concentration
unit. All other variables are held constant and this vapor rate is varied to control
the H2S content of the LPG stream. The secondary control is the 26th tray
temperature controller TIC-014. Hand selector switch, THS-014 is used to control
the HP condensate flow valve FV-10 from stripper reboiler either by TIC-14 or
FIC-09.

 Stabiliser Column (C-06)

 Top Temperature :

This variable is actually controlled by the 6th tray temperature controller (TIC-17)
which sends signal to the reflux flow control valve (FV-16), varying the amount of
reflux returned to the column top. If the tray-6 temperature is varied, then the
composition of the overhead material will vary i.e. lower the tray-6 temperature
lighter would be the overhead product.

 Pressure :

Although the pressure is not normally considered a process variable, the column
pressure is maintained by a pressure control valve PIC-09 which controls the
amount of overhead flow that is allowed to pass through the FIN FAN CONDENSER
A-02 and cooler S13 and enter the receiver V-07. A differential pressure controller
PDIC-10 is provided to allow hot overhead vapors to bypass the condenser and
enter the receiver. Thus PDIC-10 maintains a set pressure differential between
the column and the receiver. The pressure is not normally changed, but if there is
a change in the pressure, then the composition will change. For example, an
increase in pressure with heat input and flow rates constant, will make the
overhead composition lighter.

 Bottoms Temperature :

The bottoms temperature variable (i.e. TI-19) controls the amount of C 3 /C 4

material that is allowed to remain in the bottoms product. The stabiliser bottom
temperature is controlled by the reboiler heat input back to the column. This heat
input is controlled by the amount of circulating diesel flow through the tube side of
the reboilers S-09 / S-10 on flow control (FIC-19 and FIC-13). This variable is
normally adjusted to the RVP specification of the stabilised naphtha product.

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For detailed operating parameters, instrument tags and values for SAT GAS
CONC UNIT refer "Normal Operating Conditions" given in section 5.1.

3.4 SIMPLIFIED FLOW DIAGRAM

Refer attached diagram

3.5 UTILITIES DESCRIPTION

 NITROGEN SYSTEM (EAST)

Refer P&Id : G42-RD311/312-141

A 3” main header with battery limit isolation valve, local PG-418, DCS pressure
indication (PI-419), and high and low pressure alarm supplies nitrogen to the unit.

Five 3/4” tap-offs are taken from main header and connected to LP flare header.
All nitrogen lines connected to LP flare header are provided with self regulating
PCV.
Five ¾” tap-off are taken from main header for all five zone of heaters & it join
fuel gas line.
Also three 2” tap-off are taken from the main header and connected to
following points.

First 2" line

 1st stage Desalter (V-02) through 3/4” line.
 2nd stage Desalter (V-03) through 3/4” line.
Second 2” line

 1st stage Desalter (V-33) through 3/4” line.

 2nd stage Desalter (V-34) through 3/4” line.
Third 2" line
 Net gas compressor for purging purpose through 2” line.
 Purge Seal Oil Reservoir through 1" line

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Crude Complex Refinery Division Crude Distillers
Jamnagar

 NITROGEN SYSTEM (WEST)

Refer P&ID: G42-RD311/312-143

A 2” header with battery limit isolation valve and local pressure gauge (PG-426) &
FT-225 supplies N2 to the unit. A line of 2" has been tapped off from the main
header and connected to the LP Condensate Flash Condenser.
 PLANT AIR SYSTEM (EAST)

Refer P&ID: G42-RD311/312-141

A 3” header has been provided for the supply of plant air to the unit with battery
limit isolation valve and local PG-420.

3” main header supplies plant air to the following points.

 Crude Heater(311/312-F01) decoking piping through 3" line

 Vacuum Heater(311/312-F02) decoking piping through 3" line
 Crude Heater (311/312-F51) decoking piping through 3" line and
 Utility Station (US-311/312-26) through 1" line

Further the main header divides into five branch headers of 2”, which supply plant
air to various Utility Stations.(US-22/23/24/25/27/28/29/37/45/36/13
/14/104/105&106)

 PLANT AIR SYSTEM (WEST)

Refer P&ID: G42-RD311/312-143

A 2” header with battery limit isolation valve and local PG-428 has been provided
for the supply of plant air to the unit.

The header supplies plant air to Utility Station (US-085) through 2” line which
further
divides in to 1”line to supply plant air to utility station(US-084/86/87/88/89/90).

 INSTRUMENT AIR SYSTEM (EAST)

Refer P&Id : G42-RD311/312-142

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Crude Complex Refinery Division Crude Distillers
Jamnagar

A 3” header with battery limit isolation valve, local PG-422, DCS pressure
indication (PI-423), low flow alarm and low low-pressure alarm (PALL-423)
supplies Inst.air to the unit. Various instrument air tapings are taken from this
header. One 2” tap-off is taken from main header and connected to analyser
house.

 INSTRUMENT AIR SYSTEM (WEST)

Refer P&ID: G42-RD311/312-144

A 2” header with battery limit isolation valve, local PG-430, DCS pressure
indication (PI-431), along with low flow alarm supplies Inst.air to the unit. Various
instrument air tapings are taken from this header.

 BREATHING AIR SYSTEM (EAST)

Refer P&Id : G42-RD311/312-142

A 2” header with battery limit isolation valve and local PG-424 supplies breathing
air to the unit. A line of 1 1/2” has been tapped off from the main header and
connected to the breathing station (PYRRD 001). A local TG-649 is provided on
this line going to breathing station.
There are 12 breathing stations in 311/321 with 11 to be supplied from east rack.
Various
breathing air tappings are taken from this unit.

 BREATHING AIR SYSTEM (WEST)

Refer P&Id : G42-RD311/312-144

A 2” header with battery limit isolation valve and local PG-432 supplies breathing
air to the unit. A line of 11/2” has been tapped off from the main header and
connected to the breathing station (PYRRD 001). A local TG-668 is provided on
this line going to breathing station.

 PILOT GAS DISTRIBUTION SYSTEM

Refer P&Id : G42-RD311/312-132

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Crude Complex Refinery Division Crude Distillers
Jamnagar

The Pilot fuel gas from Pilot FGKOD (MV-RU742-V002) is received in main Pilot gas
header, which supplies pilot gas to U-
311/312/261/262/263/221/281/362/352/231/951 & U-281.

A 3” main header with battery limit isolation valve, local PG-371, TG-620, DCS flow
indication (FI-234), flow recorder, totaliser and low flow alarm, supplies pilot gas
to crude unit. Pilot gas from main 3" header is received into Pilot FGKOD
(311/312-V28) which is provided with Demister pad, local LG-087, PG-372, PSV-
148A/B, DCS level indication (LI-088) with high level alarm. The drum is also
connected with LP flare header. Pilot FGKOD supplies dry gas to the Vacuum and
Crude heaters through 3" main header.

Three lines of 2” have been tapped off from 3" header, which supply dry fuel gas
to the following points.

 Vacuum Heater (311/312-F02) through 2" line

 Crude Heater (311/312-F01) zone 1 & 2 separately through 2 " line
 Crude Heater (311/312-F51) zone 1 & 2 separately through 2 " line

 FUEL GAS DISTRIBUTION SYSTEM

Refer P&ID: G42-RD311/312-131/035

The fuel gas from FGKOD (MV-RU742-V001) is received in Refinery Fuel Gas
Header, which supplies fuel gas to U-
681/551/311/312/263/362/262/352/261/281/231 & 221. It also supplies Fuel Gas
to Pilot FGKOD (MV-RU742-V002).
A 10” header with battery limit isolation valve, local PG-414, TG-635, DCS flow
indication (FI-251), flow recorder, totaliser and low flow alarm supplies fuel gas to
crude unit. Fuel gas through main header is received into FGKOD (311/312-V15)
which is provided with Demister pad, local PG-236, LG-065, PSV-136A/B and DCS
level indication (LI-016) with high level alarm. FGKOD is also connected with LP
flare header and light slop header.

FGKOD supplies dry fuel gas to the following points.

 Crude Heater(311/312-F01) Zone 1&2 through 4" line

 Crude Column(311/312-C05) through 1" line

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Crude Complex Refinery Division Crude Distillers
Jamnagar

 Crude Heater(311/312-F51) Zone 1&2 through 4" line

 Vacuum Heater(311/312-F02) through 4" line &
 Purge gas connection to LP/HP flare header. (Two no. lines of 1"& 1.5”)

Also following two 2” tap-off have been taken from the main header before
FGKOD.

a. 1st 2” header

 Vac. Producing Equip.(MS-311/312-01)

 Ejector K.O.drum / Blowcase (311/312-V18/V19) &
 Purge gas connection to LP/HP flare header. ( two no. line of 1”)

b. 2nd 2” header

 High Pressure Receiver(321/322-V01)

 Stabilizer Receiver(321/322-V07) &
 Purge gas connection to LP/HP flare header (two no. line of ¾” & 1”)

Apart from this, two lines of 4" and 3" are tapped off from the main header before
FGKOD and have been connected to Recontact Drum (311/312-V13) and Crude
column Receiver (311/312-V12) respectively.

 FUEL OIL DISTRIBUTION SYSTEM

Refer P&ID: G42-RD311/312-133

Fuel Oil from main Fuel Oil storage tank (MT-RU741-001/002) is pumped into
refinery fuel oil header by Refinery Fuel Oil Circulation Pumps (MP-RU741-
P001A/B/C). The main header supplies fuel oil to U-
311/312/361/362/371/221/261/262/263/281. P001A/B are motor driven whereas
P001C is turbine driven and the capacity of each pump is 174 M3/hr. One motor
and one turbine driven pump will be running normally and on low low pressure
alarm spare pump will start automatically. Fuel oil heater (ME-RU741-S001) is
provided on common discharge header of FO circulation pumps (P001A/B/C) which
is followed by viscosity and sulfur analyzers.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

4 “ supply and 2” return headers are running in crude unit. The supply header is
provided with local PG-416, TG-637, DCS flow indication (FI-253), flow recorder,
totaliser and low flow alarm. New supply header 4” tap-off taken from top from
OSBL header. New header have TG-718. The return header is also provided with
local PG-415, TG-636, DCS flow indication(FI-252), flow recorder, totaliser and low
flow alarm .

Balancing line of 1” with restriction orifice has been provided between supply and
return headers inside the battery limit. PIC-022 joins supply and return headers
outside the battery limit. This is for establishing and maintaining FO circulation.

Three Nos. lines of 2" have been tapped off from both the headers and connected
to the following points.

 Crude Heater(311-F01) Zone 1&2

 Crude Heater(311-F51) Zone 1&2
 Vacuum Heater(311-F02)

 BOILER FEED WATER SYSTEM

Refer P&ID: G42-RD311/312-107

A 2” header with battery limit isolation valve, local PG-397, TG-630, flow indication
in DCS, flow recorder, totaliser, and low flow alarm supplies BFW to the unit.

Two lines of 2” have been tapped off from the main header, which supply BFW to
the following points.

 LP Steam Desuperheaters (311/312-Y01) at F-01 outlet.

 LP Steam Desuperheaters (311/312-Y51) at F-51 outlet.

In revamp both above point are blind off. Desuperheater is removed from LP
Steam line of F-01 and F-51.

 HP STEAM DISTRIBUTION SYSTEM (EAST)

Refer P&ID: G42-RD311/312-101

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Crude Complex Refinery Division Crude Distillers
Jamnagar

A 8” header with double isolation valves & spectacle blind, local PG-374, TG-622,
DCS flow indication (FI-236), flow recorder, totaliser, and low flow alarm supplies
HP steam to Stripper reboiler (321/322-S07). 8” tap-off taken from main header
for ejector steam.

Steam traps are provided on main header at every 75M distance and discharge is
connected to HP condensate header. Before commissioning main HP steam header
all traps have to be isolated and condensate to be drain through by pass line.
Once the steam appears, close bypass line and take traps in line.

 MP STEAM DISTRIBUTION SYSTEM (EAST)

Refer P&ID: G42-RD311/312-101

A 16” header with battery limit isolation valve & blind, local PG-373, TG-621, DCS
flow indication (FI-235), flow recorder, totaliser and low flow alarm, supplies MP
steam to the unit. Main 16” header divides into several branch headers, which
supply MP steam to the following points.

A 12” header supplies MP steam to Crude Heater (311/312-F01) for

 Emergency steam to process coils through 6" line

 Soot blowers through 4" line
 FO Atomization through 3" line in zone 1 & 2 separately
 Decoking through 6" line
 To LP steam line for stripping steam

A 12” header supplies MP steam to Crude Heater(311/312-F51) for

 Emergency steam to process coils through 6" line

 Soot blowers through 4" line
 FO Atomization through 3" line in zone 1 & 2 separately
 Decoking through 6" line
 To LP steam line for stripping steam

A 14” header supplies MP steam to

(01) Vacuum Heater (311/312-F02) for

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Jamnagar

 Emergency steam to process coils through 6" line

 Soot blowers through 4" line
 FO Atomization through 3" line
 Decoking through 6" line

(02) Steam separator (311/312-Y02) through 3" line for process steam
(Turbulising steam) to vacuum heater coils.

(03) Steam separator (311/312-Y10) through 3" line for vacuum column ejector
system.

(04) Ram Pump (311/312-P26) through 2" line

(05) Steam for (311/312) FE-006 through 1” line and for (311/312) FE-007
through 1”

A line of 12” has been tapped off from the main header, which supplies MP steam
to Crude-MP steam Exchanger (311/312-S03).

A line of 3” has been tapped off from the main header, which supplies MP steam
to Lube oil pump (Turbine drive) of Net Gas Compressor.

A line of 6” has been tapped off from the main header, which supplies MP steam
to vacuum residue pump turbine (311/312-S-18B).

A line of 6” has been tapped off from the main header, which supplies MP steam
to reduced crude pump turbine (311/312-S-10B).

A line of 10” has been tapped off from the main header, which supplies MP steam
to 321/322-S-07 (Stripper reboiler).

Steam traps are provided on main header at every 75M distance and discharge is
connected to MP condensate header. Before commissioning main MP steam
header all traps have to be isolated and condensate to be drain through by pass
line. Once the steam appears, close bypass line and take traps in line.

 LP STEAM DISTRIBUTION SYSTEM (EAST)

Refer P&ID: G42-RD311/312-102,108,109,110

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Crude Complex Refinery Division Crude Distillers
Jamnagar

A 20” header with battery limit isolation valve & blind, local PG-375, TG-623, DCS
flow indication (FI-237), flow recorder, totaliser, and low flow alarm supplies LP
steam in the unit. Main header divides into several branch headers, which supply
LP steam to following points.

A 16” header supplies LP steam to Crude Heater (311/312- F51) for

 Snuffing steam through 6" line ( zone 1 & 2 separately )

 Steam/Air pre-heater (311/312-Y52) through 8" line
 Steam for stripping steam through 12” line

A 10” header supplies LP steam to

1. Vacuum Heater (311/312-F02) for

 Snuffing steam through 6" line
 Steam/Air pre-heater(311/312-Y04) through 6" line

1. Heavy Slop Drain Tank heating coil (311/312-V22) through 1" line.
2. To slopwax quench drum (V-44) for steaming out of vessel during shutdown.

A 16” header supplies LP steam to

1. Crude Heater (311/312- F01) for

 Snuffing steam through 6" line ( zone 1 & 2 separately )
 Steam/Air pre-heater (311/312-Y02) through 8" line
 Steam for stripping steam through 12” line

2. Crude Column (311/312-C05), side strippers and Vacuum Column (311/312-

C16) - Auxiliary steam supply.

A 6” header supplies LP steam to following points for steaming out during S/D.

 1st stage Desalter (311/312-V02/V33) through 4" line.

 2nd Stage Desalter (311/312-V03/V34) through 4" line.
 FlashDrum (311/312- V04) through 4" line.

A 4” header supplies LP steam to following points for steaming out during S/D.

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Jamnagar

 Recontact Drum(311/312-V13) through 3" line

 Crude Column Receiver(311/312-V12) through 3" line

A 8” header supplies LP steam to following points for steaming out during S/D.

 Primary Absorber(321/322-C02) through 3" line

 Stripper(321/322-C05) through 4" line
 Stabilizer(321/322-C06) through 4" line
 High pressure receiver(321/322-V01) through 3" line

A 6” header supplies LP steam to following points for steaming out during S/D.

 Light Kerosene Stripper(311/312-C09) through 3" line

 Heavy Kerosene Stripper(311/312-C07) through 3" line

A tap-off of 6” has been taken from the main header, which supplies LP steam to
Gas Oil heating Coils (311/312-A07) through 12 lines of 3".

A tap-off of 6” has been taken from the main header, which supplies LP steam to
LVGO Cooler heating Coils (311/312-A08) through 06 lines of 3".

Also, a line of 2” has been tapped off from one branch header of 4” and connected
to main Crude line at B/L for steaming out.

The unit is also provided with Nos. of LP steam Utilities stations, steam lance
connection
& tracing manifold.

Steam traps are provided on main header at every 75M distance and discharge is
connected to LP condensate header. Before commissioning main LP steam header
all traps have to be isolated and condensate to be drain through by pass line.
Once the steam appears, close bypass line and take traps in line.

 MP STEAM DISTRIBUTION SYSTEM (WEST)

Refer P&ID: G42-RD311/312-106

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Crude Complex Refinery Division Crude Distillers
Jamnagar

A 4” header with battery limit isolation valve, local PG-395, TG-628, DCS flow
indication (FI-242), flow recorder, totaliser, and low flow alarm, supplies MP steam
to the unit.

Two lines of 3" have been tapped off from the main header and connected to HP
flare K.O.drum pump turbine (311/312-S27A) and LP flare K.O.drum pump turbine
(311/312-S28A).

The main header is also provided with drip leg and steam trap and discharge is
connected to MP steam condensate header through 2" line.

 LP STEAM DISTRIBUTION SYSTEM (WEST)

Refer P&ID: G42-RD311/312-106

A 6” header with battery limit isolation valve & blind, local PG-396, TG-629, DCS
flow indication (FI-243), flow recorder, totaliser, and low flow alarm, supplies LP
Steam to the unit.
Two 4” size tap-off have been taken from main header and connected to following
points.

 HP flare K.O.drum (311/312-V23) heating coil.

 LP flare K.O.drum (311/312-V24) heating coil.

Also, HP flare K.O.drum pump turbine (S-27A) and LP flare K.O.drum pump turbine
(S-28A) discharge LP steam to main header through 4" lines.

Provision exists for steaming out following:

 HP flare K.O.drum (311/312-V23) through 4” line
 LP flare K.O.drum (311/312-V24) through 4" line

The main header is also provided with drip leg and steam trap and discharge of
the same is connected to LP steam condensate header through 2" line.
The unit is also provided with number of LP steam utilities stations & steam lance.

 COOLING WATER SYSTEM

The Common Cooling Tower No.2 supplies CW to U-

311/312/351/352/361/362/722/751 & 371. Five Nos. cooling water circulation

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Crude Complex Refinery Division Crude Distillers
Jamnagar

pumps (MP- RU732 - P001A/B/C/D/E) are provided for supply of CW. All pumps
are motor driven and the capacity of each pump is 5500 M3/hr.

The common discharge header is of 72" size and provided with local PG-007, TG-
010, on line pH analyzer (AI-001) with high and low pH alarm, DCS temperature
indication (TI-011) with high and low temperature alarm and DCS pressure
indication (PI-006) with low pressure alarm. PI-012 also indicates pressure in DCS
with high pressure alarm (PAH-012) and low low pressure alarm (PALL-012).

Normally three pumps will be running and on low low pressure alarm other two
stand by pumps will start automatically.

 COOLING WATER DISTRIBUTION SYSTEM (EAST)

Refer P&ID: G42-RD311/312-121/122/123

30” supply and return headers are provided in the unit. The supply header is
provided with battery limit isolation valve & blind, local PG-405, TG-631, DCS flow
indication (FI-248), flow recorder, totaliser, and low flow alarm. The return
header is provided with battery limit isolation valve & blind, local PG-406, TG-632
and Corrosion Coupon (CC-050).

A 30” main header supplies CW to

 LVGO Trim Cooler (311/312-S20)

 Vacuum Producing Equipment(MS-RD311/312-01)
 Light slop drain tank (MV-RD321/322-V-08)
 Heavy slop drain tank (MV-RD311/312-V-22)
 Slop Wax Pump (311/312-P19A/B)

A new 20” header is taken from OSBL that supply CW to the following point.

 Full Range Naphtha Cooler (321/322-S12A/B)

 Light Kerosene Product Cooler(311/312-S06)
 Stabilizer overhead trim condenser(321/322-S-13)

A 30” supply header divides into several branch headers, which supply CW to the
following points.

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Crude Complex Refinery Division Crude Distillers
Jamnagar

A 12” header supplies CW to

 Stabilizer Net Overhead Cooler(321/322-S11)

 Stabilizer Bottoms Coolers(321/322-S08A/B)
 Primary Absorber Inter cooler(321/322-S02)
 Sponge Absorber Lean Oil Trim cooler(321/322-S04)
 Stabilizer Bottoms Recycle Pumps(321/322-P05A/B)
 Stabilizer overhead pumps(321/322-P06A/B/C)
 High Pressure Coolers(321/322-S01A/B) &
 Sample Cooler(PA004)

A 8” header supplies CW to

 Flash Drum Liquid Pumps(311/312-P04A/B/C) &

 Various Sample Coolers( PA-002/003/015/019/020/029)
 Desalting water pumps (311/312-P-02A/B/C/D)
 2nd Stage desalter water pumps(311/312-P-03A/B/C)
 Net gas Compressor(311/312-C01)
 Light Slop Drain tank(311/312-V08) cooling coil
 Heavy Slop Drain Tank(311/312-V22) cooling coil

A 6” header supplies CW to

 LVGO Pumps (311/312- P21A/B)

 Vac.residue/HVGO Pumps(311/312-P18A/P20A)
 Vac.residue/HVGO Pumps(311/312-P18B/P20B)
 HAGO Product Pumps(311/312- P11A/B)
 Diesel Circulating Pumps(311/312-P08A/B)
 Heavy Kerosene Circulating Pumps(311/312-P07A/B)
 Light Kerosene Reflux Pump(311/312-P06A/B)
 Naphtha Circulating Pumps(311/312-P05A/B/C)
 Reduced Crude Pumps(311/312-P10A/B) &
 Various Sample Coolers , PA004/005/006/007/009/010/013/014 & PA015.
 311/312 Analyzer house
A 3" header supplies CW to

 HAGO Circulating Pumps(311/312-P09A/B)

 Light Kerosene Product pumps(311/312-P12A/B/C)
 Heavy Kerosene Product pumps(311/312-P13A/B/C)
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Crude Complex Refinery Division Crude Distillers
Jamnagar

 Diesel Product pumps(311/312-P14A/B/C)

The 30" supply & return headers are provided with 2" jumpover inside the B/L and
10" jump over out side the B/L.

 COOLING WATER DISTRIBUTION SYSTEM (WEST)

Refer P&Id : G42-RD311/312-124

3" supply and return headers are provided in the unit. The supply header is
provided with battery limit isolation valve, local PG-407, TG-633, DCS flow
indication (FI-249), Flow recorder, totaliser, and low flow alarm The return header
is provided with local PG-408, TG-634 and Corrosion Coupon (CC-051).

The 3” main header supplies CW to the following points for bearing cooling.

 HP Flare Knock Out Drum Pumps (311/312-P27A/B) through 1” line.

 LP Flare Knock Out Drum Pumps (311/312-P28A/B) through 1” line.
 LP Condensate Return pumps (311/312-P33A/B/C) through 1” line.
 Various sample station PA-51/52/53/54 through 1” line.

The 3" supply & return headers are provided with 2" jumpover inside and out side
the B/L.

 POTABLE WATER DISTRIBUTION SYSTEM (EAST)

Refer P&ID: G42-RD311/312-125

A 3” header with battery limit isolation valve, local PG-409 and TG-612 supplies
potable water to the unit.

The main header serves potable water to the following points.

 Drinking water fountain (PYWRD-011) through 3/4” line.

 Safety Shower and Eye wash (PYWRD-061) through 3/4” line.
 Analyzer house through 3/4” line.

 POTABLE WATER DISTRIBUTION SYSTEM (WEST)

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Jamnagar

Refer P&ID: G42-RD311/312-126

A 3” header with battery limit isolation valve, local PG-412 and TG-615 supplies
potable water to the unit.
The main header serves potable water to the following points.

 Drinking water fountain through 3/4” line.

 Safety Shower and Eye wash (PYJG-001) through ½” line.

 UTILITY WATER DISTRIBUTION SYSTEM (EAST)

Refer P&ID: G42-RD311/312-125

A 8” header with battery limit isolation valve, local PG-410 and TG-613 supplies
utility water to the unit.

Three lines of 6" size have been tapped off from the main header, which supply
utility water to the following points.

First 6" line

 Vacuum heater(311/312-F02) Decoking piping &

 Air Pre-heater for water washing

Second 6" line

 Crude heater(311/312-F51) Decoking piping &

 Air Pre-heater for water washing

Third 6" line

 Crude heater(311/312-F01) Decoking piping &

 Air Pre-heater for water washing

3” line

 311/312-A-05 tube bundle for flushing provision

2" line

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 Utility Stations (US-311/312-13/14)

 311/312-P-40A/B pump seal

A separate line of 1” has been tapped off from the main header and connected to
Utility Station (US-311/312-26).

 UTILITY WATER DISTRIBUTION SYSTEM (WEST)

Refer P&ID: G42-RD311/312-126

A 2” header with battery limit isolation valve, local PG-413 and TG-617 supplies
utility water to the unit.

The main header supplies utility water to the Utility Station (US-311/312-
84/85/86/87/89) through 1” line.

 COLD CONDENSATE SYSTEM (WEST)

Refer P&Id : G42-RD311/312-125

A 4” header with battery limit isolation valve and local PG-411 supplies cold
condensate to the Desalting Water surge Drum (311/312-V01), through FV-019.

 HP CONDENSATE SYSTEM (EAST)

Refer P&ID: G42-RD311/312-103

A 6” header with battery limit isolation valve, local PG-376 and TG-624 is provided
in the unit to collect HP condensate. Stripper Reboiler (321/322-S07) discharges
HP condensate to main header through 6" line.

The HP condensate is flashed into HP condensate flash drum (311/312-V25) and

resultant MP steam is routed to main MP steam header.This is the common Knock
out system for entire crude complex

 MP CONDENSATE SYSTEM (EAST)

Refer P&ID: G42-RD311/312-103

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A 8” header with battery limit isolation valve, local PG-377 and TG-625 provided in
the unit to collect MP condensate.

The following various points discharge MP condensate to main header.

 Crude -MP steam Exchanger(311/312-S03) through 8” line

 Net Gas Compressor Skid(311/312-C01) through 2”
 Stripper reboiler (321/322-S-07)
 Steam Separator(311/312-Y10) through 2” line ( MS KOD for vacuum column
ejector system)
 Steam Separator(311/312-Y02) through 2” line (MS KOD of process steam to
vacuum heater coils)
 MP steam header line traps through 1” line.
 F-01/51/02 soot blowers
 F-01/51/02 atomizing steam line traps
 311/312-S-10/18 line trap

The MP condensate is flashed into MP condensate flash drum (311/312-V26) and

resultant LP steam is routed to main LP steam header.

 LP CONDENSATE SYSTEM (EAST)

Refer P&ID: G42-RD311/312-162/163

A 4” header with battery limit isolation valve, local PG-378 and TG-626 is provided
in the unit to collect LP condensate.

The following various points discharge LP condensate to main header through 2"
size collection header.

1. Crude Heater (311/312-F01)

 Zone1 snuffing steam line condensate through 1" line

 Zone2 snuffing steam line condensate through 1" line
 Condensate from steam line to steam/Air pre-heater (311/312-Y02) through 3"
line

2. Crude Heater (311/312-F51)

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 Zone1 snuffing steam line condensate through 1" line

 Zone2 snuffing steam line condensate through 1" line
 Condensate from steam line to steam/Air pre-heater (311/312-Y52) through 2"
line

3. Vacuum Heater (311/312-F02)

 snuffing steam line condensate through 2" line

 condensate from steam line for soot blowers through 1/2" line
 Atomizing steam line condensate through 2" line
 Condensate from steam line to steam/Air pre-heater(311/312-Y04) through 3"
line

4. Condensate from Gas Oil Cooler (311/312-A07) Heating Coils through six lines
of 1" size.

5. Heavy Slop Tank heating coil condensate

6. Condensate from LP steam header traps.

The following points discharge LP condensate in the main header directly.

 Net Gas Compressor Skid (311/312-C01) through 2" line

 Condensate from Steam Tracing Manifolds

 CONDENSATE COLLECTION SYSTEM:

Condensate from various units is collected in HP, MP & LP condensate headers.

Each level of condensate is separately collected in a common utility header from
where it is routed to the Crude Complex Flash Drums in unit-311. The condensate
system is identical for both the trains. And whenever any of the condensate flash
drum is down for the maintenance in Train No.1, the condensate flow from Train
No.1 can be diverted to the respective condensate flash drum in Train No.2 or vice
versa. Train 1 will receive condensate of U-311/321/351/361/371 & 372, whereas,
train 2 will receive it from U-312/322/352/362 only. Train 2 will not receive any
condensate from U-371/372. (Refer ANNEXURE-1,2 &3)
 HP & MP CONDENSATE FLASH DRUMS

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Refer P&ID: G42-RD311/312-104

HP condensate is received & flashed into HP condensate flash drum (V25) through
14" line having an isolation valve and blind at the battery limit. The resultant MP
steam due to flashing of HP condensate is routed to MP steam header through 8”
line. The line is provided with battery limit isolation valve, local PG-382, TG-647,
DCS flow indication (FI-238), flow recorder and totaliser.

The HP condensate flash drum (V25) is provided with local PG-379, LG-089, PSV-
381A & B, DCS level indication (LIC-090) and high and low level alarm. The
discharge of PSVs is located at the safe place in atmosphere. The HP condensate
flash drum discharges into MP condensate flash drum (V26) through 16” line on
level controller.
MP condensate from HP condensate flash drum (V25) enters into MP condensate
flash drum (V26) along with the condensate from various units through 12" size
line having an isolation valve and blind at the battery limit. The resultant LP steam
due to flashing of MP condensate is routed to LP steam main header through 18”
line which is provided with an isolation valve and blind at the battery limit, local
PG-388, TG-648, DCS flow indication (FI-239), flow recorder and integrator.

MP condensate flash drum (V26) is provided with local PG-385, LG-091, PSV-387A
& B, DCS level indication (LIC-092) and high and low level alarm. The discharge of
PSVs is routed to atmosphere at the safe location. The MP condensate flash drum
(V26) discharges into LP condensate flash drum (V27) through 10” line on level
controller.

 LP CONDENSATE FLASH DRUM

Refer P&ID: G42-RD311/312-105

LP condensate from various units & LP and HP flare K.O drum heater coils and
condensate from MP condensate flash drum (V26) enters into LP condensate flash
drum (V27). The resultant low-low pressure steam due to flashing of LP
condensate is condensed in A09, which is air-cooled exchanger. The condensate
from A-09 is again routed to LP condensate flash drum (V27). LP condensate flash
drum (V27) is provided with local PG-391, LG-94, PSV-389A & B, DCS level
indication (LIC-095), high and low level alarm and low low level alarm (LSLL-093).
The discharge of these PSVs is routed to atmosphere at the safe location. In order

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to avoid vacuum condition inside the LP condensate flash drum (V27) and
condenser (A09), nitrogen connections have been given at the common vent of
the PSVs and condenser (A09). Split range pressure controller PIC-390 (PV-390A &
B) is provided on nitrogen supply line of 2”.
The liquid condensate from LP flash condensate drum (V27) is pumped to
condensate return header by LP condensate return pumps (P33A/B/C) through 12”
line having an isolation valve & blind at the battery limit. All pumps are motor
driven. A control valve is provided on common discharge line of these pumps,
which controls the level of LP condensate flash drum (V27). Emergency S/D
system (ESD-16) is provided here. Pumps P-33A/B/C will stop on low low level
alarm. Alarm will appear before S/D system gets actuated.

Also the condensate line is provided with DCS flow indication (FI-241), flow
recorder, totaliser and low flow alarm. A spill back line of 6” along with the DCS
flow indication (FIC-240) is provided.

PDI-460, PDI-461 & PDI-462 will indicate differential pressure of LP condensate

return pumps (311-P33A/B/C) in DCS. The low differential pressure alarm has also
been provided along with this.

 FLUSHING OIL DISTRIBUTION SYSTEM

Refer P&ID: G42-RD311/312-134

A 8" main header with battery limit isolation valve, blind, local PG-417 and TG-638
supplies flushing oil to the unit.

Four tap-offs of 6", 4", 3" & 2" have been taken from the main header, which
supply Flushing Oil to the following points.

6" header

 LVGO Pumps(311/312-P21A/B)
 Heavy Slop Collection Header
 RAM Pump(311/312-P26) suction
 Vacuum Column(311/312-C16)
 Raw Crude-Vacuum residue exchanger(311/312-S-25)

4" header

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 Heavy Slop Collection Header

 For start-up/Flushing of Plan 32 Pump Seal Oil Header (HVGO will be used after
plant start-up)
 Desalted crude -Cold circulating HAGO exchanger(311/312-S09)
 Desalted crude -Cold vacuum residue exchanger (311/312-S10)
 Desalted crude -Cold circulating HVGO exchanger(311/312-S12)
 Flashed crude-Hot circulating HVGO exchanger(311/312-S13/S513)
 Flashed crude-Hot circulating HAGO exchanger(311/312-S14/S514)
 Flashed crude-Slopwax quench exchanger(311/312-S-28)
 Flashed Crude -Hot vac.residue Exchanger(311/312-S15/S515)

3" header

 LK Stripper Reboiler (311/312-S18) on HAGO side.

 HK Stripper Reboiler (311/312-S16) on HAGO side.

2" header

 Heavy slop collection header

 LP flare K.O drum pump (311/312-P28B) and HP flare K.O drum pump
(311/312-P27B)
As mentioned above, main header supplies flushing oil to RAM Pump (311-P26).
Subsequently Ram Pump supplies flushing oil to the following points through 4"
Ram Oil header.

 Gas Oil Cooler(311/312-A07)

 Gas Oil Rundown
 Off Spec Header
 HAGO Product Pumps(311/312-P11A/B)
 HVGO Pumps(311/312-P20A/B)
 Vac.Residue Pumps(311/312-P18A/B)
 Vacuum Column(311/312-C16)
 Slop Wax Pumps(311/312-P19A/B)
 Slop Wax quench Drum (311/312-V-44)
 HAGO Circulating Pumps(311/312-P09A/B)
 HAGO Circulating Pumps Discharge filter
 Reduced Crude Pumps(311/312-10A/B)

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3.6 UTILITY SPECIFICATION AND REQUIREMENT

SR.NO UTILITY PRESSURE TEMP NOR MAX. FLOW

FLOW
0
(Kg/Cm2.g) C (T/HR) (T/HR)
1 Nitrogen 7 38 NNF 4
2 Plant Air 7.7 40 NNF 2.67
3 Instrument Air 7 40 1.14 1.25
4 Breathing Air 7.7 40 NNF 0.04
5 Fuel Gas 3.9 38 26 27
6 Fuel Oil 11 95 18 21
Return Fuel Oil 4 95 18 21
7 Pilot Gas 3.9 38 0.16 0.19
8 Boiler Feed Water 10.9 121 NNF 2.44
9 HP Steam 42.2 391 32 34
10 MP Steam 16 232 137 149
11 LP Steam 4.1 177 15 36
12 Cooling Water 4.5 32 5795 6021
Return Cooling 3.1 49 5795 6021
Water
13 Potable Water 3.5 43 NNF 17
14 Utility Water 4.5 43 NNF 208
15 Cold Condensate 9 45 NNF 62
16 HP condensate 38 250 32 34
17 MP condensate 12 191 36 38
18 LP condensate 1.4 126 21 27

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3.4. UTILITY SPECIFICATION AND REQUIREMENT (NORMAL)

Utility PRESS. , TEMP, 0C Unit Consumption

Kg/cm2g
Cooling Water 3.5 32 m3/hr 610
Power - - KW 385
MP Steam 42.2 391 TPH 34

3.7 AUXILIARY SYSTEM

3.7.1 STORM WATER SYSTEM

Storm water system is provided to collect water from areas, which are not subject
to contamination. This system finally discharges water directly to holding ponds.
Diversion chamber has been provided in the Five Corners of the plot area from
where diversion to ETP through oily sewer is possible in case of contamination.
Main storm water header is running across the unit. Water is collected from the
respective catch basin provided in the process area and finally sent to main storm
water header via manhole.
Catch basins are provided at the following points.

1. Crude Heater Area (F01/F02) 2 nos.

2. Crude Column Area 4 nos.
3. Overhead section near V-12 4 nos.
4. Compressor Areas 2 nos.
5. Sat. Gas Conc. Area 9 nos.
6. Pre Heat Train Area 3 nos.
7. Flashed crude Area near V-04 11 nos.
8. Vacuum Heater Area 7 nos.
1) OILY WATER SEWER.(O.S)

Oily water sewer is provided to collect following:

a) Hydrocarbon process waste from equipment drains.
b) Blow down from process equipment.
c) Spilled material during sampling.

Details:
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 An 8” oily water sewer header is laid in the center of the unit parallel to the
piperack. 4”individual drain points from the heat exchanger/ equipment/
pumps discharge to 6” branch header, which is finally connected to 8”oily
water sewer main header.
 A separate 10” header has been provided for 3 Decoking pits and this header
directly joins the OSBL piping of OWS system.
 Eight oily water sewer manholes are (precast concrete) are provided on the
main 8” header. Each manhole is having 4” vent line & liquid seal for fire
protection.
 All inlet pipes to oily water sewer manhole are sealed by minimum liquid depth
of 150 mm.
 Oily water is finally routed to the effluent treatment plant.

 OWS header joins the OSBL system and is routed to ETP plants. This oily
water is routed to oil skimming sections from where the oil is skimmed out.
The skimmed oil is then pumped to light slops/Heavy slops/Cracked slops tank.

Please refer Under Ground drawings No-

3.7.2. FLARE SYSTEM

INTRODUCTION:

Flares are provided to safely combust relief valve discharges and normal process
vents. The flare system is designed to prevent over pressure and safe disposal of
discharged hydrocarbon vapors / liquids during startup, shutdown and emergency.
Released vapors are passed through an elevated stack from a closed collection
system and burnt at the top by means of pilot burners, which are at the top of the
flare stack. These pilot burners are on all the time to avoid any vapors leaving the
stack unburnt. High Integrity Protection System (HPIS) is used in the Flare design
in order to minimize the flare load.

There are four (4) major flare systems in the JAMNAGAR complex.

Main Gas Flare

FCC / Coker Flare
Acid Gas Flare

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Poly Propylene Flare

THE MAIN GAS FLARE (PSV’S DISCHARGE
WILL TAKE THE LOAD FOR HP FLARE HEADER
SET PRESSURE ABOVE 9 KG/CM2) AND LP FLARE HEADERS (PSV’S DISCHARGE SET
PRESSURE BETWEEN 3.5 AND 9 KG/CM2) FROM THE REFINERY UNITS AND THE
AROMATICS COMPLEXES. THE FCC/COKER FLARE WILL CATER TO THE LLP (PSV SET
PRESSURE BELOW 3.5 KG/CM2) DISCHARGEARGES FROM THE FCC/COKER FLARE. THE
ACID GAS FLARE WILL CATER EXCLUSIVELY FOR THE SULFUR RECOVERY UNIT AND THE
POLY PROPYLENE FLARE IS ONLY FOR THE PP PLANT. THE CONFIGURATION FOR THE
FLARES IS AS FOLLOWS:

FLARE NO. OF STACKS HEIGHT (m) DIA

(inches)
MAIN 3 150 60
FCC / COKER 2 150 72
ACID GAS FLARE 2 150 72
POLY PROPYLENE FLARE 2 150 72
Main gas flare consists of three identical flare stacks and tips in a common derrick.
Each stack and flare tip can be lowered and removed from service by
disassembling in sections while other flare and flare tips are in operation. The Main
Gas Flare will be operating with 2 stacks in line with the third stack as spare. Rest
all flares are designed with 100% spare philosophy. Derrick structure includes the
heat shields and equipment necessary to service any single flare tip while others
are in service. Diesel Hydrotreater flaring system consists of HP and LP flare
headers, which will finally go to the Main Gas Flare. Main Gas Flare (HP + LP) is
designed for handling 2200 Mt/hr based on the General Power Failure in the
complex. FCC/COKER (LLP) Flare is designed for 1350 Mt/hr based on 33KV Sub-
station failure at FCC.

Two header flare system will be installed for the whole refinery and aromatics
complex, which are finally connected to the main gas flare . Details of the Main
Gas Flare are as provided below:

MASS FLOW RATE : 2200 T/HR

NUMBER OF STACK RISERS : 3
DIAMETER OF STACK RI : 60”
OVERALL HEIGHT : 150 m DERRICK
HEIGHT OF STACK RISER : 141 m
PRESSURE AT BASE : 0.35 KG/CM2 g
GAS TEMPERATURE : 185 O C
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VENDOR : ZEECO INC., USA.

MAIN GAS FLARE CONSISTS OF THE FOLLOWING ACCESSORIES:

Knock out drums & pumps:

These are located before the flare stack in order to separate any
condensate/Liquid coming along with the released vapors. The condensate from
flare KOD will be sent to slop oil tanks via flare liquid cooler (Rs671-A001) by main
flare KOD pumps (P-001A/B). P-001A is motor driven and P-001B is turbine driven.
The Pumps are automatically activated on high level of the KOD and will stop on
low level of KOD. The stand by pump will start automatically on failure of running
pump.
Liquid seal drums :

These are provided to avoid any slops to be discharged into the flare stack and to
avoid air ingress into the flare header in case of stack molecular seal failure. A
liquid seal is provided by a continuous supply of utility water.
Flare stacks :

Flare stack is provided with aircraft warning lights at three levels. Guaranteed
noise level is 90 dB (A) at the perimeter of the sterile area. The flare stack
comprises of the following sections: -

Riser Structure: The flare gas after passing through the knockout drum and
liquid seal drum enters the bottom of the riser structure and travels up.

Molecular seal: This is welded to the riser section. It provides a seal against
entrance of air in the flare stack and minimizes formation of an explosive mixture
in the flare system. It resembles a bubble cap and creates a seal by accumulating
low molecular weight gas at the top.

Flare burner tip: It is a complete assembly sealed to the molecular seal outlet.
Accessories on the burner tip include gas pilots and steam supply nozzles for
steam injection.

Flame front generator:

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At the time of igniting the pilots, the flame front generator plays a major role. It
contains a special skid to ignite each pilot at a time. LPG is initially used as ignition
gas.

Steam control skid:

As per PCB regulations, a smokeless flare is essential for maintaining the ecology.
Smoke formation mainly occurs in fuel-rich systems where a low hydrogen
concentration suppresses the smoke. Steam control skid allows optimum amount
of steam to be introduced at the burner tip to avoid a smoky flame.

FLARE SYSTEM IN CDU / VDU

There are two types of flare systems in crude unit i.e. L.P Flare and H.P Flare
system.

 LP FLARE RELIEF SYSTEM

Refer P&ID: G42-RD311/312-111

A 54” main LP flare header provided in the unit enters into LP flare knockout drum
(311/312-V24). The header is provided with the blind & gear operated, horizontal
battery limit isolation valve.

The following PSVs, Vent, Drain points etc. discharge to LP flare header

 PSVs on crude column (PSV-130 A to H,J,K,L,M)

 Vents of Crude Column Receiver Water Pumps(P15A/B)
 PSV-133A/B and PV-005B on crude column receiver(V12)
 Vents of Crude Column Overhead Pumps(P16A/B)
 Aux. seal pot vent of Crude Column Overhead Pumps(P16A/B)
 PSV-135A/B and PV-010B on Recontact drum(V13)
 Vents of Unstabilised Naphtha Pumps(P17A/B)
 Aux. seal pot vent of Unstabilised Naphtha Pumps(P17A/B)
 Sample stations (PA-011/021/022)
 PSV-134A/B on Net Gas Compressor (C01) discharge.
 Fuel Gas main header through PCV.
 Nitrogen through PCV for purge connection.

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Also a 20" collection header for the following points joins the main header.

 PSV-136A/B on FGKOD (V15), PSV-148A/B on Pilot FGKOD (V28), PSV-

138A/B/C/D/E/F on Vacuum Column Overhead.
 Condensate blowdown from Pilot FGKOD(V28) and FGKOD(V15)
 Vent of heavy oil drain tank (V22)
 Vent of light oil drain tank (V08)
 XV-018(emergency S/D) on ejector vapor knockout drum (V18)
 Vents for LG-070, LG-069, LV-018, LT-018 & LT-019 of ejector condensate
receiver(V17) and vent for FV-101(located at ejector receiver condensate
pumps P23A/B discharge)
 Vents for LG-071, LT-017 of ejector vapor K.O drum (V18) and LG-072 of
ejector blow case (V19).
 Vents for Ejector Receiver Hydrocarbon Pumps(P22A/B) and Ejector Receiver
Condensate Pumps (P23A/B)
 Three PCVs for Nitrogen and three PCVs for Fuel gas.
 2” vent line from analyzer house.
 Sample stations (PA-016/026)

Also two more 2” collection headers, for the following points join the main LP flare
header.

 Aux. seal pot vent of High Pressure Receiver Pumps (P01A/B)

 Aux. seal pot vent of Primary Absorber Inter cooler Pumps (P02A/B)
 Aux. seal pot vent of Primary Absorber Rich Oil Pumps (P03A/B)
 Aux. seal pot vent of Sponge Absorber Lean Oil Pumps (P04A/B)
 Aux. seal pot vent of Stabilizer Bottom Recycle Pumps (P05A/B)
 Aux. seal pot vent of Stabilizer Overhead Pumps (P06A/B)
 Sample stations PA018, PA019 & PA020 of unit 311/312
 Two PCVs for Nitrogen and two PCVs for Fuel gas.

Caution: Vents and drain points which are likely to have H 2 S should never be
opened to atmosphere.

 HP FLARE RELIEF SYSTEM

Refer P&ID: G42-RD311/312-113

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A 30” main HP flare header provided in the unit enters into HP flare knockout
drum (311-V23). The header is provided with the blind & gear operated, horizontal
battery limit isolation valve.

The following PSVs, Vent/Drain points etc. discharge to HP flare header

 LT-002/LG-021/ LT-001 & LG-022 of HP Receiver(321/322-V01)

 Sample station (PA-001 to 009) of 321/322 unit
 XV-008(Emergency depressurization valve) located on HP Receiver(321/322-
V01)
 PSV-021A/B (located on HP Receiver-V01 in 321/322 unit)
 FV-001(located on discharge line of HP Receiver pump -P01A/B in 321/322
unit)
 LV-002 of HP Receiver(321/322-V01)
 Vent of HP Receiver pumps (321/322-P01A/B)
 Vent of Primary Absorber Inter-cooler Pumps(321/322-P02A/B)
 Vent of Primary Absorber Rich Oil Pumps(321/322-P03A/B)
 Vent of Sponge Absorber Lean Oil Pumps(321/322-P04A/B)
 Vent of Primary Stabilizer Bottom Recycle Pumps (321/322-P05A/B)
 Vent of Stabilizer overhead Pumps (321/322-P06A/B)
 PSV-023A/B/C(located on Stabiliser-C06 in 321/322 unit)
 PSV-027A/B (Stabilizer overhead pumps-P06A/B discharge)
 PSV-024A/B (located on Stabilizer Receiver-V07 )
 PSV-025A/B/C (located on stripper -C05)
 PSV-026A/B (d/s of Sponge Absorber Lean Oil Cooler-A01)
 PSV-022A/B(Located on Sponge Absorber-C03 )
 FV-015 (located on LPG to U-331)
 FV-016 (located on Stabilizer reflux line.)
 LT-008/081/LG-028/080 of Stabilizer Receiver (321/322-V07)
 PV-004 (located on Lean gas K.O.drum-V04 )
 LT-005/LG-025 of Lean gas K.O drum (321/322-V04)
 LT-004/LG-024 of Sponge Absorber (321/322-C02)
 LV-003 of Primary Absorber (321/322-C02)
 LT-003/LG-023 of Primary Absorber (321/322-C02)
 PCV-446 for Nitrogen.
 PCV-444 for Fuel Gas.

 LP FLARE KNOCKOUT DRUM

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Refer P & ID: G42-RD311/312-112

LP flare headers from HTs and Crude unit are combined together in a single
header (48”), which enters into LP flare K.O Drum (311/312-V24) through 48”
twine nozzles.

This Knock out drum is common to both HTs and crude unit
The drum is provided with local TG-610, LG-082A/B/C, DCS level indication (LI-
083), high and low level alarms and low low level alarm (LSLL 081). A steam
heating coil is provided at the bottom of the K.O drum. A 4” line with local PG-402
has been provided for low pressure steam supply to coil.

The gases from K.O drum are discharged to refinery LP flare header through 60"
line. This line is provided with local PG-404 and an isolation valve & blind.

The hydrocarbon liquid or LP flare condensate from K.O.D is discharged to

Refinery Heavy Slop Tank (MT-RS673-010/011) by LP flare knock out drum pumps
(311/312-P28A/B) through LP flare knockout condensate cooler (311/312-A11).
The facility is also provided to send it to Straight Run (Light) slop header of the
unit. The condensate line is of 8” and provided with battery limit isolation valve
and spectacle blind, local TG-614, DCS temperature indication (TI-611) and high
temperature alarm (TAH-611).

P-28A is turbine driven while P-28B is motor driven. P-28A & B will stop on low low
level alarm (LSLL-081) or high temperature alarm (TAH-611). P28A & B have to be
started manually. However P28A will start automatically on failure of P28B. Both
the pumps are provided with suction strainers and local PG-362 & PG-363 on the
discharge lines of P28B and P28A respectively.

 HP FLARE KNOCKOUT DRUM

Refer P & Id : G42-RD311/312-114

HP flare headers from HT and Crude units are combined together in a single
header (48”) which enters into HP flare K.O. Drum (311/312-V23) through twine
nozzles of 48’.

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The drum is provided with local TG-618, LG-085A/B/C, DCS level indication (LI-
086), high and low level alarms and low low level alarm (LSLL 084). A steam
heating coil is provided at the bottom of the K.O drum. A 4” line with local PG-402
has been provided for low pressure steam supply to coil.

The gases from K.O. drum are discharged to refinery HP header through 48" line.
The line is provided with local PG-368, and battery limit isolation valve with blind.

The hydrocarbon liquid or HP flare condensate from K.O.D is discharged to

Refinery straight run (Light) Slop Tank (MT-RS673-001/002) by HP flare knock out
drum pumps (311/312-P27A/B) through HP flare knockout condensate cooler
(311/312-A10). The facility is also provided to send it to Refinery Heavy Slop
header. The condensate line is provided with battery limit isolation valve &
spectacle blind, local TG-619, DCS temperature indication (TI-616) and high
temperature alarm (TAH-616).

P-27A & B will stop on low low level alarm (LSLL-084) or high temperature alarm
(TAH-616). P28A & B have to be started manually. However P27A will start
automatically on failure of P27B. Both the pumps are provided with suction
strainers and local PG-370 & PG-369 on the discharge lines of P27A and P27B
respectively.

3.7.3 CLOSED BLOWDOWN

 CLOSED DRAIN COLLECTION SYSTEM (HEAVY SLOP)

Refer P&ID: G42-RD311/312-151/152/153

Four U/G headers of 6” are provided in the unit to collect heavy hydrocarbon
drainage from various points. All drains connected to 6”main headers are provided
with double isolation valves and spectacle blind.

The following drain points discharge to U/G collection headers.

First header

 Flushing oil header

 Crude Column(C05)
 HAGO Circulating Pumps inlet(P09A/B)
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 HAGO stripper(C06)
 Tube side of LK stripper reboiler (S-18)
 Shell side of LVGO cooler (S-20)
 Line no: 311/312-PB-089
 HAGO IR filter (PYRD-43)
 HVGO Pump Around Filter (PYRD-41)

Second header

 Flushing oil header

 Net Gas Compressor Skid (C01)
 Vacuum residue draw off(C16)
 Line No.311/312-PB-090-6”
 Ejector blow case(V19)
 Ejector condensate receiver (V17), LT-019, LG-069, LG-070 & LT-018
 LV-018 & FV-101 of Ejector condensate receiver (V17).
 Slopwax quench drum (V44)
 Crude/Slopwax exchanger (S28)
 LVGO IR Filter (PYSRD-42)
 HVGO IR Filter (PYSRD-44)

Third Header

 Shell side of Crude- No.1 Circulating Naphtha Exchanger(S01A/B)

 Shell side of Crude-cold circulating HK Exchanger(S02)
 Shell side inlet of Crude-VR Exchanger(S25)
 Shell side outlet of Crude-VR Exchanger(S25)
 Tube side inlet of Crude-VR Exchanger(S25)
 Shell side of Crude -MP steam exchanger(S03)
 Shell side of Crude- No.2 Circulating Naphtha Exchanger(S04A/B)
 Shell side of Crude- Light kerosene product exchanger (S05A/B)
 LP flare K.O drum(V24)
 2nd stage Desalter (V03 AND V34)
 1st stage Desalter (V02 AND V33)
 Flash Drum(V04)
 Flushing Oil header (Two lines)
 Line No.311/312 PA-018
 Line No.311/312 PA-212

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Fourth header

 Flushing Oil header

 Tube side of Flashed Crude -Hot Vac.residue Exchanger(S515A/B)
 Shell side of Flashed crude -Hot vac.residue Exchanger(S515A/B)
 Tube side of Flashed crude -Hot vac.residue Exchanger(S15A/B)
 Shell side of Flashed crude -Hot vac.residue Exchanger(S15A/B)
 Tube side of Flashed crude -Hot circulating HAGO Exchanger(S514A/B)
 Shell side of Flashed crude-Hot circulating HAGO exchanger(S514A/B)
 Tube side of Flashed crude-Hot circulating HAGO exchanger(S14A/B)
 Tube side of Flashed crude-Hot circulating HVGO exchanger(S513A/B)
 Shell side of Flashed crude-Hot circulating HVGO exchanger(S513A/B)
 Tube side of Flashed crude-Hot circulating HVGO exchanger(S13A/B)
 Shell side of Flashed crude-Hot circulating HVGO exchanger(S13A/B)
 Tube side of Desalted crude -Cold circulating HVGO exchanger(S12A/B/C/D)
 Shell side of Desalted crude -Cold circulating HVGO exchanger(S12A/B/C/D)
 Shell side of Desalted crude -Cold circulating heavy kerosene
exchanger(S11A/B)
 Tube side of Desalted crude -Cold vacuum residue exchanger(S10)
 Shell side of Desalted crude -Cold vacuum residue exchanger(S10)
 Tube side Desalted crude -Cold circulating HAGO exchanger(S09)
 Shell side Desalted crude -Cold circulating HAGO exchanger(S09)
 Shell side of Desalted crude- Circulating Diesel exchanger(S08A/B)

All U/G drain collection headers are connected with Heavy Slop Drain Tank
(311/312-V22) through 12" line having an isolation valve & spectacle blind at the
drum inlet. Material collected in the tank is discharged to Refinery Heavy slop Tank
by Heavy Slop Drain Tank Pumps (P-29A/B). P-29A & B are submersible pumps
immersed in the sump. P-29A & B are provided with PG-439 and PG-438 on their
discharge lines respectively. Also local TG-652 has been provided on discharge line
of P-29B.

A vent line of 12" has been provided on Heavy Slop Drain Tank (311/312-V22) and
connected to LP flare header. It is also provided with local TG-651, DCS level
indication (LI-096) and high and low level alarm. On high level alarm standby
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pump will start automatically and on low level alarm both the pumps will stop. The
tank is also provided with Cooling/Heating coil.

In refinery there are two Heavy Slop Oil Tanks (RS673-010/011) for collecting
heavy slops from various units. Material from these tanks will be transferred to
Crude tanks by two pumps (RS673-P010A/B). On low level of Heavy Slop Oil Tanks
these pumps will stop. Both the pumps are motor driven.

 CLOSED DRAIN COLLECTION SYSTEM (LIGHT SLOP)

Refer P&ID: G42-RD311/312-154/155/156

Four U/G headers of 6" are provided in the unit with several branch headers
connected to it for collecting hydrocarbon drainage from various points. All lines
connected to headers or branch headers are provided with double isolation valve &
spectacle blind.

Following points discharge to U/G headers.

First header

 Crude Column Receiver Pump(P15A/B)

 Crude Column Receiver(V12)
 Seal Pot of Crude Column Overhead Pumps(16A/B)
 Seal Pot of Unstabilised Naphtha Pumps(P17A/B)
 Recontact drum(V13)
 Light Kerosene Stripper(C09)
 Diesel Stripper(C08)
 Naphtha Circulating Pump inlet(P05A/B)
 Light Kerosene Reflux Pump inlet (P06A/B)
 Heavy Kerosene Circulating Pump inlet (P07A/B)
 Diesel Circulating Pump inlet (P08A/B)
 Light Kerosene Product Pump(P12A/B/C)
 Heavy Kerosene Product Pump(P13A/B/C)
 Diesel Circulating Pump inlet (P08A/B)
 Light Kerosene Product Pump Seal Pot Vent(P12A/B/C)
 Heavy Kerosene Product Pump Seal Pot Vent(P13A/B/C)
 Diesel Product Pump Seal Pot Vent(P14A/B/C)
 Shell side of LK stripper Reboiler ( S18)
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 Shell side of HK stripper Reboiler ( S16)

 Tube side of LK stripper Reboiler ( S16)

Second header

 Fuel Gas knockout Drum(V15)

 Ejector Receiver Hydrocarbon Pumps(P22A/B)
 Ejector Receiver Condensate Pumps(P23A/B)

Third header

 High Pressure Receiver Pump(321/322-P01A/B)

 Seal Pot of High Pressure Receiver Pump(321/322-P01A/B)
 High Pressure Receiver(321/322-V01)
 LG-021, LG-022, LT-001, LT-002 of High Pressure Receiver(321/322-V01)
 Shell side of High Pressure Cooler (321/322-S01A/B)
 Stripper(321/322-C05)
 LV-002/002A of High Pressure Receiver (321/322-V01)
 LG-026 & LT-006 of Stripper
 Tube side of Stabilizer Reboiler (321/322-S09)
 Tube side of Stabilizer Reboiler (321/322-S10)
 Tube side of Stripper Reboiler (321/322-S06)
 HP Flare K.O.drum (311/312-V23)
 Shell side of LK product trim cooler (311/312-S06)
 FV-025 ( HK circulating reflux to C-05))
 Tube side of Crude - LK product Exchanger (311/312-S05A/B)
 Tube side of Crude -No.2 Circulating Naphtha Exchanger (311/312-S04A/B)
 Tube side of Crude -No.1 Circulating Naphtha Exchanger(311/312-S01A/B)
 FV-012 ( Stabilizer bottom to stripper feed exchanger)
 Shell side of full range naphtha cooler (321/322-S12A/B)

Fourth header

 Stabilizer Overhead Pumps (321/322-P06A/B/C)

 Seal Pot of Stabilizer Overhead Pumps (321/322-P06A/B/C)
 Shell side of Stabilizer Net Overhead Cooler (321/322-S11)
 FV-001(HP receiver pumps- P01A/B discharge)
 Stabilizer Bottom Cooler (321/322-S08A/B)
 Shell side of Primary Absorber Inter cooler (321/322-S02)
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 HP receiver (321/322-V01)
 FV-011(Stabilizer bottoms recycle pumps-P05A/B discharge)
 Shell Side of Sponge Absorber Lean Oil Trim Cooler (321/322-S04)
 Stabilizer Bottom Recycle Pump(321/322-P05A/B)
 Shell side of Stripper feed Exchanger(321/322-S05)
 Tube side of Stripper feed Exchanger(321/322-S05)
 TV 010B (Heavy Naptha to HNUU from Stripper Reboiler Exchanger)
 TV 010A(Heavy Naptha to HNUU from Stripper Reboiler Exchanger)
 Primary Absorber Intercooler Pump Suction Line (321/322-P02A/B)
 Shell side of Sponge Absorber Lean Oil/Rich Oil Exchanger (321/322-S03)
 Tube side of Sponge Absorber Lean Oil/Rich Oil Exchanger(321/322-S03)
 Primary Absorber Inter Cooler Pump(321/322-P02A/B)
 Seal pot of Primary Absorber Inter Cooler Pumps(321/322-P02A/B)
 Primary Absorber(321/322-C02)
 LG-023, LT-003, LV-003 of Primary Absorber(321/322-C02)
 Primary Absorber Rich oil Pump(321/322-P03A/B)
 Seal pot of Primary Absorber Rich oil Pumps(321/322-P03A/B)
 Sponge absorber(321/322-C03)
 LG-024, LT-004, LV-004 of Sponge Absorber(321/322-C03)
 Lean Gas Knock Out drum(321/322-V04)
 LG-025, LT-005 of Lean Gas Knock Out drum(321/322-V04)
 Stabilizer Receiver(321/322-V07)
 Stabilizer Receiver Boot (321/322-V11)
 LV-006 of Stripper(321/322-C05)
 Stabilizer(321/322-C06)
 LT-007 & LG-027 of Stabilizer(321/322-C06)

All U/G drain collection headers are connected with Light SR Slops Drain Tank
(321/322-V08). Light SR Slops Drain Tank (321/322-V08) is provided with local
TG-654, DCS level indication (LI-100), high and low level alarms and a vent line of
8" which is connected to LP flare header. Pump (P-08) will stop automatically on
low level.

The material collected in the tank is pumped to Straight Run (Light) Slop Oil Tanks
by Light SR Slops Drain Pump (321/322-P08).

In refinery there are two Straight Run (Light) Slop Oil Tanks (RS673-001/002) for
collecting light slops from various units. Material from these tanks will be

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transferred to Crude tanks by two pumps (RS673-P001/005B). On low level of Slop

Oil Tanks these pumps will stop. Both the pumps are motor driven.

CHAPTER # 4

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INTERCONECTIVITY

4.0 INTERCONNECTIVITY OF THE UNIT:

 The process side hydrocarbon system interconnectivity between
CDU/VDU/SGCU & other units is shown in Table- 4.1 attached herewith. The
design basis for these process side systems has been dealt with in Chapter -2.

 The Power & Utilities side systems interconnectivity between CDU/VDU/SGCU &
other units is shown in Table -4.2 attached herewith. The details for utilities
systems & their interconnectivity with other units have been covered in
Chapter-3.

 The interdependency between Crude Unit PIB & PIB’s for other Units is shown
in Table -4.3.

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CHAPTER # 5

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OPERATING
CONDITIONS &
CONTROL

5.1 NORMAL OPERATING CONDITIONS

DESALTER
PROJECTED NORMAL OPERATING CONDITIONS AS PER UOP
SR. ENGG NORMAL
DESCRIPTION TAG.NO
NO. UNIT VALUE
FLOW CASE#1
1 Crude I/L MT/HR FI-005 1889.6
2 Crude I/L to S-1A/B MT/HR FIC-91A 944.8
3 Crude I/L to S-4A/B MT/HR FIC-91B 944.8
Desalting water to V-03 @ 5-6 % of crude
4 MT/HR FIC-016 71
flow

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Desalting water to V-34 @ 5-6 % of crude

5 MT/HR FIC-808 43
flow
6 Phenolic water to V-01 MT/HR FIC-19 114
7 Non phenolic water to V-01 MT/HR FIC-20 NNF
8 Cold condensate to V-01 MT/HR FIC-18 NNF
9 Desalting water to sludge removal system MT/HR FIC-015 NNF
10 Desalting water to A05 MT/HR FI-099 NNF
11 Demulsifing chemical @ 3ppm KG/HR NA
PRESSURE
1 Crude at the B/L Kg/cm2 g PI-019 32
2 Crude outlet from V-02 Kg/cm2 g PI-089 25.4
3 Pressure drop across PDV-100 Kg/cm2 PDT-100 1.5-2.0
4 Crude outlet from V-03 Kg/cm2 g PI-001 23.1
5 Pressure drop across PDV-101 Kg/cm2 PDT-101 1.5-2.0
6 Pressure drop across PDV- 808 Kg/cm2 PDT-808
7 Crude outlet from V-34 Kg/cm2 g PI-089
8 Pressure drop across PDV-809 Kg/cm2 PDT-809
TEMPERATURE
0
1 Crude inlet to V-02 C TI-013 130
0
2 Crude inlet to V-03 C TI-014 122
0
3 Crude inlet to V-33 C TI-321 130

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DESALTER
PROJECTED NORMAL OPERATING CONDITIONS AS PER UOP
contd.
SR. ENGG NORMAL
DESCRIPTION TAG.NO
NO. UNIT VALUE
FLOW CASE#1
0
4 Crude inlet to V-34 C TI-831 130
0
5 A-02 outlet C TI-140 55
LEVEL
1 V-02 interface level % LIC-001 50
2 V-02 interface level % LI-43 50
3 V-03 interface level % LIC-002 50
4 V-03 interface level % LI-44 50
5 V-33 interface level % LIC-804A 50
6 V-33 interface level % LI-804B 50
7 V-34 interface level % LIC-805A 50
8 V-34 interface level % LI-805B 50
9 V-01 water level % LIC-004 50
ELECTRICAL
1 Secondary voltage of V-02 & V-03 Volts NA 16000-19200
12000-16000-
2 Secondary voltage of V-33 & V-34 Volts NA
20000
3 Current of V-02 & V-03 Amps NA 100
4 Current of V-33 & V-34 Amps NA 175

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CRUDE COLUMN
PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
SR. ENGG. NORMAL
PARTICULARS TAG NO.
NO. UNIT VALUE
CASE#1
FLOW
1 CRUDE FEED TO C05 EX F 01 MT/HR FIC- 128 92.09
MT/HR FIC- 129 92.09
MT/HR FIC- 131 92.09
MT/HR FIC- 132 92.09
MT/HR FIC- 133 92.09
MT/HR FIC- 134 92.09
MT/HR FIC- 135 92.09
MT/HR FIC- 136 92.09
MT/HR FIC- 137 92.09
MT/HR FIC- 138 92.09
TOTAL 920.90
2 CRUDE FEED TO C05 EX F 51
MT/HR FIC- 139 92.09
MT/HR FIC- 141 92.09
MT/HR FIC- 142 92.09
MT/HR FIC- 143 92.09
MT/HR FIC- 144 92.09
MT/HR FIC- 145 92.09
MT/HR FIC- 146 92.09
MT/HR FIC- 147 92.09
MT/HR FIC- 148 92.09
MT/HR FIC- 149 92.09
TOTAL 920.90
3 VAPS EX V 04 TO C 05
MT/HR FIC- 21 950.4
MT/HR FIC- 22 950.4
MT/HR FIC- 116 920.9
MT/HR FIC- 117 920.9
4 NAPH TO SO1 A /B FLOW MT/HR FIC- 06 768.7
5 NAPH TO S04 A / B FLOW MT/HR FIC- 07 768.7
6 LK IR FLOW MT/HR FIC- 24 223.2
7 LK PRODUCT FLOW MT/HR FIC- 11 254.6
8 HK IR FLOW MT/HR FIC- 26 294.8
9 HK PA FLOW MT/HR FIC- 25 202

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CRUDE COLUMN
PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
Contd.
SR. PARTICULARS ENGG. TAG NO. NORMAL
NO. UNIT VALUE
CASE#1
10 HK PRODUCT FLOW MT/HR FIC- 44 30
11 DIESEL IR FLOW MT/HR FIC- 27 187.6
12 DIESEL TO 321 C 03 FLOW MT/HR 321FIC–6 21.5
13 DIESEL PA FLOW MT/HR FIC- 14 805.9
14 DIESEL PRODUCT FLOW MT/HR FIC- 42 339.7
15 HAGO IR FLOW MT/HR FIC- 28 143.93
16 HAGO PA FLOW MT/HR FIC- 38 465
17 HAGO PRODUCT FLOW MT/HR FIC- 102 123.62
18 REDUCED CRUDE TO F-2 MT/HR FIC- 120 891.8
19 NET OVH LIQUID V 12 TO V 13 MT/HR FIC- 98 221.6
20 UNSTAB NAPHTHA TO U 321 MT/HR FIC- 48 252
21 NON PHENOLIC WATER TO U 441 MT/HR FIC- 123 35.4
22 REFLUX TO C 05 MT/HR FIC- 36 52.1
23 STRIPPING STEAM TO C05 MT/HR FIC- 35 17.8
24 STRIPPING STEAM TO C06 MT/HR FIC- 37 1.48
25 STRIPPING STEAM TO C08 MT/HR FIC- 41 6.8
26 HAGO TO C09 REBOILER MT/HR FIC- 40 200
27 HAGO TO C07 REBOILER MT/HR FIC- 39 100
TEMPERATURE
0
1 CRUDE EX F 1 TO C05 TEMP C TIC- 143 385
0
C TIC- 155 385
0
2 CRUDE EX F 51 TO C05 TEMP C TIC- 158 385
0
C TIC- 169 385
0
3 FLASH ZONE TEMP OF C05 C TI- 60
0
4 TOP TEMP OF C05 C TIC- 53 113
0
5 BOTTOM TEMP OF C05 C TI- 51 369
0
6 NAPHTHA DRAWOFF TEMP C TI- 46 129
0
7 LK DRAWOFF TEMP C TI- 47 188
0
8 HK DRAWOFF TEMP C TI- 48 231
0
9 DIESEL DRAWOFF TEMP C TI- 49 276
0
10 HAGO DRAWOFF TEMP C TI- 50 347
0
11 NAPHTHA PUMPAROUND RETURN TEMP C TIC- 2 81
0
C TIC- 5 81
0
12 HK PUMPAROUND RETURN TEMP C TIC- 6 148

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CRUDE COLUMN
PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
Contd.
SR. ENGG. NORMAL
PARTICULARS TAG NO.
NO. UNIT VALUE
CASE#1
0
13 DIESEL PUMPAROUND RETURN TEMP C TIC- 18 184
0
14 HAGO PUMPAROUND RETURN TEMP C TIC- 24 236
PRESSURE
1 FLASH ZONE Kg/cm2 g PI- 82
2 HAGO DRAWOFF TRAY Kg/cm2 g PI- 83
3 C-5 TOP PRESSURE Kg/cm2 g PI- 437 A
Kg/cm2 g PI-437 B
Kg/cm2 g PI- 437C
4 PRESSURE AT INLET OF A-5 Kg/cm2 g PIC- 5 2.2
5 PRESSURE OF V-13 Kg/cm2 PIC- 10
6 DP BETWEEN TRY-3 TO VAP.LINE Kg/cm2 PDI- 71
7 DP BETWEEN TRY-15 TO 14 Kg/cm2 PDI- 72
8 DP BETWEEN TRY-27 TO 16 Kg/cm2 PDI- 73
9 DP BETWEEN TRY-35 TO 32 Kg/cm2 PDI- 74
LEVEL
1 C05 BOTTOM LEVEL % LIC- 06 50
2 HAGO DRAWOFF TRAY LEVEL % LIC- 29 50
3 DIESEL DRAWOFF TRAY LEVEL % LIC- 28 50
4 HK DRAWOFF TRAY LEVEL % LIC- 27 50
5 LK DRAWOFF TRAY LEVEL % LIC- 26 50
6 NAPHTHA DRAWOFF TRAY LEVEL % LIC- 25 50
7 C06 LEVEL % LIC- 07 50
8 C08 LEVEL % LIC- 09 50
9 C07 LEVEL % LIC- 08 50
10 C09 LEVEL % LIC- 10 50
11 V12 WATER LEVEL % LIC- 12 50
12 V12 OIL LEVEL % LIC- 13 50
13 V13 WATER LEVEL % LIC- 14 50
14 V13 OIL LEVEL % LIC- 15 50
1 PSVS OF C05 IN LINE - 130 A
- 130 B
- 130 C
- 130 D

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- 130 E
- 130 F
130G
130H
130J
130K
130L
130M
2 PSV OF V12 IN LINE - 133 A
- 133 B
3 PSV OF V13 IN LINE - 135 A
- 135 B
FEED TO C05 PUMPS DISCHARGE PRESSURE /
4
AMPS
P04 A Kg/cm2 g PG- 163 24.60/ 109
P04 B Kg/cm2 g PG- 164 24.60/ 109
P04 C Kg/cm2 g PG- 165 24.60/ 109
REDUCED CRUDE PUMP DISCHARGE
5
PRESSURE / AMPS
P10 A Kg/cm2 g PG- 166 12.40/ 52
P10 B Kg/cm2 g PG- 167 12.40/ NA
HAGO CIR. PUMP DISCHARGE PRESSURE /
6
AMPS
P09 A Kg/cm2 g PG- 344 11.99/ 52
P09 B Kg/cm2 g PG- 345 11.99/ 52
DIESEL CIR. PUMP DISCHARGE PRESSURE /
7
AMPS
P08 A Kg/cm2 g PG- 175 11.24/ 45
P08 B Kg/cm2 g PG- 176 11.24/ 45
8 HK CIR. PUMP DISCHARGE PRESSURE / AMPS
P07 A Kg/cm2 g PG- 173 11.18/ 45
P07 B Kg/cm2 g PG- 174 11.18/ 45
LK REFLUX PUMP DISCHARGE PRESSURE /
9
AMPS
P06 A Kg/cm2 g PG- 171 8.30/ 124
P06 B Kg/cm2 g PG- 172 8.30/ 124

CRUDE COLUMN

PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL

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SR. ENGG. NORMAL

PARTICULARS TAG NO.
NO. UNIT VALUE
CASE#1
NAPHTHA CIR. PUMP DISCHARGE PRESSURE /
10
AMPS
P05 A Kg/cm2 g PG- 168 11.96/ 45
P05 B Kg/cm2 g PG- 169 11.96/ 45
P05 C Kg/cm2 g PG- 170 11.96/ 45
HAGO PRODUCT PUMP DISCHARGE PRESSURE
11
/ AMPS
13.07/
P11 A Kg/cm2 g PG- 199
142.99
13.07/
P11 B Kg/cm2 g PG- 200
142.99
12 DIESEL PRODUCT PUMP DISCHARGE PRESSURE / AMPS
P14 A Kg/cm2 g PG- 203 15.90/ 22
P14 B Kg/cm2 g PG- 204 15.90/ 22
P14 C Kg/cm2 g 15.90/ 22
HK PRODUCT PUMP DISCHARGE PRESSURE /
13
AMPS
P13 A Kg/cm2 g PG- 207 14.30/ 149
P13 B Kg/cm2 g PG- 208 14.30/ 149
P13 C Kg/cm2 g 14.30/ 149
LK PRODUCT PUMP DISCHARGE PRESSURE /
14
AMPS
20.43/
P12 A Kg/cm2 g PG- 201
26.5
20.43/
P12 B Kg/cm2 g PG- 202
26.5
20.43/
P12 C Kg/cm2 g
26.5
V12 WATER PUMP DISCHARGE PRESSURE /
15
AMPS
P15 A Kg/cm2 g PG- 210 12.86/ 87
P15 B Kg/cm2 g PG- 211 12.86/ 87
16 V12 HYDROCARBON PUMP DISCHARGE PRESSURE / AMPS
P16 A Kg/cm2 g PG- 212 9.54/ 20.5
P16 B Kg/cm2 g PG- 213 9.54/ 20.5
V13 HYDROCARBON PUMP DISCHARGE
17
PRESSURE / AMPS
19.41/
P17 A Kg/cm2 g PG- 215
43.5
19.41/
P17 B Kg/cm2 g PG- 216
43.5

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NET GAS COMPRESSOR

PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
SR. ENGG NORMAL
PARTICULARS TAG NO.
NO UNIT VALUE
1 Crude column receiver V-12 Level % LI-79 50
2 Crude column overhead pressure Kg/cm2 g PI-005 2.2
0
3 Compressor discharge temperature C TI-76 100
4 Recontact drum pressure Kg/cm2 g PI-10 2.8
5 Compressor motor rpm RPM SI-801A 2570
6 Current drawn by motor Amps II-004 113
7 Compressor vibration mm/sec VI- NA
8 Main lube oil pump discharge pressure Kg/cm2 g PG-21 8.3
9 Aux. lube oil pump discharge pressure Kg/cm2 g PG-22 8.3
10 Filter/Cooler del P Kg/cm2 g PDG-007 0.8
0
11 Cooler outlet temperature C TG-29 49
12 Seal oil/ ref gas del P at suction end Kg/cm2 g PDG-005 2.45
13 Seal oil/ ref gas del P at discharge end Kg/cm2 g PDG-006 2.45
14 Lube oil to bearing supply pressure Kg/cm2 g PG-24 1.75
15 Lube/ seal oil tank level % LG-01 70
16 Waste oil trap level(suction) % LG-03 NA
17 Waste oil trap level(discharge) % LG-02 NA
0
18 Lube oil bearing return temperature(suction) C TG-32 NA
0
C TG-33 NA
0
19 Seal oil return temperature (suction) C TG-30 NA
0
20 Seal oil return temperature (discharge) C TG-31 NA
Seal oil supply discharge end diff press
21 Kg/cm2 g PDG-08 2.8
across flow orifice
Seal oil supply inlet end diff press across
22 Kg/cm2 g PDG-09 5.95
flow orifice
0
23 Lube oil/seal oil reservoir temperature C TG-28 NA
Supply steam pressure to turbine driven
24 Kg/cm2 g NA 15-17
pump P-30A

CRUDE CHARGE HEATERS 311/312- F01 / F51

PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
TAG NO.
SR. ENGG. TAG NO. NORMAL
PARTICULAR FOR
NO UNIT FOR F51 VALUE
F01
FLOW
1 Fuel Gas Flow zone 1 Kg/hr FI-52 FI-64 5013

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Fuel Gas Flow zone 2 Kg/hr FI-58 FI-65 5013

3
2 Fuel Oil Flow zone 1 M /hr FIC-49 FIC-63 NNF
Fuel Oil Flow zone 2 M3/hr FIC-57 FIC-59 NNF
3 Combustion Air flow zone 1 Kg/hr FI- 060 FT- 067 61823
Combustion Air flow zone 1 Kg/hr FT -94 A/B FT 95A/B 61823
Combustion Air flow zone 2 Kg/hr FI- 61 FI- 66 61823
Combustion Air flow zone 2 Kg/hr FT -54A/B FT-55A/B 61823
TEMPERATURE
1 Common outlet temperature ( z 1) °C TIC-143 TIC-158 385
°C TI-144 TI-157 385
2 Common outlet temperature ( z 2) °C TIC-155 TIC-169 385
3 Heater outlet temp zone 1
Pass 1 °C TI-200 TI-240 385
Pass 2 °C TI-210 TI-250 385
Pass 3 °C TI-220 TI-260 385
Pass 4 °C TI-230 TI-270 385
Pass 5 °C TI-190 TI-390 385
4 Heater outlet temp zone 2
Pass 1 °C TI-209 TI-249 385
Pass 2 °C TI-219 TI-259 385
Pass 3 °C TI-229 TI-269 385
Pass 4 °C TI-239 TI-279 385
Pass 5 °C TI-199 TI-399 385
5 Flue Gas u/s APH °C TI- 81 TI -72 427
°C TT -82A/B TT -96A/B 427
6 Flue Gas d/s APH °C TI –79 TI -73 194
°C TT -83A/B TT -97A/B 194

CRUDE CHARGE HEATERS 311/312- F01 / F51

PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL Contd.
TAG NO. TAG NO.
SR. ENGG. NORMAL
PARTICULAR FOR FOR
NO UNIT VALUE
F01 F51
7 Flue gas temp at the inlet of conv. Section °C TI-34 TI-91 869
8 Flue gas temp at the outlet of conv. Section °C TI-77 TI-90 427

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9 Combustion air temp after steam pre heater °C TI-87 TI-99 89

10 Combustion air temp after APH °C TI-88 TI-98 346
11 Combustion air temp to heater zone1 &2 °C TI-89 TI-95 346
14 Skin temp of zone 1 DESIGN
TXI-201 TXI-241 to
Pass 1 °C 650
to 204 244
TXI-211 TXI-251 to
Pass 2 °C 650
to 214 254
TXI-221 TXI-261 to
Pass 3 °C 650
to 224 264
TXI-231 TXI-271 to
Pass 4 °C 650
to 234 274
TXI-191 TXI-391 to
Pass 5 °C 650
to 194 394
15 Skin temp of zone 2
TXI-205 TXI-245 to
Pass 1 °C 650
to 208 248
TXI-215 TXI-255 to
Pass 2 °C 650
to 218 258
TXI-225 TXI-265 to
Pass 3 °C 650
to 228 268
TXI-235 TXI-275 to
Pass 4 °C 650
to 238 278
TXI-195 TXI-395 to
Pass 5 °C 650
to 198 398
PRESSURE
PT -17
1 Pilot Gas (zone 1) Kg/cm2g PT -35A/B 0.61
A/B
Pilot Gas (zone 1) Kg/cm2g PI- 442 PI- 112 0.61
PT -24
Pilot Gas (zone 2) Kg/cm2g PT -44A/B 0.61
A/B
Pilot Gas (zone 2) Kg/cm2g PT- 108 PT- 116 0.61

CRUDE CHARGE HEATERS 311/312- F01 / F51

PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
TAG NO. TAG NO.
SR. ENGG. NORMAL
PARTICULAR FOR FOR
NO UNIT VALUE
F01 F51
2 Fuel Gas (zone 1) Kg/cm2g PT—15 PT –33
Fuel Gas (zone 1) Kg/cm2g PT -16A/B PT -38A/B
Fuel Gas (zone 2) Kg/cm2g PT-22 PT-42

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Fuel Gas (zone 2) Kg/cm2g PT -20A/B PT -43A/B

3 Fuel Oil (zone 1) Kg/cm2g PT-014 PT-32
PT-
Fuel Oil (zone 1) Kg/cm2g PT- 352A/B
350A/B
Fuel Oil (zone 2) Kg/cm2g PT-021 PT-41
PT-
Fuel Oil (zone 2) Kg/cm2g PT -39A/B
351A/B
4 Atomizing steam/Fuel oil (zone 1) Kg/cm2 PDT-094 PDT –31
PDT - PDT-
Atomizing steam/Fuel oil (zone 1) Kg/cm2
96A/B 110A/B
Atomizing steam/Fuel oil (zone 2) Kg/cm2 PDT-095 PDT-40
PDT- PDT -
Atomizing steam/Fuel oil (zone 2) Kg/cm2
106A/B 114A/B
5 Flue Gas Pressure (Arch) MMWC PIC- 011 PIC-27 -0.3
PI-
MMWC PT -103A/B -0.3
102A/B
6 Pressure at suction of ID fan Kg/cm2 g PG-246 PG-251 NA
7 Pressure at discharge of FD fan Kg/cm2 g PIC-28 PIC-47 NA
OTHER
1 Flue Gas O 2 content zone 1 % AT-002 AT-007
2 Flue Gas CO content zone 1 ppm AT-003 AT-008 150
3 Flue Gas O 2 content zone 2 % AT-14 AT-016
4 Flue Gas CO content zone 2 ppm AT-15 AT-017 150
5 ID Fan – Vibration mm/s VT –101 VT-111 _
7 FD Fan – Vibration mm/s VT- 100A VT-110A _
8 FD Fan – Vibration mm/s VT -100 B VT-110B _
9 FD Fan – Speed RPM SI- 001A SI-003A 1500
10 FD Fan – Speed RPM SI- 001 B SI-003B 1500

VACUUM HEATER 311/312- F02

PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
ENGG. NORMAL
SR.NO PARTICULAR TAG NO
UNIT VALUE
CASE#1
FLOW
1 Process Pass Flows
Pass 1 MT/HR FT-151 89.18

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Pass 2 MT/HR FT-152 89.18

Pass 3 MT/HR FT-153 89.18
Pass 4 MT/HR FT-154 89.18
Pass 5 MT/HR FT-155 89.18
Pass 6 MT/HR FT-156 89.18
Pass 7 MT/HR FT-157 89.18
Pass 8 MT/HR FT-158 89.18
Pass 9 MT/HR FT-159 89.18
Pass 10 MT/HR FT-160 89.18
2 Velocity steam to coils
Pass 1 KG/HR FT-161 560
Pass 2 KG/HR FT-162 560
Pass 3 KG/HR FT-163 560
Pass 4 KG/HR FT-164 560
Pass 5 KG/HR FT-165 560
Pass 6 KG/HR FT-166 560
Pass 7 KG/HR FT-167 560
Pass 8 KG/HR FT-168 560
Pass 9 KG/HR FT-169 560
Pass 10 KG/HR FT-170 560
3 Fuel Gas flow KG/HR FT –70 3593
4 Fuel Oil flow KG/HR FT-69 3850
5 Combustion Air flow KG/HR FIC –113 61812

VACUUM HEATER 311/312- F02

PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
ENGG. NORMAL
SR.NO PARTICULAR TAG NO
UNIT VALUE
CASE#1
TEMPERATURE
1 Common outlet temperature °C TIC-110 392
°C TI-111 392
2 Heater outlet temp

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Pass 1 °C TI-284 392

Pass 2 °C TI-289 392
Pass 3 °C TI-294 392
Pass 4 °C TI-299 392
Pass 5 °C TI-304 392
Pass 6 °C TI-309 392
Pass 7 °C TI-314 392
Pass 8 °C TI-319 392
Pass 9 °C TI-324 392
Pass 10 °C TI-329 392
3 Flue Gas u/s APH °C TI-137 427
4 Flue Gas d/s APH °C TI-122 194
5 Flue gas temp at the inlet of conv. section °C TI-107 869
6 Flue gas temp at the outlet of conv. section °C TI-106 427
7 Combustion air temp after steam pre heater °C TI-118 89
8 Combustion air temp after APH °C TI-117 346
9 Skin temp of zone DESIGN
Pass 1 °C TXI-280 to 283 650
Pass 2 °C TXI-285 to 288 650
Pass 3 °C TXI-290 to 293 650
Pass 4 °C TXI-295 to 298 650
Pass 5 °C TXI-300 to 303 650
Pass 6 °C TXI-305 to 308 650
Pass 7 °C TXI-310to 313 650

VACUUM HEATER 311/312- F02

PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
Contd.
SR. ENGG. NORMAL
PARTICULAR TAG NO
NO UNIT VALUE
CASE#1
Pass 8 °C TXI-315 to 318 650
Pass 9 °C TXI-320 to 323 650
Pass 10 °C TXI-325 to 328 650

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PRESSURE
1 Pilot Gas Kg/cm2 g PT -58 A 0.645
Pilot Gas Kg/cm2 g PT -58 B 0.645
Pilot Gas Kg/cm2 g PT –59 0.645
2 Fuel Gas Kg/cm2 g PT –55
Fuel Gas Kg/cm2 g PT -56A
Fuel Gas Kg/cm2 g PT -56 B
Fuel Gas Kg/cm2 g PT –66
3 Fuel Oil Kg/cm2 g PT- 054
Fuel Oil Kg/cm2 g PT –353A
Fuel Oil Kg/cm2 g PT –353 B
4 Steam/Fuel Oil Kg/cm2 PDT –053
Steam/Fuel Oil Kg/cm2 PDT -60 A
Steam/Fuel Oil Kg/cm2 PDT- 60 B
Flue Gas Arch
5 mmWC PT- 049 -3.0

mmWC PT –105 A -3.0

mmWC PT –105 B
6 Pressure at suction of ID fan mmWC PG-282 NA
7 Pressure at discharge of FD fan mmWC PG-280 NA

VACUUM HEATER 311/312- F02

PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
Contd.
SR. ENGG. NORMAL
PARTICULAR TAG NO
NO UNIT VALUE
CASE#1
OTHERS
1 Flue Gas O 2 content % AT-011

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2 Flue Gas CO content ppm AT-012 150

3 ID Fan – Vibration mm/s VT- 106 _
4 ID Fan – Speed RPM SE-10 980
5 FD Fan – Vibration mm/s VT –105A _
6 FD Fan – Vibration mm/s VT-105 B _
7 FD Fan – Speed RPM SI- 002A 1480
8 FD Fan – Speed RPM SI- 002 B 1480

VACUUM COLUMN
PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
ENGG. NORMAL
SR PARTICULAR TAG NO.
UNIT VALUE
FLOW
1 REDUCED CRUDE TO F2 MT/HR FIC- 120 891.8
2 SLOPWAX TO F 2 MT/HR FIC- 76 108
3 TURBULIZING STEAM TO F2 MT/HR FIC- 161 5.6
4 LVGO PUMPAROUND FLOW MT/HR FIC- 74 438.9
5 LVGO PRODUCT FLOW MT/HR FIC- 75 99
6 HVGO IR FLOW MT/HR FIC- 77 198

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7 HVGO PUMPAROUND FLOW MT/HR FIC- 81 968.8

8 HVGO PRODUCT FLOW MT/HR FIC- 86 400.4
9 SLOPWAX DRAWOF FLOW MT/HR FIC- 125 108.8
10 VR RECYCLE TO C-16 MT/HR FIC-72 117.6
11 VR TO DEL. COKING MT/HR FIC-73 420.9
12 VR TO TANKAGE MT/HR FIC-82
13 STRIPPING STEAM TO C16 MT/HR FIC- 80 5.9
TEMPERATURE
0
1 R.CRUDE EX F-2 TO C-16 C TIC- 110 392
0
2 TOP TEMP OF C-16 C TI- 124 47
0
3 LVGO DRAWOFF C TI- 129 97
0
4 HVGO DRAWOFF C TI- 130 278
0
5 SLOPWAX DRAWOFF C TI- 31 356
0
6 FLASH ZONE C TI- 128
0
7 BOTTOM C TIC-133
0
8 LVGO PA C TI- 125 43
0
9 HVGO PA C TIC- 20 198
0
10 VR RECYCLE C TIC- 24 280
0
11 CONDANSATE OUT LET FROM S21 A C TI- 103
0
12 CONDANSATE OUT LET FROM S21 B C TI- 109
0
13 CONDANSATE OUT LET FROM S22 C TI- 104
0
14 CONDANSATE OUT LET FROM S23 C TI- 105
PRESSURE
1 VACUUM COLUMN TOP PRESSURE PIC- 62
2 FLASH ZONE PRESSURE PIC- 70
3 HVGO DRW. TR.PRESSURE Kg/cm2 PI- 88 0
4 LVGO DRW. TR.PRESSURE Kg/cm2 PI- 87 0
5 DP PT70 & PT88 mmHg PDI -86 NA
6 DP PT88 &PT87 mmHg PDI- 85 NA
7 STEAM TO EJECTOR PRESSURE Kg/cm2 g PIC- 61 17

VACUUM COLUMN
PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL Contd.
SR. ENGG. NORMAL
PARTICULAR TAG NO.
NO. UNIT VALUE
LEVEL
1 C16 BOTTOM LEVEL % LIC- 31 50
% LI 35 50
2 V-44 LEVEL % LIC-201 50
3 HVGO DRAW TRAY LEVEL % LIC- 23 50
4 LVGO DRAW TRAY LEVEL % LIC- 22 50
5 SLOP OIL LEVEL IN V 17 % LIC- 19 50

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6 CONDENSATE LEVEL IN V 17 % LIC- 18 50

7 V 18 LEVEL % LI- 17 50
OTHER
1 EJECTOR VAP ROUTING - XV- 16 ON
- XV- 18 OFF
2 EJECTORS IN LINE - J01- A
- J01- B
- J02 -A
- J02 -B
J02 -C
- J03- A
J03- B
J03- C
3 C16 PSVS IN LINE - 138 A
- 138 B
- 138 C
- 138 D
- 138 E
138 F
4 V17 PSV IN LINE - 139 A
- 139 B
5 V19 PSV IN LINE - 140 A
- 140 B
6 VACUUM RESIDUE PUMP DISCHARGE PRESSURE / AMPS
P18 A Kg/cm2 g PG- 256 17.90 / 43.50
P18 B Kg/cm2 g PG- 257 17.90/ NA
7 SLOPWAX PUMP DISCHARGE PRESSURE AMPS
P19 A Kg/cm2 g PG- 258 17.31/ 136.8
P19 B Kg/cm2 g PG- 259 17.31/ 136.8

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Crude Complex Refinery Division Crude Distillers
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VACUUM COLUMN
PROJECTED NORMAL OPERATING CONDITIONS AS PER SHELL
Contd.
SR. ENGG. NORMAL
PARTICULAR TAG NO.
NO. UNIT VALUE
8 HVGO PUMP DISCHARGE PRESSURE / AMPS
P20 A Kg/cm2 g PG- 260 12.13/ 77
P20 B Kg/cm2 g PG- 261 12.13/ 77
9 LVGO PUMP DISCHARGE PRESSURE / AMPS
P21 A Kg/cm2 g PG- 263 11.32 / 23
P21 B Kg/cm2 g PG- 264 11.32 / 23
EJE.REC.CONDENSATE PUMP DISCHARGE
10
PRESSURE / AMPS
P23A Kg/cm2 g PG- 270 13.63 / 72
P23B Kg/cm2 g PG- 271 13.63 / 72
EJE.REC. HYDROCARBON PUMP DISCHARGE PRESSURE /
11
AMPS
P22 A Kg/cm2 g PG-269 10.85 / 28
P22 B Kg/cm2 g 10.85 / 28

 PRIMARY ABSORBER
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CASE#
Description Tag no. Unit
1
Gas Feed FI-002 6652 Kg/hr
0
Temperature C
Pressure PI-001 Kg/cm2g
Lean Oil Flow FIC-011 20000 Kg/hr
0
Lean Oil Temperature TI-025 38 C
0
Ovhd. Temperature TI-004 52 C
Intercooler flow FI-005 22000 Kg/hr
0
Intercooler inlet temperature TG-005 38 C
Intercooler outlet 0
TG-024 46 C
temperature
Bottoms Pressure Kg/cm2g
0
Bottoms Temperature TI-003 C

 SPONGE ABSORBER

CASE#
Description Tag no. Unit
1
0
Ovhd. temperature TI-008 51 C
Ovhd. Pressure PIC-004 12.4 Kg/cm2g
Lean Oil Flow FIC-006 21500 Kg/hr
0
Lean Oil Temperature TI-009 45 C
Bottoms Flow FI-018 22737 Kg/hr
0
Bottoms Temperature TI-006 55 C

 LEAN GAS KNOCKOUT DRUM

CASE#
Description Tag no. Unit
1
Ovhd. gas flow FI-007 13699 Kg/hr
0
Ovhd. gas temperature TI-008 50.2 C
Ovhd. gas pressure PIC-004 8.7 Kg/cm2g

 STRIPPER

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Description Tag no. AL Unit

Feed Flow FIC-001 354078 Kg/hr
0
Feed temperature TIC-010 56 C
0
Ovhd. Temperature TI-013 61 C
Ovhd. Pressure PI-005 13.5 Kg/cm2g
A/B/C
Ovhd. Vapour flow FIC-009 49429 Kg/hr
0
Tray 6 temperature TIC-014 C
0
Reboiler Inlet Temperature TI-012 128 C
Reboiler Condensate FIC-010 Kg/hr
Bottoms flow 304650 Kg/hr

 STABILISER

Description Tag no. AL Unit

PI-007
Ovhd. Pressure 10.5 Kg/cm2g
A/B/C
0
Ovhd. temperature TI-016 66 C
Ovhd. Diff. Pressure PDI-008 Kg/cm2g
Condenser out temp. TI-021 56 Kg/cm2g
0
Tray 6 temperature TIC-017 C
12010
Reflux flow FIC-016 Kg/hr
1
LPG product flow FIC-015 27316 Kg/hr
0
LPG product temp TI-020 40 C
0
Reboiler Inlet temp TI-018 181 C
Reboiler Heating Oil flow FIC-014 Kg/hr
27733
Bottoms Product flow FIC-012 Kg/hr
3
0
Bottoms Product temp. TI-022 181 C

5.2 OPERATION AND CONTROL FEATURES

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 INTRODUCTION:
The Crude & Vacuum Unit normal operating control features are enumerated
briefly in the following sections. The interlocks & safety related features have been
dealt with in Chapter No.3, “Detailed Process Flow Description Section”. The values
of critical operating variables & parameters are mentioned for Design case#01
(AL-48%,AH-32%,Maya-20%) Crude Processing in the description below.
However the tables (for Desalting System, Crude Column, Vacuum Column, Net
Gas Compressor & Fired Heaters F-01/F-51/F-02) have been attached indicating
various process parameters, with instrument tag numbers & their projected values
for the above Design Case Crude Processing at design throughput.

 CRUDE PREHEAT & DESALTING

 Raw Crude Preheat Train:

Crude oil is pumped (a combination of booster & main charge pumps having spill
back flow controller facility) through a 20-inch header from refinery tank farm to
the unit. TI-001 & FI-005 indicate the crude oil temperature & flow to the unit
respectively. The temperature of the crude oil to the unit is approx. 25 deg C. The
crude oil flow to the unit is controlled by a split range flow controller (FIC-91A/B)
and pre-heated in two parallel raw crude preheat-exchanger-trains before being
combined and routed to two parallel two-stage desalters system.

The first preheat train consists of S-01/S-02/S-25/S-03 with circulating naphtha

stream, cold circulating HK stream, VR stream & MP steam as heating medium
respectively. Split range flow controller FIC-91 controls the crude oil flow through
S-01/S-04. The naphtha pump around stream flow is controlled by FIC-06. In case
the temperature of the naphtha pump around stream drops below its set point,
naphtha bypass control valve TV-753 across S-01 would open more and vice-
versa. TIC-006 (i.e. TV-006A/B) & FIC-25 control the HK pump-around
temperature & flow across S-02 respectively. Crude from S-02 outlet will go to S-
25, which is parallel to S-03. Crude flow to S-25 is controlled by FIC-453. TIC-754
& FIC-453 control the temperature of VR stream through S-25. The temperature
of the crude oil from S-03 can be varied as per requirement by controlling the flow
(FIC-008) of medium pressure condensate from the tube side.

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The second preheat train consists of S-04/S-05 with circulating naphtha stream
and hot stripped LK product stream as heating medium respectively. Split range
flow controller FIC-91 controls the crude oil flow through S-04. In case the
temperature of the naphtha pump around stream drops below its set point,
naphtha bypass control valve TV-752 across S-04 would open more and vice-
versa. The naphtha pump around stream flow across S-04 is controlled by FIC-07.
The flow of LK stripped product to S-05 is controlled by FIC-011.

The raw crude oil is heated to a temperature of approximately 130 0C centigrade

before entry to the desalters.

 Desalters System:

Two parallel train two-stage desalters system (V-02/V-03 & V-33/34) is designed
to remove 99% salt contained in the incoming crude. The desalter is an integral
part of unit and is the first line of defence against HCl corrosion in the crude
column overhead system.

Fresh desalting water is pumped (by P-02 through FIC-16 & FIC-808, 3-5% by
volume on crude charge) from Desalting Water Surge Drum (V-01) and mixed
(across PDV-101 & PDV-809) with the Crude Oil to Second Stage Desalter (V-03 &
V-34). P-03A/B & P-40A/B) pump brine-Water effluent from second stage desalter
on interface level control of 2nd desalter (LIC-2 & LIC-805B) to Crude Oil entering
the first stage desalter (V-02/V-33).

Brine effluent leaving on interface level control (LIC-1/ LIC-804A) of the first stage
desalter exchanges heat (in S-07/S-27) with fresh water for second stage desalter
and is discharged to Effluent Water System after cooling in fin fan cooler A-12 &
Plate & frame trim heat exchanger Y-08 which can be isolated by XV-802. Also,
there is provision to inject fresh water to the inlet of crude preheat exchangers S-
01/S-04 for washing crude exchanger circuit, upstream of the desalters. Also there
is one brine cooler A-02 available whenever the problem come with brine outlet
temperature from A-13. The provision is made to route brine from desalters to A-
13/A-02.

There is a provision to isolate any of the desalter from the system & keep the
other one in line. In this case the brine effluent control from desalter would be
through a selector switch. Also there is provision to inject fresh water in the first
stage desalter through FIC-016/FIC-808.
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The source of desalting water in the unit is phenolic & non- phenolic water from
waste water stripping units or cold condensate. The phenolic water flow from
waste water stripping unit is controlled by FIC-19 which is getting a signal from
the level controller of stripper in waste water stripping unit (WWSU) to output
selector switch. When there is low signal from WWSU the FIC-19 would work as
level control valve for WWSU. The non-phenolic water flow from WWSU is
controlled by FIC-20 which is cascaded with the level controller LIC-004 on water
surge drum V-01. The cold condensate flow from utility section is controlled by
FIC-18.

Also there is a provision for on line de-sludging in desalters by injecting fresh

water under high pressure from the discharge valve of P-02 through a flow
controller FIC-015/FIC-809.

There is a provision to inject de-emulsifier (3-5 ppm wt on Crude to each desalter),

by using dosing pumps P-34A/B/C, in first stage & second stage desalter inlets
upstream of the water injection points & at B/L d/s of FT-005. Also there is a
provision to inject antifoulant (20-30 ppm wt on Crude) by using dosing pump P-
24A in desalted crude line downstream of the 2nd stage desalter.

 Desalted Crude Preheat Train & Flash Drum:

Desalted crude flow is equally split and further pre-heated in two parallel desalted
crude oil pre-heat exchanger trains and flashed in the Crude Flash Drum (V-04)
where water and light ends in the raw crude oil are flashed-off & routed to Crude
column flash zone.

The first desalted crude preheat train consists of S-08/S-09/S-10 with circulating
cold Diesel stream returning from sat gas concentration unit, cold circulating HAGO
stream & cold circulating vacuum residue as a heating medium respectively. The
provision is made to take S-08 in the up steam of desalters. The second desalted
crude preheat train consists of S-11/S-12 with circulating hot HK stream & cold
circulating HVGO stream as heating medium respectively. The desalted crude is
preheated to a temperature (TI-33 & TI-32 at the outlet of S-10 & S-12
respectively) of 196 0C in these two preheat trains & flashed in V-04 operating at a
pressure of 4.9 Kg/cm2g.(PIC-02). The flashed vapours are routed to Crude
Column flash zone. The flow of the crude oil to the flash drum through these
desalted crude preheat trains is controlled by FIC-22 & FIC-21 which are cascaded
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with flash drum level controller LIC-5. FT-21 & FT-22 are relocated in up stream
of S-11 & S-09.

The purpose of flash drum is to lower design pressure of the crude pre-heat
exchanger trains downstream of the flash drum and reduce pressure drop across
Control Valves, Crude Heaters &. Crude Heater Transfer Lines.

 Flashed Crude Preheat Train & Crude Oil Charge Heaters:

Flashed crude is pumped by flashed crude oil pumps P-4 & further heated in two
parallel flashed crude oil preheat exchanger trains. The flow of flashed crude oil
through the flashed crude preheat trains is decided by the flow of crude oil
through the fired crude heaters F-01 (minimum flow through ten passes FI-130A
to J) / F-51 (minimum flow through ten passes FI-140A to J).

The first flashed crude preheat train consists of S-13/S-14/S-28/S-15 with hot
circulating HVGO stream, hot circulating HAGO stream, hot slopwax circulating
stream & hot circulating vacuum residue as heating medium respectively. The
second parallel flashed crude preheat train consists of S-513/S-514/S-515 with hot
circulating HVGO stream, hot circulating HAGO stream & hot circulating vacuum
residue as heating medium respectively.

The flashed crude is preheated to a temperature of approximately 260 0C as

indicated by TI-29 & TI-30 at the outlet of S-15 & S-515 respectively. The flashed
crude oil from S-15 & S-515 is fed to fired crude heaters F-01/F-51 respectively
operating in parallel.

Hot flashed crude from first pre-heat exchanger train is routed through Crude
Charge Heater F-01 (having two zones) where the final heating / vaporization of
crude oil takes place. F-01 heater is having total ten passes (five passes per zone)
& a pass flow control valve controls the flow of the crude oil through each pass.
The heater firing is controlled by the TIC-143 & TIC-155 for Zone -1 & Zone-2
respectively. The common outlet line from zone-1 & zone-2 of F-01 join together
& form the transfer line which is then routed to Crude Column flash zone.

Hot flashed crude from second pre-heat exchanger train is routed through identical
Crude Charge Heater F-51 (having two zones) where the final heating /
vaporization of crude oil takes place. F-51 heater is having total ten passes (five
passes per zone) & the flow of the crude oil through each pass is controlled by a
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pass flow control. The heater firing is controlled by the TIC-158 & TIC-169 for
Zone -1 & Zone-2 respectively. The common outlet line from zone-1 & zone-2 of F-
51 join together & form the transfer line which is then routed to Crude Column
flash zone.

Steam coil in convection bank were replaced with process coil to minimise the
tube film temperatures and hence coking potential. To get superheated steam to
crude & vacuum column & side stripers. Mixing MP steam will superheat LP steam.
The temperature is controlled by TIC-765/764.

 Heater Lead – Lag control system

The heat input to the heater varies in accordance with the required coil outlet
temperature. Only either increasing or decreasing fuel flow to the burners can vary
heat input. While doing so it has to be ensured that sufficient excess air is always
available for complete combustion of fuel fired. To achieve this, whenever heater
duty has to be increased the flow of combustion air should be increased prior to
increasing the flow of fuel to the burners and vice versa. In other words
combustion air leads fuel in the case of increase in firing requirement and lags the
fuel in case of decrease in firing requirement. Hence such a control is called “Lead
–Lag” control. The Lead-Lag control system has been explained in chapter 11,
section 3 for Fired Heaters details.

 CRUDE COLUMN SECTION

The crude column has total 49multi-pass valve trays & 4 chimney trays. The
rectifying section has 43 no. Four-pass-valve-trays & the stripping section has 6 no
two-pass-valve-trays. The column is divided into the following sections:

 Naphtha pump-around (3 trays)

 Naphtha / Light Kerosene Fractionation (11 trays)
 Light kerosene / Heavy kerosene Fractionation (9 trays)
 Heavy kerosene pump-around (3 trays)
 Heavy kerosene / Diesel fractionation (5 trays)
 Diesel Pump-around (3 trays)
 Diesel / Heavy Atmospheric Gas Oil (HAGO) fractionation (6 trays)
 HAGO pump-around (3 trays)

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 HAGO / Reduced Crude oil fractionation (250Y Flexi pack bed)

 Flash zone (Crude feed / flashed vapours from V-04 entry point)
 Reduced Crude Stripping (6 trays)

LK, HK, DIESEL, HAGO the side draw-off streams are taken from total accumulator
trays (chimney trays). Naphtha draw off stream is taken from partial draw-off tray.
A portion of LK, HK, DIESEL, HAGO side draw-off stream is pumped and returned
hot, back to the column immediately below the draw-off tray as internal reflux.
Only naphtha have down comers in draw-off tray as so it donot have external
reflux. The strippers level control valve is cascaded with the draw-off tray level
controller. This provision facilitates stable operation of the column and is necessary
for advanced process control application. Also some portion of the draw-off stream
is circulated (pump-around streams) and used for preheating crude oil, and as
means of heat removal from the respective sections in the column. Also a portion
of the side draw-off streams for Light Kerosene / Heavy Kerosene / Diesel and
HAGO is fed to respective strippers for product flash point correction. Hot HAGO is
used in LK / HK Stripper reboilers, whereas Super heated LP stripping steam is
used in Diesel and HAGO side strippers.

Valve trays are used in the crude column and LK, HK, Diesel cut stripper. Shell HI-
FI trays are used in HAGO stripper. This type of tray provides maximum operating
flexibility with respect to stable operation of column at design throughput
(maximum capacity) & turndown ratio (minimum feed rate to sustain unit
operation).

 Crude Column Flash Zone :

Thus hot flashed crude oil leaving above crude charge heaters F-01/F-51 at a
temperature of 382 0C is routed to the crude column flash zone on tray no.50
through separate transfer lines. The column flash zone temperature & pressure is
indicated by TI-60 & PI-82. The column is designed for 3% over-flash. Due to
flashing of the preheated crude oil there is drop in the temperature of the stream
entering the column by approximately 3 to 4 0C . Thus during Design case-1 Crude
processing the temperature of the flash zone would be around 370 0C. The
pressure in the flash zone would vary 1.4 Kg/cm2g depending upon the type of
feed, feed rate & vapor load on the column.

The cooled / heavier crude oil due to flashing effect travels down the column
across tray no 44 to tray no.49 . Crude column bottom is steam stripped and then
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pumped hot to the vacuum column through a vacuum heater F-02 having ten pass
flow control valves (FIC-151 to FIC-160) cascaded with the crude column bottom
level controller LIC-6.

 Crude Column Bottoms Section & Vacuum Heater

The superheated low-pressure steam is injected into crude column bottom through
FIC-35. The reduced crude from the column bottom is pumped by P-10A/B. The
RCO pump P-10B is driven by medium pressure steam turbine. The column bottom
level is controlled by LIC-6 cascaded with the pass flow control valves (FIC-151 to
FIC-160) of Vacuum Heater F-02. The slop wax recycle from vacuum column joins
the RCO from crude column before its entry to vacuum heater.

The total stream is heated / vaporized in the vacuum heater before entering
vacuum column flash zone. Process medium pressure steam (sometimes referred
as Turbulizing steam) is injected into 1st & 111h tubes of the heater each pass
process coils & its flow controlled by FIC-161 to FIC-170 & FIC-461 to FIC-470.
The vacuum heater transfer line temperature is controlled by TIC-110 at 392 0C .

Heater transfer line is sized for subsonic velocity. This minimizes entrainment in
the vacuum column and, along with proper layout, avoids erosion / corrosion in
the transfer line. Thus, the RCO in partially vaporized state enters the vacuum
column flash zone.

 HAGO draw-off Section & HAGO Circuits

Withdrawing HAGO from crude column unloads both vacuum heater and vacuum
column. The HAGO draw-off-section (tray no.43 liquid) is above the flash zone.
The HAGO draw-off tray temperature is indicated by TI-50 & its projected value in
Design case-1 Crude is 347 oC. The pressure in the HAGO draw-off section is
approx. 1.45 Kg/cm2g as indicated by PI-83.
 HAGO Internal Reflux Circuit (Hot Reflux):

The HAGO draw-off tray level is controlled by LIC-29, which is cascaded, with FIC-
28 on HAGO internal reflux stream returning back to crude column on structured
packing from P-9 discharge.

 HAGO Stripper Feed & Product :

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A portion of HAGO side draw off, from P-9 suction header, is fed to the HAGO
stripper (C-06 having 6 shell HI-FI tray) on its level control (LIC-7) where it is
steam stripped. The flow of the superheated low pressure stripping steam is
determined by the IBP / flash point correction required for HAGO product &
controlled by FIC-37. Stripped HAGO product is then pumped (by P-11) under flow
control FIC-102 to the VGO Unionfining units (without cooling) and / or to the gas
oil tankage system through vacuum gas oil cooler A-07. The vapours from HAGO
stripper are routed back to crude column in vapor space above tray no. 41

 HAGO Pump Around Circuit (Cold Reflux):

A portion of circulating unstripped HAGO from P-9 discharge is used as a heating

medium for light kerosene stripper reboiler S-18 and heavy kerosene stripper
reboiler S-16. The total cold circulating HAGO flow is controlled by FIC-38.
However, the flow of circulating HAGO to LK / HK stripper reboilers is determined
by the IBP / flash point correction required for LK/HK stripped product & controlled
by FIC-40 & FIC-39 respectively. The HAGO streams coming out of LK/HK reboilers
are combined & used for preheating flashed crude in S-14/S-514 and desalted
crude in S-09 respectively. The circulating HAGO stream temperature is controlled
by TIC-22 (i.e. by control valves TV-22A/B) across S-09. This cold circulating
HAGO is then returned back to the crude column on tray no. 41.

 Diesel draw-off & Circuits :

The Diesel draw-off-section (tray no.34 liquid) is above the HAGO section. The
Diesel draw-off tray temperature is indicated by TI-49 & its projected value in
Design case-1 Crude is 276 oC. The differential pressure across Diesel pump-
around section (i.e. between tray no. 34 to tray no. 32) is indicated by PDI-74.

 Diesel Internal Reflux Circuit (Hot Reflux):

The Diesel draw-off tray level is controlled by LIC-28, which is cascaded, with FIC-
27 on Diesel internal reflux stream returning back to crude column on tray no. 35
from P-8 discharge.

 Diesel Pump Around Circuit (Cold Reflux):

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The Diesel stream in CDU is heat integrated with Sat Gas Concentration Unit. A
portion of circulating unstripped Diesel from P-8 discharge is used as heating
medium for stabiliser reboilers 321/322-S-09/S-10 in saturated gas concentration
unit & returned to desalted crude preheat exchanger 311/312-S-08. The
temperature of the return Diesel stream to crude column on tray no.32 is
controlled by TIC-18A/B across 311/312-S-08.

The flow of Diesel to stabiliser reboilers is determined by the “C 3 /C 4 content & RVP
of stabilized naphtha” from stabiliser bottoms & controlled by 321/322-FIC-19 &
321/322-FIC-13 respectively. There is a provision to cut – off Diesel flow through
these reboilers (321/322-XV-5) & bypassing through total flow controller 321/322-
FIC-14, in case of Stabilizer getting pressurized.

A slipstream of circulating Diesel is cooled in 321/322-S-03/321-A-01/321-S--04 &

pumped by 321-P-04 as lean sponge oil to Sponge Absorber (321-C-03) for
recovery of C5/C 4 components in gas feed to column) in the Saturated Gas
Concentration unit. The lean oil flow to sponge absorber is controlled by 321/322-
FIC-6. The cold rich circulating Diesel stream from sponge absorber bottom is then
cooled in 321/322-S-03 & returned back to the crude column after joining with
Diesel ex 311/312-S-08.

 Diesel Stripper Feed & Product :

A portion of Diesel side draw off, from P-8 suction header, is fed to the Diesel
stripper (C-08 having 6 valve trays) on its level control (LIC-9) where it is steam
stripped. The flow of the superheated low pressure stripping steam to stripper is
determined by the flash point correction required (for Diesel product) & controlled
by FIC-41. The vapours from Diesel stripper are routed back to crude column in
vapor space above tray no.32.

Stripped Diesel product is pumped out by P-14.The stripped Diesel product is

controlled by flow controller FIC-42. FIC-42 is a split flow range controller,
cascaded with the feed surge drum (V-01) level controller in Diesel Unionfiner
(DHTU). The level controller on DHTU feed surge drum gives set point to FV-42B
(for hot feed to DHTU) & FV-42A (for balance Diesel to storage).

The Diesel product to storage is cooled in “Diesel Fin Fan Cooler 311/312-A-04”
Diesel from Unit-311/Unit-312 can be routed to either of the unit. Hence the Diesel
product streams from both Unit-311 & U-312 cooled in A-04 can be routed to
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Diesel storage tanks & then sent to either DHTU feed tanks or Diesel Blending
Pool.

The provision has been made to route Diesel from product pump to A-13 cooler.
The outlet from A-13 cooler will join A-04 outlet.

Thus the flow of total Diesel stream from U-311/312 to DHTU feed tanks is
controlled by back-pressure controller 311/312 PIC-4 and is measured by 311/312
FI-43 which gives signal to blending system.

The total flow of Diesel product stream to Diesel product blending system is
controlled by FIC-217 which get the set point from Diesel product blending system.
The measured value of FR-217 is then being fed back to Diesel product blending
system.

 Heavy Kerosene draw-off & Circuits :

The HK draw-off-section (tray no.26 liquid) is above the Diesel section. The HK
draw-off tray temperature is indicated by TI-48 & its projected value in Design
case-1 Crude is 231 oC.
The differential pressure across HK fractionation section (i.e. between tray no. 26
to tray no. 15) is indicated by PDI-73.

 HK Internal Reflux Circuit (Hot Reflux):

The HK draw-off tray level is indicated by LIC-27 which is cascaded with FIC-26
on HK internal reflux stream returning back to crude column on tray no. 27 from
P-7 discharge.
 HK Stripper Feed & Product :

A portion of HK side draw off, from P-7 suction header, is fed to the HK stripper
(C-07 having 6 valve trays) on its level control (LIC-8) where it is stripped by using
circulating HAGO stream as described earlier. The flow of the HAGO steam is
determined by the flash point correction required (for HK product) & controlled by
FIC-39. Stripped HK product is then pumped by P-13 under total flow control (FIC-
44) to Diesel blending system as per requirement & balance through HK cooler A-
03 to SKO blend / Unit-351 tankage through FIC-45 or LAB blend through FIC-46.
The vapours from HK stripper are routed back to crude column in vapor space

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above tray no.24. The provision has been made to route HK from P-13 to A-13
cooler & outlet of A-13 will join the out let of A-03.

 HK Pump Around Circuit (Cold Reflux):

A portion of circulating unstripped HK from P-7 discharge is used as heating

medium for desalted crude preheat exchanger S-11 & raw crude preheat
exchanger S-02. The flow & temperature of the return HK stream to crude column
on tray no.24 is controlled by FIC-25 & TIC-06A/B across 311/312-S-02
respectively.

 Light kerosene draw-off & Circuits :

The LK draw-off-section (tray no.14 liquid) is above the HK section. The LK draw
off tray temperature is indicated by TI-47 and its projected value in Design case-1
Crude is 188 oC. The differential pressure across LK draw-off chimney tray & tray
no.14 is indicated by PDI-72.

 LK Internal Reflux Circuit (Hot Reflux):

The LK draw-off tray level is controlled by LIC-26, which is cascaded, with FIC-24
on LK internal reflux stream returning back to crude column on tray no. 15 from P-
6 discharge.

 LK Stripper Feed & Product :

A portion of LK side draw off, from P-6 suction header, is fed to the LK stripper (C-
09 having 6 valve trays) on its level control (LIC-10) where it is stripped by using
circulating HAGO stream as described earlier. The flow of the HAGO steam is
determined by the flash point correction required (for LK product) & controlled by
FIC-40. Stripped LK product is then pumped by P-12 through raw crude preheat
exchanger S-05, fin fan cooler A-01 & trim cooler S-06 as per requirement under
split flow control FIC-11A/B to Kerosene Merox Unit (U-341) for ATF production /
SKO blending system respectively & balance LK is routed to Diesel blending system
through FIC-9 or LAB feedstock blending system through FIC -10.

The vapours from LK stripper are routed back to crude column in vapor space
below tray no.14.

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The above two LK/HK product cuts provide operating flexibility in the Crude Unit..

 Naphtha draw off & Circuits :

Naphtha pump-around is the top draw off. There is no net product draw from this
stream. Circulating naphtha is used for preheating for raw crude oil and reducing
overhead condenser duty. The naphtha draw-off-section (tray no.3 liquid) is above
the LK section The naphtha draw off tray temperature is indicated by TI-46 and its
projected value in Design case-1 Crude is 129 oC. The differential pressure across
Naphtha pump around section ( tray no.3 to Crude Column top) is indicated by
PDI-71.

 Naphtha Internal Reflux Circuit (Hot Reflux):

The naphtha draw-off-section (tray no.3 liquid) is above the LK section. The
naphtha section have partial draw-off tray & hence there is no control on liquid
flowing down through draw-off tray.

 Naphtha Pump Around Circuit (Cold Reflux):

A circulating unstripped naphtha from P-5 discharge is used as heating medium for
raw crude preheat exchangers S-01/S-04. The flow & temperature of the return
naphtha stream to crude column on top tray is controlled by FIC-6 /FIC-7 & TIC-
753 & TIC-752 across preheat exchangers S-01 & S-04 respectively. The
temperature control across these preheat exchangers is achieved by varying
naphtha flow through them. Both exchangers out let naphtha stream enters
separetly in crude column & join inside the column.

 Crude Column Overhead System :

Crude column overhead vapours are partially condensed in fin fan condensers A-05
before entering Crude Column Receiver V-12. The column pressure is controlled by
split range pressure controller PIC-005 at 1.0 kg/cm2g (through PV-005A for fuel
gas injection to V-12, PV-005C for spill back from net gas compressor discharge to
V-12 through A-05 when the column pressure falls below the set point & PV-005B
for flaring when the column pressure rises above the set point of PIC-005).

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Jamnagar

Hydrocarbon liquid stream from receiver is pumped by P-16 & split into external
reflux and net overhead liquid. Reflux flow controller FIC-36 is cascaded with TIC-
53 at 113 0C for Crude Column top temperature control & joins naphtha pump
around stream from S-01 entering the top tray of the crude column. The net
hydrocarbon liquid from V-12 is drawn on level control LIC-13 & routed to V-13
through A-06.

Sour water from the crude column receiver V-12 is pumped by P-15 under boot
interface level controller LIC-12 to Waste water-stripping unit (non-phenolic).

 Net Gas Compressor & Recontact Drum Section :

Vapour from the crude column receiver is compressed by “Screw Type Net Gas
Compressor C-01” and combined with net hydrocarbon liquid pumped from the
receiver. The total unstable naphtha and gas is routed to the recontact drum V-13
after cooling in A-06.

The net gas compressor is a variable speed machine with a normal compression
ratio of 3.24. However the compression ratio could be as high as 3.5. The normal
suction pressure & temperature for the compressor is around 1.4 Kg/cm2 absolute
& 55 0C. The compressor discharge pressure & temperature is in the range of 4.6
Kg/cm2 absolute & 98 0C respectively.

The compressor running speed would be in the range of minimum 935 rpm to
maximum of 3122 rpm. The running speed of the compressor would be controlled
by HIC-41 depending upon the gas make which in turn may depend upon the type
/ source of Crude Oil. There is a spill back facility provided (PV-005C) on the
compressor discharge through crude column overhead condenser A-05.

A selector switch PHS-005 has been provided to take either HIC-41for compressor
speed variation on auto or Fuel Gas injection valve PCV-005A to overhead receiver
V-12 on auto.

As discussed in earlier section the compressed gas is mixed with the net overhead
liquid from P-16 discharge, condensed/cooled in fin fan cooler A-06 & routed to
recontact drum V-13 under hydrocarbon liquid seal.

The recontact drum pressure is controlled at 2.8 Kg/cm2 by a split range pressure
controller PIC-10 (through PV-010A for FG injection & PV-010B for flaring).
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Normally there is no net gas flaring from the recontact drum. The hydrocarbon
liquid from V-13 is pumped by P-17 to the HP receiver in Sat Gas Concentration
unit through 311/312-FIC-48 cascaded with level controller 311/312-LIC-15 for V-
13. Sour water from recontact drum is returned to the crude column receiver
through interface level controller LIC-14 for V-13 boot.

 Chemical Injection to Crude Column Overhead Section

 Ammonia Injection :

An aqueous ammonia injection facility has been provided to control corrosion rate
due to chloride attack in the crude column overhead system. To avoid the
possibility NH 4 Cl salt deposition in overhead fin fan condenser tubes water is
continuously injected & measured at the inlet to each A-05 tube bundle. Aqueous
ammonia from pumps P-36 & P-49 is injected into the wash water to A-05 line
which is injected in to A-05 individual tube bundle through a special injection quill.
The rate of aqueous ammonia injection is adjusted such that the pH of V-12 boot
water maintain in the range of 6.2 to 6.5.. To monitor & minimise the corrosion
rate in overhead system , send samples of V-12 boot water for pH, chloride & Iron
(Fe) content. The iron content of the boot water should not exceed 3-5 ppm. If
the chloride content of the boot water is above 5 ppm take corrective actions in
the Desalter section.
 Corrosion Inhibitor Injection:

Corrosion inhibitor injection facility is provided to control corrosion rate and

protect crude column overhead system,. The corrosion inhibitor is basically filmer,
which form a thin film over metal surface and protect it. The inhibitor is diluted
with a continuous slip-stream of naphtha through a flow orifice (FO-300) drawn
from crude column reflux pump (P-16) discharge, and injected in Crude Column
overhead vapour line as close to the column as possible. The dosing of the
corrosion inhibitor is carried out by metering pumps (P-25 A /B) and the normal
dosing rate is ranging from 6 ppm (wt) on the column overhead vapor flow rate.

 VACUUM COLUMN SECTIONS

Vacuum column can be either wet or dry. Wet (or damp) design provides flexibility
in operating pressure and results in lower heater / flash zone temperature. Lower
temp minimizes thermal cracking & thereby cocking tendencies.

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Vacuum column is designed for damp conditions wherein the steam consumption
is reduced to about 25% of the steam consumption in wet design. Provision is
made to use dry medium pressure steam in vacuum heater process coils and
superheated low pressure steam in Vacuum Column bottom stripping section.

Consideration is given to time-temperature-relationship for cracking in the vacuum

column. Residence time in the bottom boot is minimized to prevent cracking of
heavier hydrocarbons. Provision is made to quench vacuum residue below its point
of incipient cracking by introducing a slip stream of partially cooled vacuum
residue stream in the column bottom.

The vacuum column consists of four packed sections with structured packing
above the flash zone & six special type sieve trays ( i.e. fixed valve type trays)
below the flash zone. Chimney type trays have been provided below LVGO &
HVGO packed bed for side-draw-offs for liquids. Below slopwax packed bed double
decker chimney tray is provided. Chimney tray is provided just below the column
flash zone also. Packed beds are specified/configured based on proven
performance in each vacuum section. Spray nozzle selection / layouts are critical to
packed bed performance. The vacuum column can be divided in to the following
sections :

 Vacuum Column Flash Zone

 Slop Wax Section
 Heavy Vacuum Gas Oil Draw-off Section & Circuits
 Light Vacuum Gas Oil Draw-off Section & Circuits
 Column Overhead Section
 Column Bottom Section & Vacuum Residue Circuits

 Vacuum Column Flash Zone :

The RCO from the vacuum heater outlet at a temperature of 392 0C enters via
radial inlet device in the column flash zone above sixth sieve tray from the bottom.
Due to flashing the temperature drops in the flash zone The vacuum column flash
zone temperature is indicated by TI-128 (normal value 380 0C). The column flash
zone pressure is indicated by PI-70 (normal value 30 mmHg absolute). The column
top pressure is indicated by PI-62. There is a provision to control either of the
flash zone or column top pressure through a selector switch PHS-062. Generally
column top pressure would be controlled by PIC-62 at 20 mmHg absolute.

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 Slop Wax Draw-off Section :

The slop wax packed section is provided to remove approximately 5% of the
existing gas oil from the vapours rising out of the C-16 flash zone. Along with this
5% VGO, normally the heavier fraction, is a significantly higher amount of metals
and associated asphaltenes than the lower boiling gas oils contain. The slop wax
draw provides some measure of control of these troublesome metals. These heavy
materials (asphaltenes) and metals are poisons for Unionfining / FCCU catalysts &
hence would have a negative effect on the downstream VGO Unionfiner / FCCU.
Slopwax will be collected on double decker cimney tray. Collected slopwax stream
will go to new slopwax drum V-44.Slopwax drum(V-44) level is controlled by LIC-
201 & FIC-76. One stream (Quench stream) from pump P-19 routed through
flashed crude exchanger S-28. Slopwax temperature at the outlet of S-28 is
controlled by TIC-751 & FIC-415 & recycled to slopwax drum feed inlet line as a
quench. Second stream can be recycled to vacuum heater inlet line or exported
with the vacuum bottom stream. By varying the slop wax recycle flow through FIC-
76, the amount of metals and heavier hydrocarbons that pass up the column to
the HVGO section can be controlled. The presence of heavier hydrocarbons &
metals content can be generally judged by colour of the HVGO sample.

The slop wax draw-off temperature is 376 0C as indicated by TI-031. The

differential pressure across the slop wax packed section is indicated by PDI-086.
This differential pressure is an indication of cleanliness of the slop wax packed
section & hence should be closely monitored.

 Heavy Vacuum Gas Oil (HVGO) Draw-off Section &

Circuits:
The HVGO section above the slop wax draw off section is referred to as the heat
removal section in Vacuum Column. The HVGO draw-off temperature is 278 0C as
indicated by TI-130. The pressure at the HVGO draw-off tray is indicated by PI-
088 & the differential pressure across the HVGO packed section is indicated by
PDI-085. This differential pressure is an indication of vapor-liquid-traffic / packing
fouling across HVGO fractionation section & hence should be closely monitored.

In HVGO fractionation section of the vacuum column most of the light & heavy
vacuum gas oil components are condensed & drawn. The HVGO is drawn from the
accumulator tray & pumped by P-20.

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 HVGO Pump Around Stream (Cold Reflux) :

A portion of HVGO from P-20 discharge is routed to the crude pre-heat exchangers
S-13/S-513 & S-12. The flow & temperature of cold circulating HVGO is controlled
by FIC-81 & TIC-20A/B across S-12 respectively across S-12. After the heat
exchange is completed, the cold HVGO is returned to the vacuum column at the
top of the HVGO section above the grids or packed bed.

Also a slip stream of hot circulating HVGO is drawn upstream of S-13/S-513

exchangers & used for “Plan 32 Pumps Seal Flushing” during normal operation of
the unit. During unit start-up flushing oil from RTF is lined up for seal flushing..

 HVGO Internal Reflux Stream (Cold Reflux) & Net HVGO Product :

Also a portion of the HVGO draw-off from P-20 discharge is returned hot back to
the vacuum column at the top of the slop wax packed section. This stream helps in
washing the metals and heavier hydrocarbons from the rising vapours. At no time
in normal operation the hot HVGO reflux flow should be reduced below
the specified limits as this would lead to coking tendencies in the section
just below. The hot HVGO reflux flow is controlled by FIC-77. Both the
cold & hot reflux to the vacuum column are critical process variables &
should be controlled near optimum values. Also the provision has been
made to put LVGO (from P-21 discharge) with HVGO hot reflux by FV-
77A.
A part of HAGO product from HAGO product pump will joined into HVGO pump
around stream for recovery of gasoil component

The HVGO net product draw-off is 50-80% of the total gas oil. The net HVGO
product draw-off from the vacuum column is controlled split range flow controller
FIC-86A/B cascaded with level controller LIC-23 on draw-off tray. The net HVGO
product stream from vacuum column to VGO Unionfiner is controlled by FIC-86A.
The HVGO product flow to VGO Unionfiner intermediate feed storage tanks is
controlled by FIC-86B & routed through vacuum gas oil cooler A-07.

 Light Vacuum Gas Oil (LVGO) Draw-off Section &

circuits

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The light vacuum gas oil section can be described as the top or final condensing
region. It is here where the LVGO is condensed and separated from the non-
condensable gases going to the ejector jets. The quantity of vapours rising to this
section is considerably less than the section below, hence the vacuum column is
swaged at this point. The LVGO draw-off temperature is 97 0C as indicated by TI-
129. The pressure at the LVGO draw-off tray is indicated by PI-087 & the
differential pressure across the LVGO packed section is indicated by PDI-084. This
differential pressure is an indication of vapor-liquid-traffic / packing fouling across
LVGO fractionation section & hence should be closely monitored.

 LVGO Pump Around Stream (Cold Reflux) :

The LVGO draw-off from the accumulator tray is pumped by P-21 & split into three
streams. The first stream is cooled in A-08 fin fan cooler followed up by trim cooler
S-20 and then sent on flow control (FIC-74) back to the top of LVGO packed
section as cold reflux. The temperature of this cold reflux stream to column is 43
0
C as indicated by TI-125. The flow rate of this stream is the process variable for
this section. In varying this flow rate, the composition of the liquid collected on the
LVGO accumulator tray will be changed. If the flow rate is increased, then more of
the lighter vapours will be condensed out and the initial boiling point of the LVGO
will be less.

 LVGO Net Product Stream & Hot reflux :

The second stream is a net LVGO product stream from vacuum column. The flow
of net LVGO product stream from the vacuum column is controlled by a split flow
range controller FIC-75A/B which is cascaded with the LVGO draw off tray level
controller LIC-22. The hot LVGO product flow to VGO Unit is controlled by FIC-75B.
The LVGO product flow to the VGO feed tankage is controlled by FIC-75A & routed
through gas oil cooler A-07. The VGO to storage from A-07 is indicated by TI-074.
The VGO to storage temperature should be monitored & maintained at around 80
0
C (i.e. above VGO pour point). New LVGO IR packing bed is installed between
HVGO pump around bed & LVGO draw-off. Hot reflux flow from P-21 is controlled
by FIC-454.

 Vacuum Column Overhead Section:

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The uncondensed hydrocarbon vapor / steam escaping from the LVGO packed
section are sucked, condensed by three stage ejector (J-01 A/B, J-02A/B/C, J-
03A/B/C) & condensers (S-21A/B, S-22, S-23) system. The condensate as well as
non-condensable vapours from these condensers are routed to hot well V-17. The
vacuum column top temperature is around 47 0C as indicated by TI-124.

The process variable for the overhead section is the pressure (PIC-62, normal
value 20 mmHg absolute) or vacuum being maintained. H.P. steam temperature is
reduced by injecting HP BFW. Temp. in the outlet of PRT is controlled by TIC-772
& Press. is controlled by PIC-61. That low temperature H.P. steam is used in
ejecters. Any change in the steam pressure or temperature or the condenser (S-
21A/B, S-22, S-23) cooling water supply temperature (CWS normal value 32 0C) &
flow will vary the column pressure or vacuum, thus varying the operation of the
entire column.

The condensed hydrocarbon liquid from hot wall is pumped by overhead

hydrocarbon pump P-22 to slops system. The pump P-22A/B auto start/stop is
actuated by hydrocarbon side level (LI-19) switch. The sour water is pumped by P-
23 to waste water stripping unit or unsaturated gas concentration unit through a
sour water side level controller LIC-18 on V-17.

The sour gas from the hot well (V-17) is routed to sour gas KOD (V-18) wherein
the condensate is knocked off from the sour gas before diverting it either to the
sour gas burners in crude charge fired heaters F-01/F-51 or to LP flare header.
The sour gas diversion to F-01/F-51 is through XV-16 or to the LP flare header
through XV-18. The condensate from the sour gas KOD is routed to blow case (V-
19) from where it is pressured back to hot well (V-17). The sour gas KOD level is
indicated by LI-017.

 Vacuum Column Bottom Section & Vacuum Residue

Circuits
The vacuum column bottoms level ( LI-21 DP cell type, LI-20 & LI-35 nucleonic
level indication) is normally operated at 50%. If the level is operated at a higher
set point, then the residence time of vacuum residue in C-16 will increase. This
level build up in vacuum column bottom would lead to a higher degree of thermal
cracking resulting in coke formation & in increasing load on the ejector system as
well.

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The superheated low pressure stripping steam is used in vacuum column bottom
for lowering the boiling points of high boiling heavier hydrocarbons (to avoid
thermal cracking) by partial pressure effect & improving the recovery of valuable
gas oil components. The flow of LP steam to the column bottom is controlled by
FIC-80.
The vacuum residue is drawn from the vacuum column bottom & circulated in the
crude preheat train exchangers S-15/S-515 for flashed crude , S-10 & S-25 crude
preheat train exchanger train for desalted crude in order to recover the heat.

The vacuum column bottom temperature is a very important process variable. The
vacuum bottom temperature is indicated by TI-136 controlled at approx. 358 0C
by TIC-133. The control of this variable is accomplished by returning a slip-stream
of vacuum residue from S-25 outlet through flow controller FIC-72, back to the
column boot. Thus the vacuum bottom temperature is controlled by TIC-133
cascaded with FIC-72 for VR quench flow to C-16. If the vacuum column bottom
temperature is not controlled as specified and allowed to increase then there are
chances of thermal cracking in the column bottom section as discussed earlier.
Quenching the vacuum column bottom section also aids in avoiding chances of
vacuum column bottom pump cavitation.

The net vacuum residue product from S-10 exchanger outlet is diverted to Delayed
Cocker unit. To control the temperature of VR stream going to coker small portion
from the outlet of S-25 is joined with VR going to coker through TV-756B. VR
from S-25 outlet is divided in two part, one will recycled back to vacuum column
as quench & second part is routed to tankage. A slip-stream of about (10-
15%) would be continuously diverted to VR tanks in RTF so that this line
is always in operation & available whenever required. The flow of the VR
stream to tanks is controlled by FIC-82.

The VR to Delayed Cocker unit flow is controlled by FIC-73 cascaded with level
controller LIC-20 on the vacuum column bottom. The VR feed temperature to
Delayed Cocker Unit is approx. 260 0C as indicated by TI-112.

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CHAPTER # 6

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PREPARING UNIT FOR

INITIAL START-UP

6.0 PREPARING UNIT FOR INITIAL START-UP

6.1 INTRODUCTION

During the final stages of construction and on completion of construction, there

was a large amount of detailed preparatory work, which is was done by the
operating personnel in cooperation with others at the job site. The primary
purpose of this work was to inspect the equipment to make certain that the
construction was done exactly as shown on the piping and instrument diagrams
and per project specifications, to ensure the equipment was free of debris and dirt,
to "run in" pumps and drivers, and to commission all utilities and supporting
facilities.

This section covers the work required in preparing the unit for initial start-up. This
work (such as testing and cleaning) was carried out during the last stages of
construction and generally it was one time work; however, it may be necessary to
repeat some procedures after major turnarounds. Careful and thorough
preparation of the unit, which can eliminated many problems and delays during
the startup. An outline is presented for a general method of cleaning and flushing
lines and equipment.
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The outline for checking pumps, after installation and prior to operation, is
applicable for all start-ups. Much of the work noted in this section was performed
by construction personnel under the observation of operations personnel. No
attempt is made herein to designate the personnel performing this preparatory
work. There are some phases of the preparation, such as run-in of the pumps
during water circulation for line cleaning, which was best completed by the
refiner's operating personnel.

FOR TAKING OVER AND FINAL CHECKING OF ALL EQUIPMENT, RELATED PIPING AND INSTRUMENT
DETAILED CHECKLISTS PREPARED, WHICH WAS REFERRED DURING INITIAL START UP ACTIVITY.

 SEQUENCE OF READINESS

The objectives of fixing the sequence are:

1. To commission all the utilities as quickly as possible.

2. To have the trial run of the all-rotary equipment as quickly as possible.

The operation group prepared the various loops of the units in the sequence as
desired by them for the purpose of start up. The sequences are as follows:

 Underground piping for Storm Water, Fire Water, Light & Heavy Slops CBD
Systems & OWS
 Cooling water
 Plant Air
 Instrument Air
 Utility water
 Potable water
 Steam (low pressure, medium pressure & high pressure)
 Boiler feed water
 LP Flare & HP Flare
 Fuel gas
 Fuel oil
 Chemical injection facility
 Other process lines like crude, reduced crude, etc.

6.2 INSPECTION OF PIPING, VESSELS AND COLUMNS

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 6.2.1 INSPECTION OF VESSELS

All process vessels was physically inspected from inside by the operations group,
for the prime objective of checking out the internals and ensuring conformity to
approved drawings. This is done in the following sequence:

 Open the manhole of the vessel

 Ensure adequate lighting and sufficient air for the people to work inside the
vessel, follow the safety procedure of vessel entry.

 Ensure the connected Nitrogen line, if any, has been positively isolated
(Blinded) and proper ventilation / oxygen requirement for entry to the vessel.

 Get the inside of the vessel thoroughly cleaned.

 Check the internals for proper mounting as specified in the vessel drawing.

 All vessel nozzles are properly connected as per nozzle orientation.

 Verify the location and length of all thermowells.

 Determine that all level instrumentation and differential pressure nozzles are as
specified.

 Blowout the nozzles with air or water hose connection.

 Baffles, vortex breakers, distributor nozzles and demister pads should be

thoroughly checked for cleanliness.

 The vessel insulation is complete as per the specifications.

 Note the hydro testing record of the vessel ( done in the fabrication shop)
and cross check with name plate and specification

 Any safety valve connected to the vessel will be removed, reset in the
workshop, certified by the designated authority and will be reinstalled.

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 Box up the vessel manhole with specified gasket.

 6.2.2. INSPECTION OF COLUMNS

 Following points to be check for carry out inspection of columns.

 All the distillation columns in the unit will be checked during the construction
stage for proper installation of trays by the operations and the construction
group and proper record is maintained for these activities. In addition to this
the following will also be checked.

 Check all connecting nozzles orientations / sizes & elevations.

 Be sure tray installation is complete and that all inspection plates where used
are in place. If perforated trays or sieve trays are used, verify that all openings
are clear. If side to side draw type trays are used with trap trays, make sure
these are clear and properly installed. Test where required. Take water hold
test for valve trays for checking internal leaks. Check other tray details as per
UOP specs(Refer point 6.3).

 Make sure all internal distributors for all columns have been installed as
specified. Verify that the openings and sizes of the distributors are as specified.
Before boxing up of the nozzle with the process flanges, make sure that
vendor’s gaskets are removed.

 Where internal draw-off piping is installed at the bottom of the columns or

vessels, make sure that these installations are as specified.

 Verify the location and length of all thermowells.

 Determine that all level instrumentation and differential pressure nozzles are as
specified. Verify that all orifice plates are available to be installed in their
proper locations and are properly sized. Prior to any hydrostatic testing, make
sure that all impulse lines are shut off at the orifice tap flanges. Check direction
of flow for orifice plate installation.

 Blowout the nozzles with air or water hose connection.

 Check baffles, vortex breakers.

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 Safety valves if any, connected to the column will be removed, reset in the
workshop, inspected by the authority and reinstalled.

 The column insulation is completed as per the specification

 Note the Hydro testing record of the column (carried out in the manufacturer’s
shop) and cross check with name plate and specification.

 Box up column manholes with specified gasket.

 6.2.3. INSPECTION OF PIPING

 Following points to be check for carry out inspection of piping.

 Piping check is done as per P & ID, Isometrics and other project specification in
order to check mechanical completion and subsequently carryout
commissioning activity. The entire section is divided into various systems and
subsystems. Based on hydrotest pressure, various piping loops are formed.
Once the particular loop is declared mechanically complete, the operations
group will systematically study the status of completion, with special attention
to following points.

 The system is exactly as defined in the approved P&I diagram and isometrics.

 All the isolation valves and control valves are installed correctly; special
attention should be given for flow direction of globe valves, check valves and
control valves.

 Do not install flow orifices till the flushing activity is completed.

 Special attention should be paid for safe and efficient operability of the valves.
Wherever required, additional working platforms may have to be provided for
operation of valves. However, such additional platforms should be kept to bare
minimum, keeping in mind the frequency of such operation (Chain operated
valves also can be provided for this purpose).

 Proper size of studs and bolts (No short bolting is allowed in flange).

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 All flanges need to be checked for proper rating, proper face to face matching,
Check for proper pipe supports. The proper gaskets should be installed as per
specifications.

 Check for proper thickness and completion of insulation as specified by detailed

engineering. Check for heat tracing / painting etc.

 Check for adequacy of piping vents and drains. Wherever necessary, especially
while handling hazardous materials, and high pressure and high temperature
fluids, the piping vents and drains should have flanged joints. In other
services, the vents and drains should have threaded caps. Also check for safe
approach for operating and maintaining such valves, especially in column’s over
headlines.

6.3 LEAK TEST OF TRAYS :

The tray installation in the column is checked for tray levelness, weir height,
downcomer clearance, seal-pan leak test, overlay between tray and TSR, number
of holes per tray in case of sieve trays, functioning and freeness of valve in case of
valve trays.
Following table gives tolerances for various measurements (Ref; Bechtel
Specification 22960-3PS-MV-002 rev 3 and UOP standard specification 3-18-5)

Tray Weir height : (+) or (-) 1.5 mm

Down comer clearance : (+) or (-) 3.0 mm
Tray levelness : (+) or (-) 3.0 mm for vessels upto 4.5mtrs
diameter
: (+) or (-) 5.0 mm for vessels above 4.5mtrs
diameter
Tray diameter : (+) 0 or (-) 6.0 for vessels upto 2100mm and
(+) 0 or
(-) 13.0 mm for large diameters.
Seal Pan leak test : 50 mm drop in 30 minutes.
Overlap between tray : 20mm minimum
and TSR
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6.4 HYDROSTATIC TESTING

Hydrostatic tests are made on new or repaired equipment to prove the strength of
materials and welds. This test is made by completely water filling the equipment to
be tested and increasing the pressure to the specified test pressure. If there is no
specified test pressure, the rule of thumb is 1½ times the operating pressure.
Normally a portable positive displacement pump will be used to increase the
pressure to that specified. It is best to introduce the water at the lowest point on
the equipment with the high point vent open. When all the air has been displaced
with water through the high point vent, then the vent can be closed and the
pressure increased to the specified test pressure. This test should not be confused
with other less severe tests generally carried out before a startup to check
tightness of connections.

An air pressure test can be conducted on sections of the unit prior to any water
test so that any open flanges or leaks may be discovered and taken care of prior
to liquid is admitted.

It should be remembered that when pressure testing vessels the test gauge is
placed at the bottom of the vessel so that the liquid head will be taken into
account. After the test has been completed, the pressure should be reduced very
slowly by opening the top vent. After the pressure has been released, the top vent
should be left open while the water inventory is drained through the low point
drain. This is to prevent the possibility of a vacuum being created while draining.
The following suggestions should be completed prior to any hydrostatic test:

 All relief valves or pressure discs must be removed, blinded, or gagged.

 Any instrumentation that is not designed for the test pressure must be
removed or isolated from the equipment to be tested.

 All connecting piping and equipment that has been designed for the test
pressure can be included in the test. Any connecting vessels or equipment that
is not designed for the test pressure must be isolated from the test by blinding.

 All relief valves must be shop tested and also isolated from the hydrostatic
testing. The hydrostatic testing of the equipment provides an opportune time
for relief valve shop testing.
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6.5 FLUSHING OUT OF LINES

All piping should be thoroughly cleaned of debris and scale. All lines are flushed
with water and thoroughly drained. Where possible clean water should be supplied
to the vessels and the connecting piping is flushed away from the vessel. Do not
flush debris into equipment such as exchangers. Water flushed lines that do not
drain freely should be blown clear with air.

Gas handling piping can be flushed with water or air blown. If water is used to
flush these lines after the water has been drained the lines must be thoroughly
cleared of water with air. Instrument airlines should be thoroughly blown clear
with clean dry air.
In all cleaning either by water, steam, or air, maximum volume and velocity should
be maintained for thorough cleaning.

Care must be taken to avoid a vacuum condition in any pieces of equipment not
designed for vacuum service during water flushing of lines. All connected
equipment must be adequately vented.

The following is a guideline for flushing:

 Orifice plates must not be installed prior to flushing.

 Control valves should be removed or rolled out. Flexitallic gaskets cannot be

reused so they should not be installed until flushing is completed. Temporary
gaskets can be used for initial installation.

 All instrument impulse lines should be isolated or disconnected.

 All pump suction and discharge piping should be flushed while disconnected.

 The steam supply and exhaust piping to and from turbines are cleaned by
blowing them while disconnected.

 When flushing through lines regulate the flow of flushing medium at the source
and not at the outlet of the lines being flushed. For example, water from a
column, should be regulated at the column; and steam, at the valve on the
steam supply to the line being blown.
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 Flush through all vents and drains.

 Where possible flush downwards or horizontally.

 Always flush through the upstream isolation valves on control loops , before
flushing through the bypass valves into the down stream control valve piping.

 For steam systems, flush thoroughly the dirt leg drains and steam trap
bypasses before placing the steam trap in service.

 Disconnect the lines into and out of exchangers, then flush the lines thoroughly
before reconnecting and flushing through the exchangers.

 Upon completion of line flushing of a system, carefully check that all temporary
disconnects are reconnected, control valves reinstalled, and pump alignments
are normal. All lines are properly supported wherever required, line flanges are
electrically bonded to avoid static charges etc. and permanent gaskets are
installed.

6.6 INSPECTION AND RUN-IN OF ROTARY EQUIPMENT

Proper installation and operation of the pumps and drivers is essential for trouble
free performance. The pumps and drivers carefully handled during initial run-in.

The initial running of the pumps was generally done by circulating water through
the new equipment. During these trials it was important to check that the right
fuse ratings were installed in MCC to avoid motor burnout. Temporary strainers
were installed in the suction of the pumps. During running of the pumps, the
strainers got some restriction of flow. Flow to the pump was fall off due to debris
collected in strainers. In this event, it was necessary to switch to the spare pump if
possible and clean the strainer. The switching of the pumps and cleaning of the
strainers carried out until the pumps operated for a reasonable period of time.
Since most pumps are designed to pump material much different in specific gravity
than water, it was necessary to throttle the discharge valve during this period to
maintain the specified discharge pressure to protect the discharge piping / motor.
But never restrict the flow across the discharge valve to the extent that it will
cause internal slippage or excessive heat generation. During this time period the
operators observed the pumps closely so that there was no loss of suction
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pressure before the pumps are switched nor any unusual noises or excessive heat
generated in any of the pump parts.

Never throttle discharge valve of positive displacement type pump because this will
cause over pressuring and possible damage to the pump.

For details refer pump SOP.

The following is a checklist for preparing pump for trial run.

 The manufacture's operating instructions should be reviewed for any specific
precautions that should be observed.
 Check that the overall installation is complete.

 Verify that the pump and driver have been aligned for cold operation. There
must be no undue strain on the pump or driver by the piping.

 Verify that the water piping is connected where required like bearing jackets,
pedestals, stuffing boxes, etc.

 If the driver is a turbine, check that all steam piping is complete, inlet, exhaust,
traps, bleeders, etc.

 Check the seal or gland oil piping. Conventionally packed pumps in hot service
are generally furnished with gland oil. Verify that this installation is correct and
complete.

 Verify that packing or seals are installed.

 Check that temporary strainers in the suction piping have been installed.

 Verify that bearings and shafts have been cleaned prior to final lubrication.

 Check that the pump and driver have been lubricated according to the vendor's
lubrication instructions.

 Check the rotation of the electric drivers uncoupled from the pump. Run-in
uncoupled to verify operability.

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 Run-in all other drivers, uncoupled from the pumps. During run-in, the
overspeed trips, high bearing temperature trips, and vibration trips etc., are all
satisfactorily checked for operability. Abnormal conditions must be corrected
before coupling to the pump.

The pumps are normally pumping a material of lighter weight or lower specific
gravity than the water circulated during initial run-in. The pump driver is sized for
the normal fluid, consequently while pumping water the electric motors are easily
overloaded. To avoid this problem, the flow was limited by throttling the pump
discharge valve to maintain the normal amperage of the motor.

The following checklist is for initial commissioning of the pump:

 Rotate the pump and driver by hand, verifying that they will roll freely.
 Check that the suction and discharge circuits are properly lined up.

 Verify that the pump suction valves are open fully, venting air from the piping
and pump, completely filling it with water.

 Establish cooling water flow where required.

 Check that the pump lubrication system is lined up and operating properly.

 Verify that electric power is available from the switchgear to the starter of the
electric motor. For steam turbines, the turbine is warmed by slowly opening the
exhaust valve and backing in steam while draining water from the case. The
steam exhaust valve is always fully opened before starting. Where the exhaust
steam system is under vacuum, the case is warmed by gradually introducing
the driving steam, after opening the exhaust valve. In vacuum exhaust
systems, sealing steam to the turbine shaft labyrinths must be admitted to
avoid loss of vacuum.

 Crack open the discharge of a centrifugal pump and fully open the discharge
valve of a positive displacement pump before starting.

 Start the pump driver and bring it up to speed immediately, observing the
discharge pressure. If the pressure does not build immediately, stop the driver
and investigate the problem. Refill the pump and restart the driver when the
problem is resolved.

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 When the discharge pressure of the centrifugal pump has increased

satisfactorily, gradually open the discharge valve to obtain the desired flow
rate.

 In the event of unusual noise, vibration, overheating or other abnormal

conditions, shut down the pump immediately. Correct the cause before
restarting the pump. Continue checking for abnormal conditions as these may
occur after prolonged operation.

 Mechanical seals should show no leakage. Conventionally packed stuffing boxes

must always be permitted to leak slightly, to provide some lubrication and
prevent overheating. Stuffing box gland nuts are generally only finger tight. A
mechanical seal may show some leakage on startup. After the pump has been
started and stopped a few times, the leakage should stop. If the seal leakage
persists, then steps should be taken to correct the problem.

 The pump should be operated so that flows are directed through all suction
and discharge piping circuits.

 As the suction pressure begins to drop, the spare pump will have to be started
and the operating pumps shut down so that the suction screen can be cleaned.

 Recheck and realign if required, after any disturbance of the piping, such as
after suction screen inspection or cleaning.

 In shutting down a centrifugal pump, close the discharge valve first,

maintaining discharge pressure while the pump rolls to a stop. On positive
displacement pump, the discharge valve should not be closed until all
movement of the shaft has stopped.

 After the suction line of the pump has been thoroughly flushed, the temporary
suction screen has been inspected twice with no signs of debris either time,
then the temporary screen can be removed and the permanent screen can be
installed.

 INSPECTION AND RUNNING IN OF GAS COMPRESSOR

(For details refer Compressor SOP)

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Startup of any gas compressor should be in accordance with the manufacturers

recommended operating instructions. Before operation it was necessary to check
the operation of the machine.

Whenever a compressor was placed in service and the unit contains hydrocarbons,
the compressor must be air freed and filled with nitrogen. Before air can be
introduced into any compressor, which has contained hydrocarbons, the machine
must be isolated, depressurized, and nitrogen purged.

The following is a procedure for putting in service a screw compressor.

 Check compressor interlocks.

 Purge the compressor with nitrogen through the suction, into the machine and
out through the atmospheric vent or flare line.

 Roll the compressor over to insure complete purging.

 Gradually open the compressor suction valve to pressure up the compressor to

line pressure.

 Start steam to the steam tracing or in-line heater. Drain the suction line and
pulsation dampener of any liquid.

 Open the discharge control valves and the spillback control valves prior to
starting the compressor.

6.7 INSPECTION AND DRYING OUT OF FURNACES

Before startup circulation was established, the moisture in the insulating refractory
was expelled by slowly raising the temperature of the heater firebox. For UOP type
heaters, the following dry out procedure and precautions apply.

NOTE: Other types of heaters may require changes in the procedure

which are to be made according to the manufacturer's recommendations
(Refer heater sop for details).

 Check for heater interlock before firing the heaters.

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 Make a temporary installation of thermocouples for temperature measurement

in the hip sections of the heater. The tips of these thermocouples should
extend 6" to 8" beyond the inside face of the insulating concrete.
 Light up all pilots (For details refer chapter no. 11or heater SOP).

 Light one or more burners, as required, in each section of the heater and fire
slowly so that the temperatures in the firebox, as indicated by the temporary
thermocouples in the hips, are increased at a rate of approximately 14 oC (25
o
F) per hour until a general firebox temperature of 110-121 oC (230-250 oF) is
reached.

 Maintain this temperature for at least 18 hours, during which period the burner
operation is to be rotated frequently in order to distribute the heat as evenly as
possible throughout the length of the heater. This will also help in testing all
the burners for operability & cleanliness.

 Light additional burners as required after the 18 hour period to increase the
temperature at a rate of approximately 20 oC to a general temperature of
approximately 450 oC .Hold this temperature for 24 hrs.

 All of the burners should be shut off and the heater allowed to cool slowly at
the rate of 30 0C /hr by keeping the air dampers and stack dampers closed.
Insert blinds in fuel gas line if the shutdown is for longer duration.

 After the heater has been dried out, the temperatures can be subsequently
raised or lowered at any desired rate unless the heater has been shut down for
a prolonged period of time.

 When the unit is shut down, the gas supply is to be blinded, also the pilot gas
should be blinded if it is a separate system, to prevent gas from leaking
through the block valves at the heater and causing an explosion hazard.

The following discussion concerns the proper operation of oil fired heaters. Some
of the concerns for oil fired heaters are the same as those for gas fired heaters.
Such as, when shutting down and before lighting burners all individual block valves
on the burners should be checked to verify that they are blocked. Also the firebox
should be steamed out

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 For approximately 20 minutes minimum prior to lighting a burner [ Purging of

the box with LP steam only ]. Verify that all airports and dampers are fully
open.

 When an oil-fired heater is shut down, the oil gun should always be steamed
and pulled out.

 Before lighting any oil burners, verify that all individual oil guns have been
removed from the burners.

 With combustion burners, it is desirable, when firing heavy oils, to operate the
gas portion for at least an hour before admitting oil. Have the fuel oil
circulating through the bypass at normal operating temperature.

 FO & Atomizing Steam PDIC should be checked. Maintain proper U/S pressure
of fuel by PRC to control proper flame pattern and velocities the burners are
designed for.

 Observe the oil burner tip for coke formation.

 Observe the heater pass skin temperature thermocouples.

 Observe the heater tubes for flame impingement.

 Observe & record heater draft gauges/oxygen analyzers readings.

6.8 COMMISSIONING OF INSTRUMENTS

Prior to initial startup, the instrumentation was completed and checked out. The
following is the recommended checklist:

 Ensure calibration of all safety valves before installation.

 All transmission lines from the field to the DCS for each instrument must be
checked for proper installation.

 Completion of the control air supply to all control valves. The control valves are
removed during flushing, when they are replaced the control air system should
be re -tested.
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 All control valves should be checked for direction of flow valve operability, such
as, stem travel, and action on air failure, interlocks etc. Also stroke checks
should correspond to the output from controller.

 Check calibration certificate of all pressure and temperature instruments.

 All instrument lead/impulse lines must be checked for tightness.

 Check for proper instrument sealing fluid levels where required.

 Calibrate all instruments and synchronize the transmitter and receiver readings
for each instrument.

 After line flushing install all orifice plates. Check the orifice plates for plate
direction, weep hole orientation and tag accuracy.

 Check all instrumentation for correct metallurgy.

6.9 FIN-FAN HEAT EXCHANGERS

(Refer SOP for details)

The Fin-Fan heat exchangers installed and commissioned with the manufacturer's
recommendations. Special attention should be given to the following:

 Check the condition of the fins and remove any debris that might be left such
as wool, insulating scraps, etc.

 Check the alignment and coupling of the motor and fan. Also the check the
drive pulley belt tension.

 Check that all safety guards have been installed.

 Check that the bearings have been cleaned and lubricated.

 Check for proper fan-motor rotation.

 Check amperage usage to ensure insures proper pitch setting.

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 Check that the louvers have been greased and move freely.

6.10 OTHERS

 6.10.1 PAVED AREA

The area paving was completed along with the respective underground system,
check for the following.

 Proper grading of the area.

 The surface finish should not be slippery. At the same time it should be
conducive to safe and efficient operation.

 The operation group should check that there is no stagnation of water by

actually pouring some water on the surface and confirming that it smoothly
flows to the underground pipe.

 6.10.2 AREA LIGHTING

Check the area lighting with respect to following.

 The area lighting and electrical fixtures are suitable for the unit as defined by
hazardous area specification.

 The height of fixture does not hamper safe movement of operation personnel
and for safely carrying out maintenance work.

 Adequacy of area lighting especially around the emergency exit area.

 Automatic switch over to emergency lighting, during power failure.

 6.10.3 PUBLIC ADDRESS SYSTEM

It is the responsibility of the operations group that public address system is

properly connected and is as defined in the detailed engineering. In this
connection the following points to be checked.

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 Proper audibility of the message when received by the field operator . This
must be checked when sufficient number of rotary equipments are in
operation in the unit.

 Adequacy of public address system, keeping in mined the emergency

operations, which will have to be done by field operator.

 Proper training should be given to both the field operator and control room
operator for effective communication through public address system.

 6.10.4 STRUCTURAL

The structural was checked by the operations when particular equipment or the
concerned system is declared mechanically complete.

The following is a checklist regarding structural.

 The alignment and grouting is complete.

 Fire proofing is done as required by detailed engineering.

 Adequacy of hand rails in normal movement area and at higher elevations.

 Proper completion of cages for the entire monkey ladders.

 All the gratings are properly erected and are not slippery. Safe movement of
the personnel should be ensured while working on the gratings.

 Staircase steps are properly spaced. Whenever possible, platforms at the

higher elevations should be interconnected so as to ensure the effective
movement of operating crew.

 6.10.5 FIRE AND SAFETY

Fire and safety equipment made available approximately 1 months before the unit
start-up.The fire chief along with the chief of operations of the unit made a visit to
the plant for identification of the location of the fire extinguishers as well as the
type of fire extinguisher. The following things were kept in mind while deciding
the same:

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 The operator is not required to move long distances more than about 10 meter
to the nearest fire extinguisher. These needs are to confirm statutory
requirements dictated by statutory regulators.

 Usefulness of the fire extinguisher, i. e. It’s physical placement in the plant, its
approximate weight etc. The fire and safety group will also periodically check
this.

 All the operating and maintenance personnel are given periodic fire fighting
training and they are completely familiar with the method of using every type
of fire extinguisher.

 All the operating and maintenance personnel are fully aware of the fire incident
reporting procedure, their roles in case of a disaster and awareness of where to
assemble in case of disaster.
 With respect to safety the following points need to be checked by the
operations in charge as well as safety in charge:

 All the exit routes are clearly identified marked and are not blocked by any
equipment or piping etc.

 The safety showers are in position and are operable.

 All operating and maintenance personnel should be educated on the various

hazards associated with unit. Wherever necessary written instructions should
be given. At the strategic locations in the plant, safety signboards should be
displayed.

 All the operating and maintenance personnel should be compelled to wear

safety shoes and helmets, while working in the process area.

 Specific safety equipments such as gas masks and canisters should be available
handy in required areas in the plant.

 The first aid boxes along with necessary fixtures should be available round the
clock for all the plant personnel.

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 In addition to the above, safety audit must be carried out by designated

personnel in the plant area, approximately one month before start up of the
unit to identify any safety aspect overlooked.

 All the work permits necessary to carry out cold work and hot work, excavation
and vessel entry should be made ready sufficiently in advance so as to
implement the same at the appropriate time.

 6.10.6 CHEMICAL CLEANING

Chemical cleaning is done for piping and equipment of the system, where no
grease, mill scales rust, or welding beads is tolerable. Important pipes such as lube
oil piping for suction line of compressor and special service pipelines like breathing
air, cooling water lines were chemically cleaned. Detailed procedure for chemical
cleaning was developed for each requirement .It was ensured that proper
circulation velocities were maintained and no stagnant pockets remain during
chemical cleaning.

 LINE CHEMICAL CLEANING PROCEDURE

 PURPOSE:

 TO CHEMICALLY CLEAN THE PIPELINES MADE OF CARBON STEEL/CAST

IRON/UPTO12% CR STEEL/AUSTENITIC STAINLESS STEEL/CU – NI ALLOYS TO
REMOVE IRON OXIDE DEPOSITS AND SCALE.

 SCOPE:

 THIS ACTIVITY IS DONE DURING THE INITIAL STARTUP OF THE UNIT AT THE TIME OF
PRE-COMMISSIONING.

 PROCEDURE:

 IT WOULD BE NECESSARY TO REMOVE THE LINE PIPING FROM THE VESSELS /

COLUMNS AND FORM THEM INTO LOOPS OF FEASIBLE SIZES. ALTERNATELY, A
SUITABLE LOOP CAN BE FORMED USING JUMP-OVERS AND CONNECTING SPOOLS. A
BIG RESERVOIR WITH ENOUGH SURGE VOLUME SHOULD BE USED FOR CHEMICAL
SOLUTION FROM WHERE THE CHEMICAL CLEANING PUMP TAKES SUCTION.

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The procedure is divided into the following steps.

 Precautions
 Water Flushing
 Degreasing
 Rinsing.
 Acid Cleaning.
 Rinsing and Neutralisation.
 Passivation and Final Rinse

Step-wise description of the procedure is given below.

 PRECAUTIONS:

 Make arrangements to dispose the generated effluent. It is highly acidic and

may contain dissolved ferrous salts.
 Isolate all instruments.

 Do not use process pumps.

 Do not expose the control valve to the cleaning solution

 Do not use process Reboiler for heating the acidic medium. Use steam spargers
for heating or temporary coils.

 After the final rinse, the vessel lines should be thoroughly purged and dried
with nitrogen and then maintained in nitrogen atmosphere.

 Personal protective equipment like apron, PVC gloves and goggles should be
used.

 During acid cleaning step restrict liquid velocity to max. 0.5 m/sec for effective
inhibition

 WATER FLUSHING:

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 Make up with clean water, either utility or cold condensate and circulate.
Continue until return water is clear.

 After circulating water is clear, raise temperature to 70oC in increments of 5oC

per hour and circulate for 2 to 3 hours
 DEGREASING:

 When clear circulating water is at 70oC, add the following chemicals to the
specified concentrations:
{1}Trisodium Phosphate -1.2%
{2} Caustic Soda -2.8%
{3} Detergent -0.12%.

 Circulate for 6 – 8 hrs hours at 70 -80oC

 Monitor pH, alkalinity, and oil in return line.

 When the alkalinity and oil content remain constant while solution is circulated,
degreasing is complete

 RINSING:

 Drain caustic solution and flush with clean water.

 Makeup and circulate water at 40 to 50oC.

 Monitor pH and alkalinity.

 When PH and alkalinity of the solution are the same at the inlet and outlet to
the solution tank, stop the circulation.

 ACID CLEANING:

 Inventory the system with cold condensate, circulate and heat to 70 to 80oC.

 ADD THE APPROPRIATE RHODINE 92.

 Add citric acid to make a 3.0 to 3.5% wt solution.

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 Slowly add NH 3 to control PH at 3 to 3.5.

 Monitor PH, acid concentration and dissolved Iron. If acid concentration goes
below 0.5% wt , make up to 1.0%.

 When Iron concentration reaches 0.4% wt the solution should be dumped. The
equipment should then be rinsed

 RINSING, NEUTRALISATIONAND PASSIVATION:

 Rinsing / Neutralization and Passivation should be performed using a fresh

batch of Cold Condensate. Citric acid is added to a concentration of 0.5% wt
and circulated until the Iron concentration reaches equilibrium level. The pH is
then adjusted to 9.5 by adding NH 3 ( or alternatively sodium carbonate to avoid
ammonia odour )

 Add NaNO 2 to make a 1.5% wt solution. The solution is circulated for six
hours. Closely monitor pH and control at 9.5 by adding of NH 3 . ( or
alternatively sodium carbonate to avoid ammonia odour)

 Drain the system under inert gas (nitrogen). Refill with Cold Condensate and
circulate for 2 hours. Adjust pH to about 7.5 by adding NH 3 . ( or alternatively
sodium carbonate to avoid ammonia odour)

 FINAL RINSE:

 Makeup with clean water and circulate.

 Add hydrazine to a concentration of 50 ppm.

 Adjust pH to 7.5 to 8.5 by adding NH 3 .

 Circulate for one hour. Drain under nitrogen atmosphere.

 6.10.7 CONSUMABLES

In addition to the usual consumables of the unit in the form of catalyst, chemicals,
lubricating oils etc., the newly constructed plant required certain typical
consumables, which required during the precommissioning stage. Some of these

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consumables may find subsequent application even during the plant operations as
well as in subsequent start-ups. It was the responsibility of operations group that
these consumables available at hand before precommissioning activities were
taken up. The list of these consumables is given below:

 Hand barrel pump (for decanting lubricating oil)

 Jerry cans 1/2/5 litter’s capacity
 Liquid soap
 Waste cotton
 Plastic bottles 500 / 1000 CC capacity for sniffing soap solution
 Stop watch for measuring time upto 60 minutes
 Safety torch
 Ordinary torches
 Steam hose of the 1” size, 10-M long suitable for low-pressure steam with
lancers
 Low temperature hose for using on service water and process area, suitable for
40°C and 10 Kg/cm2 pressure, 1” diameter, 10 M long
 Fire water hose 2 1/2” diameter, standard length
 Valve wheel keys. Of smaller size and of large size
 Wheel key stand, located in strategic points in the unit.
 Hand gloves for handling steam, chemicals, and normal hydrocarbon service.
 Tags for miscellaneous use in the plant
 De-watering pump
 Multipurpose grease

 Folding ladder, to reach approximately 10 M height

 Fixed ladders. Approximately 6 M

 Wheel barrow house
 Trash bins / half cut drums
 Paints for various miscellaneous plant use.
6.11 VACUUM TEST

The prerequisite of Vacuum test is to pressurize the system with air upto 1.0
kg/cm2g and carry out the leak test and the pressure hold test. (Refer marked up
P & IDs G41-RD311/312-020, 021, 043, 044, 045, 045, 047, 049, 050, 057 & 069).
Ensure that all related branch lines and instruments are in line and pressurized
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(PT’S &PG’S), which are not designed for that pressure should be isolated). If
pressure hold test is OK, proceed for vacuum test. The pressure test is very
important. If it fails, the system should be thoroughly checked & redo the vacuum
test.

 Vacuum test is carried out as per following

procedure.

 Remove blinds, which would interface with vacuum test on the Equipments.

 All flanges must be checked for proper gaskets, short bolts.

 Check all valves, which are to be in closed condition, must be tight shut. Check
all valves glands for any leak. If they found defective, replace them.

 System line-up should be as follows

 F02 CIRCUIT:
 Close F02 all pass flow control valves (FV 151 to FV160) upstream isolation
valves and bypass valves. All the valves must be tight shut.

 Close all isolation valves of emergency steam to F02 pass flows.

 Close coil steam all isolation valves (downstream of FV 161 to FV 170 and
FV461 to FV470)

 OVERHEAD CIRCUIT:

 Isolate over head PSVs (PSV 138 A to F) downstream isolation valves, keep
open upstream isolation valves. These pilot operated PSVs drain valve must be
in closed condition.

 Close all steam isolation valves to Ejectors.

 Line up PV62 and PV62A and keep control valves in closed condition.

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 FG supply (upstream of PV62) isolation valve in closed condition.

 Close overhead sample point PA 025, vent to flare isolation valve.

 Fill up water into 311 V17 upto 25% by external water hose connection.

 Close V17 LG / LT vent and drain isolation valves.

 Line up PSV 139A/B, upstream isolation valves and close downstream isolation
valves.

 Blind OWS, SH drains of V18, V19.

 Isolate PSV 140A/B downstream isolation valves.

 Blind FG supply to V17.

 Close XV 18 (Flare) and keep open XV 16 (Furnace).

 Isolate XV 18 downstream isolation valve.

 Drop One flame arrestor at F01 and its upstream isolation valve in closed
condition.

 LVGO CIRCUIT:
 Isolate P21A/B suction valves.

 Isolate LVGO IR filters downstream isolation valves.

 Isolate FV 74 downstream isolation valve & bypass valves.

 Isolate LVGO sample point PA 015.

 HVGO CIRCUIT:
 Isolate P20A/B suction XV57, XV58.

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 Blind SH/OWS points upstream of XV57, XV58.

 Isolate FLO to upstream of XV 57, 58.

 Isolate pump casing/discharge vent to vacuum column.

 Isolate HVGO sample point PA 014.

 Isolate HVGO PA filters downstream isolation valves.

 Isolate HVGO IR filters downstream isolation valves.

 SLOPWAX CIRCUIT:
 Isolate P19A/B, suction isolation valves.

 Blind SH/OWS points upstream of suction isolation valves.

 Isolate FLO to upstream of suction isolation valves.

 Isolate Slopwax sample point PA013.

 Blind SH/OWS drains of V44

 Isolate FLO and steam out points of V44.

 Isolate FV451 upstream isolation valve and bypass valve

 Isolate P19A/B spill back FV125 downstream isolation and bypass valve.

 Isolate pump casing/discharge vent to vacuum column.

 Isolate V44 LG/LT drains and vents.

 HAGO CIRCUIT:

 Isolate FV 112 downstream to vacuum column.

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 VR CIRCUIT:
 Isolate P18A/B suction isolation valves.

 Blind SH/OWS point (4”) upstream of suction isolation valves.

 Isolate FLO upstream of suction isolation valves.

 Isolate pumps casing and discharge vents to vacuum column.

 Isolate FV124 control valve downstream & bypass isolation valves.

 Isolate FV72 downstream & bypass isolation valves.

 Isolate FLO at the bottom of vacuum column.

 Isolate FV80 downstream and bypass isolation valves.

 Isolate all (LVGO/HVGO/SLOPWAX/VR) LGs &LTs vents & drains.

 Charge FG header with Nitrogen.

 Back up Nitrogen into Vacuum column from overhead line FG point.

 Pressurize Vacuum unit with Nitrogen upto 1.5 kg/cm2g. Read the pressure
form PT65A/B/C and PG on V19 [Existing PG to be replaced for measuring
positive pressure].

 Drop Ejector off gas one flame arrestor at F01 and keep its upstream isolation
valve in closed condition.

 Open XV 016, and de-pressurize Vacuum unit by opening Flame arrestor

(Dropped) upstream isolation valve. De-pressurize upto 0.1 kg/cm2g.

 Repeat steps e and g once more. {For making sure air is displaced by
Nitrogen}.

 Check Oxygen content during de pressurization.

 If Oxygen content is above 0.1%, repeat steps e and g.

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 Start cooling water to the ejector condensers.

 Box up dropped flame arrestor at F01 and keep both Flame arrestors isolated.

 Ensure LP flare header in charge condition.

 Line up vacuum overhead soar gases to LP flare through ejector condensate

receiver (V17) and sour gas KOD (V18) by opening XV18 downstream isolation
valve.

 Ensure Vacuum overhead ejector condensate receiver (V17) is filled with water
to minimum level (say 25%) & ensure water seal.
 Line up MP steam to the ejector system upto PV61. Line up steam traps, drain
condensate till dry steam comes out (It should be noted that wet steam will
cause fluctuations in ejector performance and will erode the nozzle and
diffuser).

 Ensure steam inlet valves to all ejectors are in closed condition.

 Close all Process inlet valves to all Ejectors except J03C.

 Open Ejector steam control valve PV 61. Open steam isolation valve to J03C

 Open ejector off gases to Flare by opening XV18.

 Start J03A /C (one by one) ejector by opening Process side and steam side
isolation valves.

 Start J03B ejector. Read the pressure form overhead PT 65A/B/C and PG on
overhead line.

 Lineup second stage ejectors J02 A/B/C (one by one) and try to bring overhead
Vacuum to 25mmhga.

 If required line up first stage ejectors (J01A/B).

 Check each flange for leakage.

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 Check valve gland packing leakage.

 Close XV 18 and isolate its downstream isolation valve.

 Hold the Vacuum for at least one hour. Maximum allowable pressure drop is
25mmHg/hr.

 If Vacuum test fails, break the Vacuum with Nitrogen, check the system
thoroughly. Repeat the test. If it fails again, pressure test must be carried out
again.

 If Vacuum hold test is OK, break the vacuum by opening Nitrogen valve at the
overhead line.

 Pressurize Vacuum unit by Nitrogen upto 0.5 kg/cm2g and maintain it.

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CHAPTER # 7

START-UP
PROCEDURES

 7.0 START UP PROCEDURE

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 7.1 GENERAL
Start-up and shutdown are the most critical periods in operation. The hazard
possibilities due to pressure / temperature upsets, fire and explosion are greatest
during the unit start up activities.

The hazards encountered most frequently in start-up and shut down of units are
accidental mixing of air and hydrocarbons and contacting of water with hot oil.
Other hazards primarily associated with start up are pressure / vacuum surges and
thermal / mechanical shocks. These can result in fires, explosions, destructive
pressure surges, and other damages to unit as well as injury to personnel.

Fires occur when oxygen and fuel vapor or mists are mixed in flammable
proportions and come in contact with an ignition source. They may run out of
control or set off devastating explosions. Pressure surge from unplanned mixing of
water and hot oil may cause damage of equipment or bump off the column trays
and/or loss of valuable production. Extensive, costly downtime on process unit
may result. Fires usually follow if the explosion knocks off pipeline or vessels.
Preparation for start up begins with a complete review of the start up procedure
by the operating crew. Check lists should be made indicating each step that is to
be performed. The importance of communication between shifts and between
individuals must be emphasized. Each shift must clearly understand what has been
done in previous shifts and what is expected of it. Some overlap of supervision
between shifts can improve communication and continuity of work. Activities of
CDU/VDU/SGCU should be coordinated with RTF, HTU, Coker, Merox, CPP,
Hydrogen, platformer and Utilities section.

 PRE-REQUISITES
Before proceeding with the startup, the following preliminary items should be
checked to
ensure that a safe and orderly startup of the unit can be effected:

 Safety:

All safety equipment, which will be required for hydrocarbon addition to the unit,
should available on-site and operable. Check that:

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1) All portable fire equipment are in place.

2) The fire hydrant system is in service. Also ensure F&G system is commissioned
& functional.
3) Miscellaneous safety equipment are available (e.g. air masks, first aid etc.)
4) The area is reasonably free from obstructions and free from oil.
5) Necessary warning signs are posted.
6) Adequate lighting is available for night operations.
7) All communication channels are in working condition.

 Other pre requisites:

Prior to actual commissioning of the plant it should be established that all

preparatory works have been successfully completed and all equipment are ready
to be put in operation. Ensure that:

- All equipment nos., service of lines with flow direction ( like control valves,
check valves/ NRVs & globe valves ) within the unit and battery limit are
marked properly.
- Ensure that the crude oil inlet valve is fully closed at B/L.
- Ensure that the steam and condensate to S03 is isolated.
- Blinds are installed as per master blind list. Each removal and insertion of a
blind should be noted and initialed by the operator in-charge / Zone-in-charge /
Shift Coordinator on daily basis as and when changes are made.
- Ensure all temporary lines for N2 purging etc. are disconnected to
prevent back floe of HC into these temporary purging / flushing lines.
- All vessels / columns are cleaned & boxed up, piping, equipment are pressure
tested, flushed and ready for service. Also ensure that all vessels / columns
internals e.g. demister pads are installed.
- All rotating equipment such as pumps, motors etc, have undergone functional
test successfully.
- All instruments have been checked and calibrated. Control should be on
manual. New graphics are developed, checked & incorporated in DCS.
- Control valves are stroke checked, interlocks are simulated and functional,
alarms settings are done and all orifice plates are installed. If the range of any
meter is changed, ensure this re-ranging is done in DCS also.
- All safety valves are in position after setting, isolation valves for PSV/PRV are
locked in open position. Spare valves should be kept isolated.

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- Before starting any rotating Equipment, ensure that seal system, CW set up,
and drain connections are in order and commissioned or blocked as the case
may be.
- All utility headers are charged.
- LP/HP Flare, closed blow down, sewer and flushing oil systems are in operable
condition.
- All pre-commissioning activities are completed.
- Fuel oil and fuel gas blinds are removed and both headers charged.
- Tracing steam to the lines is opened and steam traps on the headers are
functional
- Ensure that the unit is steam purged and Crude section is kept under positive
pressure (with Fuel gas / Nitrogen back up) of 0.3 kg/cm2g and Vacuum
section is kept under a positive pressure of 0.5 kg/cm2g.
- Inform RTF / Coker to keep flushing oil storage ready for startup purpose.
- Inform RTF to keep slop tank and crude tanks ready.
- Ensure that startup audit and safety audit have been completed and audit
points have been liquidated
- Ensure that the crude oil tank has been drained for water, sample analyzed for
sp. Gravity, salt content, BS & W and Sulfur. Line up for feeding to unit with
spill back system in line.
- Ensure that Flushing oil tank has been drained for water and has enough
inventories to give Flushing oil to the unit.
- Ensure the Desalters are water filled and kept isolated and its bypass valves
opened.
- During Cold oil circulation (Flushing), spare pumps also to be started one by
one for water removal and strainer cleaning.
- Use checklist no. 1 for pre start up activities.

 7.2 NOTIFICATION TO OTHER DEPARTMENTS /

START UP CO-ORDINATION

Inform about the Crude unit start up to all the following upstream /
downstream units i.e. VGO Unionfining Unit, Diesel Unionfining Unit, FCCU,
Merox units, Delayed Coker unit, CPP, Utility, Sulfur unit, RTF, Aromatics &
Fire Station.

 7.3 PRE START UP / START UP ACTIVITIES:

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Start up of the unit involves the following consecutive phases.

 Tightness Test
 Removal of air from the unit by steam purging
 Backing-in fuel gas / Nitrogen
 Furnace Refractory dry out
 Commissioning of new exchangers & passivation of water coolers
 Draining water from the system
 Cold oil circulation and removal of water.
 Hot oil circulation and hot bolting.
 Raising the unit throughput to design capacity

 7.4 START UP DETAIL:

 7.4.1 TIGHTNESS TEST

The tightness test of the unit involves two steps.
1. Pressure test of the CDU/VDU for leaks identification / tightening
2. Vacuum Test of VDU section.

 PRESSURE TEST FOR CDU/VDU:

For leak testing / tightness test, ensure that all vents and drains are closed.
Pressure test to be done system wise. Each system to be pressurized
independently. Check for any leaks through the flanges / ‘instruments. The leak
identification is normally done by applying tape across the flanges followed by
soap bubble test. Spray / pour liquid soap solution on all the joints one by one and
check for any bubble formation. In case bubble is formed, there is air leakage.
Leaks are to be attended after identifying. Big leakage can also be identified by
rapid fall in pressure. The allowable system pressure drop is 0.05 Kg/cm2 per
hour.

All systems are to be leak tested from original point upto battery limit.
Following are the systems for pressure test
 Naphtha System [ From B/L to Crude Column]
 L.K System [From Crude Column to B/L]
 H.K System [From Crude Column to B/L]
 Diesel System [From Crude Column to B/L]

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 HAGO System [From Crude Column to B/L]

 RCO System [From Crude Column to F02 inlet C/Vs,]
 LVGO System [From Vacuum Column to B/L]
 HVGO System [From Vacuum Column to B/L]
 Slopwax System [From Vacuum Column to F02/VR ckt.]
 VR System [From Vacuum Column to B/L]
 Crude System [From B/L to V04]
 Crude System [V04 to F01/F51 Pass flow c/vs.]
 Crude Column & over head system
 Vacuum Column & over head system.
 Flash Drum V04

CAUTION: In each system pressure should not exceed its PSV set
pressure while doing pressure test.
 PRESSURE TEST FOR SGCU:

Following are the steps for leak test.

 All PSVs downstream isolation valves, PSV bypass valves are in closed condition
 Unit feeds from other units, lines blinded at B/L
 Unstbilised Naphtha from other units to 311/312- C05, line blinded toward CDU
isolation valve.
 321/322 XV008 downstream isolation valve blinded towards HP flare.
 Product line to ATU, LPG and naphtha to be blinded at B/L.
 321/322-PV009A isolated from flare side by blind.
 321/322 LV002, 321/322 LV 081 isolated towards WWU unit.
 321/322 LV004 isolated towards Diesel circuit.
 All SL, OWS and vents blinded.
 Keep open 321/322 XV 011, XV 003, XV 008 and XV10
 Close all pumps suction, discharge valves, XVs.
 Line up entire unit for leak test.
 Pressurize the unit with air by connecting air hose at pumps discharge steam
out points [321/322 P01, P06, P04, P03].
 Pressurize the system upto 3 kg/cm2g and carry on the leak test.
 If pressure drop is less than 0.05 kg/cm2g, the unit is leak proof
Once above systems are pressure tested, entire CDU/VDU/SGCU circuit to be lined
up and unit pressure hold test to be done at 1kg/cm2g. The allowable system
pressure drop is 0.05 Kg/cm2 per hour.

 VACUUM TEST FOR VDU:

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Vacuum test should be done from F02 pass flow control valves upto all vacuum
pumps suction valves, V44, PA/IR circuits. Carry out PRESSURE TEST on VDU
before vacuum test as per above method. [Refer Pressure test & Vacuum test
Procedure] Isolate CDU section & all the instruments except compound pressure
gauges etc. from vacuum unit before carrying out the Vacuum Test on VDU. Once
pressure test is complete, pressurize VDU with Nitrogen upto 1.5 kg/cm2g. De
pressurize the system to 0.1 kg/cm2g. Again pressurize and de pressurize VDU
section. While de pressurizing second time, check Oxygen content in VDU. If O2
content is below 1%, proceed for Vacuum pulling. [This is to ensure that the
Nitrogen from VDU can be routed to Flare header]. If O2 content is not below 1%,
again go for pressure & de pressurization till O2 content is below 1%. Ensure that
water & moisture is removed before going for Vacuum test. Then gradually pull
vacuum upto 50 mmHg in the Vacuum column and connected systems. Isolate the
ejector system & block the system. Hold under such condition for minimum 4
hours and check for the vacuum holding. If the vacuum does not break or if
the rate of vacuum break is less than 0.025 to 0.03 kg/cm2 (20 to 25 mm
of mercury column) per hour for at least two consecutive hours, vacuum
may be considered to be holding. Once the pressure test is carried out
critically, the vacuum testing is expected to be OK for vacuum column and it’s
connecting piping and equipment. Apply mask tape to flanges for vacuum test.
Once vacuum hold test is over, slowly break the vacuum by Nitrogen and keep
VDU at 0.5-kg/cm2g pressure.

Note: Ensure B/L LP flare header valve is closed while doing vacuum test.
 7.4.2 REMOVAL OF AIR FROM THE CDU/VDU UNIT BY
STEAM PURGING

The idea of steaming is to remove air from the system before admitting
hydrocarbon
The following precautions are to be taken before introducing the steam into the
unit
1) Ensure that cooling water to all-trim coolers and condensers is isolated &
open vent on cooling water return line. If TSV is provided on cooling
waterside, commission it.
2) The equipment drains are opened to drain condensate & high point vents
are kept open to remove air from individual equipment
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3) Feed and run down B/L valve blocked and bleeders opened.
4) Commission V25, V26, V27 Steam KODs
5) Charge LP, MP steam headers
6) Charge all utility headers.
7) All instrument tapings are isolated except some pressure gauges and
pressure transmitters (which will be required to observe the unit pressure
during the steam out period.)
8) Suction and discharge of all pumps and compressor closed condition.
Caution: Be aware of the following HAZRADS during Steam Purging of
the Unit:

 Collapse due to Vacuum:

Some vessels are not designed for vacuum. Hence these equipment should not be
isolated & “KEPT IN BLOCKED-OFF-POSITION WHILE STEAMING OPERATION IS
ON”, since the condensation of the trapped steam within will develop / generate
vacuum, resulting in collapse of the equipment. The vessel must be vented during
steaming and then immediately followed with inert or fuel gas purge at the
completion of the steam out. Thus the equipment / unit must always be kept
under positive pressure and monitored through PI / PGs on the equipment.

 Flange or Gasket Leaks:

Thermal expansion and stress during warm-up of equipment along with dirty
flange faces can cause small leaks at flanges. These must be corrected at this
time.

 Water Hammering:
Care must be taken to prevent "water hammering" while steam purging the unit.
Severe equipment damage can result from water hammering. "Water hammering"
is the phenomenon of rapid condensing of steam or vaporization of condensate,
causing two phase flow.

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iv) After starting steaming, do not attempt to stop as it can cause rusting of
column & vessel internals and create scale formation.
Note: During steaming out do not forget to steam out level gauges of all
columns and vessels.
Connect steam hoses / use permanent steaming out connections on the
equipment & gradually open steam to various circuits described below. Observe
the system pressure so that it does not cross 1.5 Kg/cm2g at any point.

 CRUDE OIL CIRCUIT

Steam connection at (2” LS 081) at B/L Crude inlet, S01A/B, S04 A/B, S 02, S03,
S05A/B, S25A/B Desalters outlets [ V02 and V33] 2” steam out points, S 08A/B, S
11A/B, S09, S10, S 12A/B/C/D (exchanger cc/pp steam hose connection) & LP
steam connection (4” LS 009) at V 04, Steam out point at P04A/B/C pump
discharge, S 13, S14, S15, S513, 514, S28, S515 (exchanger cc/ pp steam hose
connection), All heater pass flows C/V down stream (F 01 & F51) emergency MP
steam connection.

 CRUDE COLUMN & VESSELS

FV 035 (crude column stripping steam flow C/V), FV 037 (HAGO stripper
stripping steam flow C/V), LP Steam connection (3” LS 020) at Light Kero stripper
(C 09), FV 041 (Diesel stripper stripping steam flow C/V), LP Steam connection (3”
LS 019) at Heavy Kero stripper (C07), LP Steam connection (3” LS 017) at V 12, LP
Steam connection (3” LS 016) at V 13
Keep desalters filled with water and keep them bypassed from the crude circuit.
 VARIOUS OTHER CIRCUITS
CIRCULATING NAPHTHA: P 05 A/B pump discharge steam hose connection and
S01, S04 (exchanger cc/pp steam hose connection).
LIGHT KERO REFLUX:: P06 A/B pump discharge steam hose connection

HEAVY KERO CIRCULATING REFLUX: P 07 A/B pump discharge steam hose

connection and S 11 A/ B, S 02 (exchanger cc/pp steam hose connection).

CIRCULATING DIESEL: P 08 A/ B pump discharge steam hose connection and

S09, S10 (UNIT 321), S 08 A/B(exchanger cc/pp steam hose connection).

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Crude Complex Refinery Division Crude Distillers
Jamnagar

CIRCULATING HAGO: P 09 A /B pump discharge steam hose connection and S

18, S16 , S 14 , S 514 ,S 09(exchanger cc/pp steam hose connection).
LIGHT KERO PRODUCT: P 12 A/B/C pump discharge steam hose connection
and S 05 A/B , A 01 , S06 (exchanger cc/pp steam hose connection).

HEAVY KERO PRODUCT: P 13 A/B/C pump discharge steam hose connection

and A 03 / A13 (exchanger cc/pp steam hose connection).

DIESEL PRODUCT: P 14 A/B/C pump discharge steam hose connection and A04
(exchanger cc/pp steam hose connection).

HAGO PRODUCT: P 11 A/B pump discharge steam hose connection

CRUDE COLUMN BOTTOM: P 10 A/B pump discharge steam hose connection

 Since air is already removed from VDU circuit during Vacuum Test, Steaming
out will not be carried out again in VDU. Lines/Loops, equipments in VDU,
which are not taken in line during vacuum test, are to be steamed out.

 STEAMING MUST BE EFFECTIVE UP TO THE BATTERY LIMIT. FUEL GAS BACK UP CAN PROCEED
AFTER THE UNIT IS THOROUGHLY PURGED OUT FOR 6-8 HRS WHEN STEAM IS COMING OUT
FROM CRUDE / VACUUM COLUMN TOP, THE SYSTEM WOULD BE FREE OF OXYGEN. CHECK
SAMPLE FROM VENT FOR O2 CONTENT. THEN FUEL GAS OR NITROGEN BACK UP CAN BE
STARTED.

 7.4.3 REMOVAL OF AIR FROM THE SGC UNIT BY STEAM

PURGING

The idea of steaming is to remove air from the system

before admitting hydrocarbon
The following precautions are to be taken before introducing steam into the unit

i. Ensure cooing water to S01A/B, S02, S04, S08A/B, S12A/B, S13 is isolated,
vents and drains kept opened.

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Jamnagar

ii. The equipment vents and drains are to be opened to drain condensate &
high point vents are kept open to remove air from the unit.
iii. Remove steam line blinds at steam out points of V01, C05, C06, V07.
Connect steam hose at C02 steam out point.
iv. All pumps inlet and outlet isolation valves to be closed during steaming.
v. All instrument tapings are to be isolated except some pressure gauges and
pressure transmitters [which will be required to observe unit pressure
during steaming].
vi. Vessels are not designed for vacuum. Hence care must be taken during
steaming that the vessels are always at some positive pressure.
vii. Care must be taken to prevent water hammering while steam purging the
unit.
viii. After starting steaming, do not attempt to stop as it can cause rusting of
column & vessels internals and create scale formation.
ix. If pressure drops in the unit during steaming, take fuel gas into V01 and
maintain positive pressure.

 Start the steaming from the steam out points of V01, C05, C06, V07 and steam
hose at C02. Steaming must be effective upto the battery limits. Fuel gas or
nitrogen back up can be proceeded after the unit is thoroughly purged for 6-8
hrs & steam is sufficiently coming out of C05/C06. Drain the condensate from
all low point drains.

 7.4.4 BACKING IN FUEL GAS:

Stop all hot works in the unit. Before taking fuel gas into the unit,
commission LP, HP flare headers in line by opening isolation valves at
the battery limit. Take underground systems in line.

Care must be exercised during fuel gas backing by adjusting steam and fuel gas
addition rates, so that the system is always under positive pressure. Before
backing up fuel gas into the system make sure that all the vents & drains are
closed except top vent of crude & vacuum column. Take FG & pressurize the
system upto 0.3 to 0.5 kg/cm2g & then close the column top vents. System
pressure may gradua
lly drop due to steam condensation & hence if required fuel gas should again be
injected in to the system to maintain positive pressure.

The following are the fuel gas back up points in the unit:
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A. Crude column overhead receiver (V12) through control valve PV 005 A

B. Recontact drum (V-13) through control valve PV-010A
C. Vacuum column over head through 2” fuel gas connection upstream of PIC-
062.
D. Ejector blow-case (V-19)
Drain condensate from CDU/VDU sections as per the following procedure. Do not
leave any drains unattended while draining condensate.
Keep the system floating with LP flare system by maintaining positive
pressures in crude & vacuum columns @ 0.3 & 0.5 kg/cm2g respectively.

 Once steaming is over, stop steam slowly into the unit. Slowly back up fuel gas
or nitrogen into the V01. Slowly close all vent points and blind it. Pressurize the
unit by fuel gas or nitrogen at 1-1.5 kg/cm2g. Remove blinds from feed line,
product lines, flare lines etc. Monitor pressure through PI, PG etc. on the
equipment

IF FG BACKING IS NOT DONE, THEN NITROGEN BACK UP TO BE DONE AS

EXPLAINED BELOW.

 7.4.5 BACKING IN NITROGEN

Close FG isolation valve at B/L. Deblind Nitrogen line FG header at BMS skids of
F01/F51/F02 and connect nitrogen to FG header at B/L. Charge nitrogen into FG
header. Control nitrogen into FG header so that FG header pressure should not go
beyond 6kg / cm2.

Stop steaming slowly at all points except C05 and C16 and drain the water. Slowly
close the steam into C05 and C16 and start backing up Nitrogen.

The following are the nitrogen back up points via FG header in the unit:

a. Crude column overhead receiver (V12) through control valve PV 005 A

b. Recontact drum (V-13) through control valve PV-010A
c.. Vacuum column over head through 2” fuel gas connection upstream of PIC-
062. [FOD(210)]

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d . Ejector blow-case (V-19)

e. Existing nitrogen connections at V02 and V03 outlet lines.

 7.4.6 DRAINING WATER FROM THE SYSTEM

Once the system is pressurized with fuel gas /Nitrogen, water should be drained
from low point drains. Close all the vents, bleeders and drains afterwards.

FOLLOWING ARE WATER DRAINING POINTS FOR DIFFERENT SECTION

 CRUDE COLUMN OVERHEAD SECTION:

P -15 A/B suction, P -16 A/B suction, compressor C - 01 suction isolation valve up
stream drain, Compressor C - 01 discharge isolation valve down stream drain, P -
17 A/B suction, LV 14, FV 36, Unstabilised Net ovhd. liquid from Heavy naphtha
unionfining unit line drain at B/L.

 NAPHTHA SECTION

P 05 A/ B /C suction, S -04, S –01, FV006, FV007, TV 752 and TV753

 LIGHT KERO PRODUCT & I R SYSTEM

P 06 A/ B suction, FV 24 up to batter limit.

 STRIPPER SECTION

P-12 A/B/C suction drains, FV100, S -05, A 01, S -06, FV 09, FV 10, FV 11, product
lines at B/L bleeders and S -18

 HEAVY KERO CIRCULATING REFLUX LINES

P07 A/B suction, FV 26 A/B, S -11, S -02, TV 6 A drains. TV 6 B drains, FV 25

drains.

 HEAVY KERO PRODUCT LINE

P-13 A/B/C suction, S -16, A 03, A 13, FV 45, FV 46, FV 44, Product lines at B/L
bleeders.

 DIESEL SECTION CIRCULATING REFLUX LINE

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1. P-08 A/B suction, FV 27, FV 14 A/B, FV 13, FV 19, S -9 (U321 section), S -10
(U321 section), S -3 (U321 section).
2. S -4 (U321 section) , LV 004 , FV006 , S03 , S08 A , S08 B , TV18 A ,
TV18 B

 PRODUCT SECTION
LV 09, P 14A/B/C, FV 126, A04, FV 42A, FV 42 B, Product lines at B/L bleeders.

 HAGO SECTION

P 09 A/B suction, FV 28, Filter Drains, S 16, S 18, FV 38, FV 39, FV40, S 14 A /B,
S 514 A/B, S 09, TV 22A, TV 22B

 PRODUCT

P 11 A/B suction, FV 102, FV112, FV 455, Product lines at B/L bleeders

 REDUCED CRUDE SECTION

P10 A/B suction, FV 151 to 160, Bleeders at startup circulation line (F01/F51)

 CRUDE INLET SECTION

S 01 A/B, S 04 A/B, S02, S 03, S25, S 05 A/B, S 08 A/B, PDV 100, PDV 101, PDV
808, PDV 809, FV 801A/B, S 09, S 10, S 11 A/ B, S 12 A/B/C/D, FV 21, FV22, S 13,
S 513, S 14, S 514, S 28, S 15, S 515, F 01 Pass flow C/V I/L, F 51 Pass flow C/V
I/L

 In Sat Gas concentration Unit water to be drain from all the control valves
bleeder which comes in bottom loop and also from drain point all heat-
exchangers.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

CHAPTER # 8

NORMAL SHUTDOWN

CHAPTER –8

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Crude Complex Refinery Division Crude Distillers
Jamnagar

8.0 NORMAL SHUTDOWN

8.1 GENERAL
While shutting down the unit, care should be taken to avoid air entry into the
system until all hydrocarbon vapors have been removed. All related upstream /
downstream units including utilities which are likely to be affected, due to
CDU/VDU/SGCU shut down, should be informed well in advance about the
shutdown plan. It is to be ensured that one of the crude tanks has sufficient ullage
to receive the slops / off-spec material from the unit. Closed blow-down system
[i.e. heavy slop drain tank (311/312 V-22), light slop drain tank (321/322 V08) in
CDU/VDU/SGCU are pumped out and kept ready) should be in a position to receive
draining / flushing from equipment. Flushing oil supply from RTF should be lined
up to CDU/VDU. All shutdown checklists should be complied with.

 PRE-REQUISITES
 All safety equipment, which could be required during shutdown, is on-site and
operable.

 Notify the Heavy naphtha Unionfining Unit operator that Heavy naptha will be
reduced and stopped.

 Notify the VGO Unionfining Unit operator that VGO will be reduced and
stopped.

 Notify the Diesel Unionfining Unit operator that Diesel will be reduced and
stopped

 Notify RTF that Diesel, LK and HK will be reduced and stopped, hence blending
system may be affected.

 Notify the downstream Merox units that the light kerosene and LPG will be
reduced and stopped.

 Notify the Delayed Coker unit that the hot vacuum residue ex CDU/VDU will be
reduced and stopped, hence make arrangement for feeding delayed COKER
from VR storage tanks.

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 Notify the CPP Steam and Power Consumption would change.

 Notify the RTF about the Crude / Vacuum Units shutdown. Injections from the
Crude Tanks will have to be adjusted as Crude charge is being reduced. Also
the off-spec material from CDU/VDU would be diverted to crude tank. RTF
should keep watch on crude tank temp.

 Notify the Sulfur Unit that the FG & Sour Water from CDU/VDU would be
reduced & stopped.

 CDU/VDU/ SGCU SHUT DOWN MILESTONES:

The major steps involved in CDU/VDU/SGCU are as follows:

 Gradually reduce CDU/VDU/SGCU feed rate to about 50% of normal capacity.

Cut-off burners in furnaces F01, F51 and F02 as required and noncondensable
from V18 to be diverted to flare.

 The Desalter will be taken out of service.

 Stop chemical injections.

 Cut-off fires in F-02 at transfer line temperature of 350 oC & shut down VDU.

 Stop Net gas compressor.

 Cut-off fires in F-01/F-51 at transfer line temperature of 200 oC & shut down
CDU

 Cut off gradually HP or MP steam in 321/322 Stripper reboiler.

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Crude Complex Refinery Division Crude Distillers
Jamnagar

CHAPTER # 9

EMERGENCY SHUT-DOWN

CHAPTER -9

9.0 EMERGENCY SHUTDOWN

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Crude Complex Refinery Division Crude Distillers
Jamnagar

9.1 GENERAL INSTRUCTION

Emergencies are caused mostly by interruption of power / utility or by equipment
failure and some times by fire.

NATURE OF EMERGENCY CAN VARY DEPENDING UPON TYPICAL SITUATION AT THE TIME OF
OCCURRENCE. THEREFORE, NO WRITTEN PROCEDURE CAN COVER ALL DETAILS OR PROBLEMS
WHICH MIGHT ARISE IN EMERGENCY. GOOD JUDGEMENT MUST BE EXERCISED ON SPECIFIC CASES
OF KNOWN EMERGENCIES.

Effects & stepwise actions have been listed briefly for some emergency scenarios
to understand & immediately carry out critical operations in order to ensure safety
of the plant and personnel. Communication is also equally important factor during
emergencies as plants are interconnected and co-ordination is required for
effecting changes in flow streams, product routings etc without affecting the other
units.

9.2 POWER FAILURE:

The power failures may be of three type – power dip, total power failure at the
unit and total power failure across the complex. The effects felt & actions required
during each of the three scenarios are dealt with in the following sections :

 POWER DIP
 EFFECTS
 All LT motors will trip. Also Desalter transformers will trip.
 FD fan of 311/312 F-02 would fail & hence vacuum furnace would shut down
on ESD-10.
 If lube oil motor driven pump was in operation for Net Gas Compressor, the
compressor would trip.
 All fin fan coolers will trip. So there will be pressure rise in the column and
temperature rise in run down stream.
 Desalting water pumps 311/312 P-02A/B/C/D will trip. As a result there will be
no Crude Desalting.

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 LK internal reflux pumps 311/312 P-06A/B will fail resulting in the increase in
the draw off tray level, LIC-26 which may lead to overflow of the LK draw off
tray.
 Heavy Kero product pump 311/312 P-13A/B/C will fail resulting in rise in H.K
stripper ( C-07 ) level LIC-008. This will lead to closure of LV-008, which will
cause increase in the draw off tray level LIC-027.
 HAGO product pumps 311/312 P-11A/B will fail resulting in rise in HAGO
stripper, C-06 level LIC-007. This will lead to closure of LV-007, which will
cause increase in the draw off tray level LIC-029. This will lead to increase in
the IR flow, FIC-028 of HAGO which will cause drop in tray temperatures are
going to come down. Also Crude column bottom level, LI-006 will increase. This
will lead to increase in feed, FIC-151 to FIC-160, to vacuum heater and may
also effect the vacuum PIC-062 of vacuum column.
 Crude column overhead receiver V-12 water pump 311/312 P-15 A/B will fail.
This will lead to Increase in the boot water level, LIC- 012. ( Caution: This may
lead to carry over of water along with naphtha )
 Slop wax pump 311/312 P-19A/B will fail. This will lead to increase in the Slop
wax quench drum level, LIC-201. If P-19 A/B is not getting started up to 3-4
minuets, drum will become full. This will lead to overflow slop wax from double
decker tray to the bottom. This will cause decrease in the Flash zone
temperature TI-128 and vacuum column bottom level, LI-020 & LI-021 will
tend to rise. Also flow of slop wax in shell side of 311/312 S-28 will be
stagnant, which will cause pressurisation of S-28 at shell side.
 Vacuum column overhead receiver oil pump 311/312 P-22 A/B will fail. This will
lead to increase in the oil level, LI-019 in the hot well.
 311/312 P-23A/B vacuum column overhead receiver water pump will fail
resulting in increase in water level, LIC-018 in the tank. If receiver gets
completely filled up it may lead to drop in vacuum, PIC-062 of the column.
 H.P Flare K.O.D pump if running will fail.
 L.P Flare K.O.D pump P-28B if running will fail.
 Chemical injection pumps for de-emulsifier, antifoulant, corrosion inhibitor,
aqueous ammonia will fail.

 ACTIONS
 First isolate main gas & Fuel oil burners in F-02. Start FD fan then start firing
F-02 as early as possible (Follow heater start up SOP).
 Start the fin fans as early as possible.
 Put Desalter in operation as early as possible (Follow Desalter Start Up SOP).
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 Start Reflux/ LK product/ HK product/ HAGO product / Slop Wax pumps/

Ejector receiver water pumps as soon as possible.
 Vacuum column overhead gases from Ejector vapour K.O.D, V-18 would get
diverted to LP Flare through XV-18 and XV-16 would close ESD13). Isolate the
sour gas to F-01/F-51 burners.
 Start 311/312 P-23A/B immediately otherwise it may upset vacuum PIC-062 in
the column.
 Increase the draw off rate of Diesel by increasing the set point of FIC-042, to
bring down the draw off tray level, LI-029 and to maintain column temperature
profile.
 Increase the draw off rate of LK by increasing the set point of FIC-011 to
maintain the draw off tray level, LIC-027.
 Increase draw off rate of Slop wax by increasing the set point of FIC-076, to
bring down the level of Slop wax drum V-44, LIC-201.
 Start crude column overhead receiver boot water pump 311/312 P-15A/B to
bring down the water level, LI-12.
 10. Resume chemical injections to Crude Column as early as possible.

Note: Before starting any of the pumps, first close the discharge valve & the start
all the pumps as per SOP for the PUMP.

 POWER FAILURE IN CDU/VDU/SGCU:

 EFFECTS
 All motor driven pumps, net gas compressor C-01 (if running ), fan motors of
all air coolers, desalter transformer power supply will be cut off.
 I.D & F.D fans of heaters F-01, F-051 & F-02 will trip. All fired heaters, i. e.
311/312 F-01, F-51 and F-02 will trip under logic control (ESD5,8,10). Stack
dampers will open.
 The F-01/F-51 coil flow would be below minimum flow requirement due to
flashed crude pump failure Sour off gases from Ejector gas K.O.D will get
diverted to LP Flare on Logic control. (ESD-13 ) i.e. XV-016 would close & XV-
018 would open.
 Disulfide oil separator vent gas (from Unit-331) will get diverted to LP Flare.
XV-91 will be closed on ESD-13.
 Preheat train exchangers and F-01/ F-051 crude will depressurize in Crude
column (C-05), so column (C-05) bottom level, LI-006 & LI-060 may go up if P-

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10B is not running. Thus the RCO flow through F-02 heater coils would not be
there.
 In F-02 turbulising steam will push transfer line hydrocarbon hold up to
vacuum column C-16 which may lead to increase in Vacuum column bottom
level, LI-020/LI-021 if P-18B is not running (steam should be stopped if the
level is not in the readable range).
 Stripping steam to the Crude column, Diesel stripper, HAGO stripper, vacuum
column, will be cut-off on high level.(ESD-12 )
 Crude column reflux flow would not be available due to non-availability of
311/312 - P16. Also all fans on air coolers would stop, so column pressure will
start rise ,and PV-005B will open to flare to maintain the column pressure. Very
high flaring will start.
 As 311/312 P-15 & p-16 failure C-05 overhead V-12 hydrocarbon / water level,
LIC-013 and LIC-012 respectively will rise.
 Vapour liquid traffic in vacuum column would change.
 Due to 311/312 P-19A/B failure level of slop wax quench drum will increases. If
p-19A/B will not getting started for 3-4 minutes level of slop wax drum will be
l00%. This will lead to overflow slop wax from Double Decker tray to bottom of
vacuum column. This will cause in decrease flash zone temperature and
increase vacuum column bottom level. Also flow of slop wax in shell side of S-
28 will stagnant, which will cause pressurisation of S-28 at shell side.
 MP steam flow to exchanger (S-03) in crude preheat train will continue which
may overheat crude and Desalters pressure may rise.
 Vacuum column C-16 ejector will remain on for sometime, which will increase
water level LIC-018 in V-17.
 Motor driven pumps on LP/HP Flare K.O.D would not be available and liquid
level may build up in these.
 All pumps would trip. (All pumps in the unit 321/322 are motors driven.)
 Fin fan motors of 321/322 A-01 and A-02 would trip.
 Lean oil flow to Sponge Absorber (C-03) stops.
 No cooling effect across primary absorber intercooler.
 No reflux for the Stabiliser (C-06)
 Feed to Stripper (C-05) stops
 Lean oil flow to primary absorber (C-02) stops.
 Rich oil from primary absorber (C-02) to HP receiver (V-01) stops
 Stripper bottom temperature (TI-012) will increase because of HP or MP steam
supply through FIC-010 to stripper reboiler (S-07), which may result in
increase in pressure of the column.

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 Momentarily valve PV-004 in the Lean gas from 321/322 to ATU will open fully
and there can be liquid carry over to ATU.

 ACTIONS
 Close Crude column stripping steam control valve, FV-035. Also close the block
valves in the stripping steam line to the crude column.
 Close the stripping steam valves FV-37 and FV-41 to the strippers, C-06 and C-
08 respectively. Also close the block valves in the stripping steam lines.
 Close Vacuum column stripping steam control valve, FV–80. Also close the
isolation valves in the stripping steam line to Vacuum column.
 Cut off steam to crude-MP steam exchanger (S-03) by closing supply line
isolation valve and condensate return line control valve FV–008. Keep low point
drain on condensate side open.
 Close individual burner isolation valves on FG , FO and flush the F.O burners
with steam for F-01/F-51/F-02.
 Take crude column pressure controller PIC-005 on manual mode if required .
Watch the column pressure if it is still in increasing trend open control valve
bypass and control the pressure (Can keep higher column pressure i.e 1.0 to
1.2 Kg/cm2).
 Start 311/312 P-16 & put reflux to crude column (Emergency power supply to
crude column reflux pump is given).
 Before routing 311/312 P-10B and 311/312 P-18B discharge to A-07 ensure
that A-07 O/L is routed to the heavy slop tank.
 Take flushing oil from flushing oil header for seal flushing of plan 32 pumps as
311/312 P 20 A/B (HVGO pumps) will not be available.
 Start crude column bottom turbine driven pump P-10B and route hydrocarbons
to Heavy slops header through 311/312 A-07 cooler by opening block valve in
the line going to gas oil cooler till the crude column bottom level, LI-006/LI-060
in readable range and stop the flow to slops. Then start opening of start - up
circulation line block valve for F-01/F-51 and go for bottom circulation.
(Caution : Take care of rundown temperatures through A-07)
 Start Vacuum column bottom turbine driven pump 311/312 P-18B and route
hydrocarbons to Heavy slops header through A-07 cooler by closing block valve
of VR to DCU at B/L and opening the block valve in the line going to A-07 till
vacuum column bottom level LI-20, 21 in readable range, and stop the flow to
slops. Then starts opening of start up line block valve and go for bottom
circulation. (Caution: Take care of rundown temperatures through A-07)

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Jamnagar

 If 311/312 P-10B and 311/312 P-18B are not available due to some
maintenance problem, start emergency steam to first F-02 & then F-01/F-51, to
push heater coil holdup material to Crude and vacuum column respectively
(Ensure crude and Vacuum bottom levels are low i.e in readable range).
 Request RTF for lining out flushing oil tank, start ram pump for flushing HAGO,
RCO, HVGO, LVGO Slop wax and vacuum column bottom circuits. Route it to
slop. (While flushing vacuum bottom close FV-72 bottom quench going back to
column once quench circuit is through). This activity to be done for longer time
power failure.
 Close 311/312 FV-40 and FV-39 in HAGO return line to Light Kero./ Heavy
Kero. Stripper reboilers, S-18 and S-16 respectively and open bypass valve FV-
38.
 Cut off vacuum heater (F-02) turbulizing steam after 5-10 minutes (If vacuum
column bottom level is not in readable range close the steam immediately) by
closing FV-161 to FV-170 and FV-461 to FV-470 and also Ejector steam by
closing control valve PV–061 and ESD valve (XV-094).
 If Fuel oil pump is running on Turbine open the bypass slightly outside the
battery limit. Inform CPP about this operation. Close the battery limit valve on
supply and return header and flush the supply and return header till battery
limit(This activity to be done only for longer shut down)
 Isolate all product line control valves.
 Isolate all product lines by closing isolation valve at battery limit. Also close all
pumps discharge valves.(Note: Do not close discharge valves of 311/312 P-
22A/B, HP/LP Flare K.O.D and heavy/light slop C.B.D pumps.)
 Bring down Vacuum column overhead receiver V-17 water boot level LIC-18
and oil level LI-019 (if it is high) by routing 311/312 P-22A/B and P-23 A/B
suction to slop oil tank.
 Close 321/322 FV-13 and FV-19 in Diesel circulation line for Stabilizer bottom
reboiler 321/322 S-09 and S-10 respectively. Open 321/322 FV-14 which will
bypass both reboilers for diesel circulation.
 Effluent water from all the desalters (V-02, V-03, V-33 and V-34) to be isolated.
(311/312 LV-001, LV-002, LV- 804A, LV-805A.)
 Try to maintain level 311/312 LI-097, LI-098 & LI-095 in HP, MP and LP
condensate flash drums (V-25, V-26 and V-27).
 Back up fuel gas in vacuum column through 311/312 PCV-062 till pressure is
0.5-kg/ cm2. Maintain the column at this pressure.
 Following actions are to be taken in Sat Gas Concentration Unit (321 & 322 )

i. 321/322 Stabiliser (C-06)

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Crude Complex Refinery Division Crude Distillers
Jamnagar

1. Close XV-05 - Circulating Diesel to S-09/S-10

2. Close FV-13 - Diesel to S-10
3. Close FV-19 - Diesel to S-09
4. Open FV-14 - Circulating diesel bypass to Unit-311.
5. Close FV-15 - LPG to Units 331 (or 415).
6. Close FV-12 - Stabilised Naphtha to Naphtha Union fining unit.
7. Close FV-11 - Naphtha from Stabiliser (C-06) to Primary absorber (C-
02).

ii. Sponge Absorber (C-03)

1. Close FV-06 -Lean oil from Unit 311/312 to 321/322- A-01 S-

04P04 A/B  C-03.
2. Close LV-04 - Sponge absorber Level control valve on rich oil to U-
311/312.

iii. Lean Gas Knock Out Drum (V04)

1. Close PV-04 on lean gas to ATU and keep watch on System

Pressure

iv. Stripper (C05)

1. Close XV-04 - On HP or MP Steam to stripper reboiler S-07

2. Close LV-06 - On feed line from C-05 to C-06
3. Close FV-10 – HP or MP condensate line ex stripper reboiler S-
07 to HP or MP Condensate drum on U-311/312.

v. High Pressure Receiver (V-01)

1. Close 311/312 -FV-48 on unstabilised naphtha from (311-P17 A/B

discharge) to HP receiver in 321/322 unit.
2. Close XV-101- off gases from Platforming unit to HP receiver in
321/322 unit.
3. Close XV-102- Unstabilised naphtha from Unionfining units

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Jamnagar

4. Close FV-01 - Unstabilised naphtha from HP receiver (V-01) to

Stripper (C-05)
5. Close LV-02, LV-02A and XV03 - Boot Water outlet of HP receiver
(V-01)
6. Close XV-01 and XV02 - Stripper feed pumps suction line

vi. Primary Absorber

1. Close XV-11 - HP receiver gas from V-01 to C-02.

2. Close LV-03 - Rich Naphtha from C-02 to V-01

 When power is restored and feed is available to re-start the Sat Gas
Concentration unit gradually and establish normal operation.

 TOTAL POWER FAILURE IN CDU/VDUSGCU:

 The similar effect as discussed above would be felt plus the Crude from RTF
would not be available.
 In this case Refer cooling water failure, instrument air failure, Steam failure
along with Power failure in CDU/VDU/SGCU to find out the effects and actions
to be taken.

9.3 COOLING WATER FAILURE:

 EFFECTS

 All pumps, which are having cooling water for bearing cooling, will get hot.
 Cooling water flow to Light Kero. Product Trim Cooler (S-06 ) , LVGO
circulation trim cooler (S-20 ), Ejector inter-stage condensers (S-21 A/B, S-22,
S-23 ) will be stop.
 Because of loss of cooling water to S –20 the LVGO Reflux temperature TI-125
will increase which will further affect vacuum (PIC-062) in VDU.
 Vacuum will start breaking because of loss of cooling water to Ejector inter-
stage coolers.
 Condensers and coolers may start hammering.
 Net gas compressor lube oil trim cooler will starve for water. Net Gas
Compressor may trip
 321/322 P-05 A/B and P-06 A/B/C bearings will get heated up.
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 321/322 S-11 - LPG to Unit-331 (or U-415/417) rundown temperature would

rise.
 321/322 S-01 - Unstabilised Naphtha to HP receiver cooling does not take
place. As a result HP receiver (V-01) pressure will go up, which will increase
system pressure and PIC-004 will open more to maintain the same due to
which C 3 and C 4 may escape in Lean gas to ATU. This may lead to foaming
tendency in ATU & affect its performance.
 321/322 S-02 - Absorption of C 3 and C 4 will be poor due to high temperature in
Primary absorber, as there will be no inter cooling.
 321/322 S-04 - Absorption will be affected in Sponge absorber due to high
temperature, TI-09, of lean oil.
 321/322 S-08 - Lean oil to Primary absorber hot and hence pressure may
increase in C02
 321/322 S-13 – LPG to V-07 not getting condensed completely, so this will lead
to increase the pressure of V-07, in other words it will decreases pressure
difference between the stabiliser (C-06) and the stabiliser overhead receiver (V-
07 ). This will cause effect in to the rate of transfer of LPG between 321/322 C-
06 & C-07.
 321/322 S-12 -If the cooler is in line the stabilised naphtha to tankage
temperature would increase & there could be hazardous situation in HNUU feed
storage tanks.

 ACTIONS :
 In the event of this emergency the hot pumps cannot be kept running as there
is a chance of bearings getting ceased. Unit (crude and vacuum section)will
have to be shutdown otherwise a smooth shutdown also may not be possible,
as the pumps will not be available. Unit may have to be kept in bottled up
condition with all pumps stopped , cutting off furnace fires, opening stack
dampers, isolating stripping steam to Crude / Vacuum Columns & Diesel/HAGO
Side strippers.
 Open cooling water outlet side vent on all coolers/condensers.
 If alternate source of cooling water is made available for pumps then following
action can be taken in vacuum section.
 Start reducing the 311/312 F-02 coil outlet temperature and cut off firing
finally.
 Stripping steam to 311/312 C-16 (FV-80) would close due to actuation of ESD –
12. Close the main isolation valve on FV-80.(Caution: If high pressure ESD-12
is not actuated, close FV–80 and it’s isolation valve.)
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 Close Turbulizing steam main isolation valve and individual control valves. ( FV-
161 to 170 & FV-461 to FV-470 )
 Route HVGO, LVGO product to Slops. Reduce drawoff tray level.
 Cut off ejector steam control valve (PIC-061) and close isolation valves.(If high
pressure ESD is not actuated).
 Keep bottoms quench on for Vacuum column (C-16), route Vacuum residue to
slops.
 If cooling water failure is prolonged , shut down the crude unit by following
normal shutdown procedure.
 Stop Net gas compressor, C-01 (if running). Close its discharge valves. Stop all
pumps and close discharge valves.
 Cut off HP or MP steam to Stripper reboiler (S-07)
 Close XV-05 on Diesel to 321/322 S-09, S-10 and FV-11 on lean oil to C-03.
 By pass Stabiliser bottom reboiler (321/322 S-09 and S-10) by opening FV-014
and closing FV-019 and FV-013 for 321/322 S-09 and S-10 respectively.
 Close B/L valve for Stabilised Naphtha
 Close B/L valve for LPG to Unit-331 and 415.
 Vent vessels to HP flare if pressure increases.

 When cooling water is restored, startup the unit in accordance with

the applicable steps in the “Normal Startup Procedure".

9.4 TOTAL STEAM FAILURE:

 EFFECTS
 Steam to Ejector will get cut off. This will lead to breaking of vacuum (PI-62)
and Vacuum column. 311/312 C-16 may get pressurized
 In Fired heaters atomizing steam will come down slowly and it will cut off FO
firing on low differential pressure, PDT-096A/B
 Turbulizing steam (MP steam) through FIC-161 to 170 and FIC-461 to FIC-
470 will get cut off in 311/312 F-02. This may result in Vacuum heater passes
getting coked up.
 Net gas compressor lube oil circulation turbine driven pump 311/312 P-30 B
speed will come down and turbine will be automatically changed over to motor
driven pump 311/312 P-30A.
 MP steam to 311/312 S-03 (crude pre-heater) would not be available. As a
result Desalter inlet temperature , TI-013 will come down. Desalter
performance may get affected.
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Crude Complex Refinery Division Crude Distillers
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 Stripping steam flow in both Strippers, 311/312 C-06 and 311/312 C-08
through FIC-37 and FIC-41 and both the columns 311/312 C-05 and 311/312
C-16 through FIC-35 and FIC-80 will stop.
 Crude column pressure PIC-005 will come down because of lack of stripping
steam in 311/312 C-05.
 Crude heater pass outlet temperature, TI-149, 137 would be reduced because
of FO firing cut off in 311/312 F-01/F-51.
 Fuel gas injection valve PV-005A to 311/312 V-12 will open or compressor
speed will come down (Depending on the position of selector switch PHS-005)
to maintain Crude column overhead pressure.
 Crude column overhead receiver V-17 boot water level LI-12 will come down
and LCV –12 will get closed.
 Diesel / HAGO flash point will go off and product will be lighter.
 If 311/312 P-10B is running then because of MP Steam failure, the turbine
would stop and F-02 would trip.
 If 311/312 P-18B is running then because of MP Steam failure, the turbine
would stop and Vacuum bottom level will rise.
 In case of steam failure, HP or MP steam, one of them which will be use as a
heating media for 321/322 S-07, will not be available for the Saturate Gas
Concentration unit. As a result stripper bottom temperature will come down
and hence stripping would get affected in Stripper Column due to non
availability of steam supply to S-07 Reboiler.

 ACTIONS:
 Cutoff firing in 311/312 F-02 and isolate individual burners block valves of
F.G.& F.O burners.
 Route VGO and VR to slops.
 Reduce the firing in 311/312 F-01/F-051.
 Reduce the feed to Crude unit to 50-60% step wise by bringing down the set
point of HIC-38 & 39 keeping watch on Desalter pressure, Heater Coil Outlet
Temperatures and fuel gas pressure and draw off tray levels and temperatures.
 Route all products to slops. Monitor and maintain the levels in the side
strippers. Also monitor rundown temperatures for off spec. Products.
 Isolate off gases to F-01/F-051 by closing XV-16 and divert to flare by opening
XV-18.
 Isolate MP steam injection to LP steam, which is use as a stripping steam for
crude column, vacuum column, diesel stripper and HAGO stripper, by closing
either XV-401 or TV-765 and it’s isolation valves.
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 Isolate stripping steam c/v ‘s and isolation valves of Crude column, Vacuum
column, HAGO, Diesel strippers.
 Isolate M.P. steam main block valve XV- 094 to ejector and individual ejector
isolation valves.
 If P-10 B and P-18 B are running then due to low pressure of M.P. steam
turbine speed will reduce and ultimately the Turbine will stop. Start P-10 A and
P-18 A . Isolate P-10 B & P-18B pumps discharge valves. Isolate turbine steam
valves.
 As the firing is reduced in F-01/F-051 the coil outlet temperatures will drop as a
result crude column bottom temperature will come down. Adjust the firing in
the heaters to maintain the coil outlet temperatures at around 250-260 oC.
 Inform RTF to line out the slop header from the unit to crude tank. This will
ensure circulation of crude from Vacuum column bottom back to crude tank
through 311/312 gas oil cooler A-07.
 Isolate M.P. steam through FIC-8 for Crude-M.P. steam exchanger (311/312 S-
03) in crude unit.
 Isolate turbulising steam in F-02 by closing FV-161 to 170, FV-461 to 470 and
their isolation valves.
 Start flushing oil from tank farm and flush HVGO, HAGO and Slop wax circuits.
 Stop all chemical injections.
 If APH inlet temperature falls below 300 oC it should be isolated to avoid
corrosion and stack damper should be opened.
 In Sat Gas Concentration Unit (311/312) take following actions.

1) Stabiliser
1. Close FV-13 - Diesel flow to Stabiliser Reboiler S10.
2. Close FV-19 - Diesel flow to the Stabiliser reboiler S9.
3. shutt off XV-05
4. Close FV-06 - Lean Oil flow to Sponge absorber
2) High Pressure Receiver (V-01)
1. Close FV-01 - Unstabilised Naphtha from HP receiver (V-01) to
Stripper (C-05).
3) Primary Absorber (C02)
1. Close FV-11 - Lean oil (stabilised naphtha) from stabiliser to
Primary absorber.
2. Open FV-16 more and put stabiliser (C-06) on total reflux.
3. Close FV-15 - LPG to Units 331 (or 415 in case U-331 is under
Turn around).
 If steam failure is for a longer time then go for normal shutdown of
the unit.
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Jamnagar

9.5 INSTRUMENT AIR FAILURE

In case of instrument air failure all control valves and XV’s would go to their FAIL
SAFE positions as specified below :
( It may be either fully open , fully closed or fail in position depending upon their
services.)

 All control valves on product rundown lines are fail close.

 Control valves on all exchangers inlet, outlet streams are fail open and
control valves streams bypassing the exchanger are fail close.
 Pump minimum circulation’s FCV’s are FAIL OPEN.
 All heater passes are FAIL OPEN.
 All heating media control valves are FAIL CLOSE. (e.g. FG / FO in fired
heaters, H.P. and M.P. steam for S-07 in SGCU and S-03 in CDU. )
 MP Steam injection to stripping steam control valve TV-765 is FAIL
CLOSE
 Stripping steam control valves (FV-35/FV-80) to column C-05/C-16 and
FV-37 / FV-41 to side strippers C-06/C-08 are FAIL CLOSE.
 All fuel gas injection valves & flare valves for pressure control of vessels
/ columns are air FAIL to CLOSE
 Turbulising steam for F–02 is FAIL OPEN.
 Ejector steam control valve PIC-61 will open fully.
 All pump suction XV’s (remote operated valve ) will remain in locked in
position.
 Stripper feed control valves LV-7/LV-8/LV-9/LV-10 are fail closed

 EFFECTS
 Crude column (C-05) pressure will rise as flare valve PV-005B would close. Spill
back control valve PV –005C will open.
 Vacuum in vacuum column (C-16) would improve. More HP steam will go to
Ejectors as PCV–061 will open fully and PCV-062 is fail closed.
 Crude heaters (F-01 and F-51) pass flow control valves would be full open and
heater will trip due to low F.O. and F.G. pressure.
 C-05 bottom level will increase very fast as there will be less vaporization and
more feed to the column. Stripping steam control valve FV-035 would get
close.
 Net gas compressor spill back control valve PV-005 C will open fully.
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 There will not be any change in Desalter level (V-02, V-03, V-33 & V-34) as
desalters level control valves (LV–001, LV-002, LV-804A & LV-805A) and
desalting water flow control valves FV-16 and FV-808 are fail to close. Mixing
valves (PDV-100, 101, 808 and 809) on Desalters are fail open.
 FV-21 and FV–22 on crude inlet to flash drum are fail closed & hence upstream
PSV will pop in V 04. Due to more crude charge Flash drum (V-04) level will
increase.
 In VDU, Vacuum heater (F-02) will trip due to low F.O. and F.G. pressure and
flow to Vacuum heater passes will increase as pass flow control valves are fail
open. Also turbulising steam control valves FIC-161 to FIC-170 and FIC-461 to
FIC-470 will open fully.
 Vacuum column bottom level will increase suddenly because of less
vaporization and more incoming RCO feed. Stripping steam control valve FV-
080 would be closed.
 Vacuum column overhead receiver (V–17) level will increase as LV–018 is fail
close and ejector steam (PV-061) is on.
 HP, MP, and LP condensate drum levels (LCV–90, LV-92 and LV- 95
respectively) may go up as these control valves are fail to close.
 LP condensate drum (V–027) pressure may go up, as PV–390B is fail open
which will pressurize the drum with Nitrogen.
 HAGO to LK/HK stripper reboilers through FV–040 and FV–039 will get closed
and FV-038 on reboiler bypass line will open fully.
 For Diesel and HAGO stripper (C-008 and C-006) stripping steam (FV-41 & FV-
37 respectively) will get cut off.
 321/322 PIC-004 will close, pressure will increase initially and subsequently it
will decrease (lack of heating media)
 Flow of unstabilised naphtha from 311/312 unit will stop in HP receiver (V-01)
 Both Stripper and Stabiliser bottoms LCV's (LV-006 and LV-007 cascaded with
FCV-012) will close.
 HP or MP steam for Stripper reboiler, S-07, will close (FCV-010 and XV-004).
 321/322 C-03 and C-04 level control valves LCV-003 and LCV-004 will close.
 321/’322 S-09 and S-10 Circulating diesel FCV's, FCV-013 and FCV-019, and
XV-005 will close and bypass valve, FCV-014, will open.
 LPG product flow control valve, FV-015, will close and reflux flow control valve,
FV-016, will full open.

 ACTION

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1. Close individual burners isolation valves of Fuel oil, Off gas and Fuel gas in both
zones of the F-01 and F-51. Also in F-02 isolate Fuel oil and Fuel gas individual
burners isolation valve.
2. Stop all chemical injections.
3. Close block valves in stripping steam to Crude Column, Vacuum Column, Diesel
stripper and HAGO stripper to avoid tray bumping.
4. Close all turbulising steam block valves after some time.
5. Close ejector steam block valves.
6. Stop all the pumps, except 311/312 P-10A and P–18 A (i.e. RCO & VR pumps)
and close their discharge valves.
7. Open bypass of FCV–082 to bring down Vacuum column bottom level.
8. Isolate M.P. steam block valve for S-03.
9. Stop the Net gas compressor. Open PV–005 B bypass valve for FG injection to
V-12, watch & maintain C-05 pressure.
10. Throttle crude feed (FV–091 A and B) block valves and isolate it after some
time Inform RTF.
11. Stop flashed crude pump P-04 after bringing down the level (LI-5) in flash
drum V-04.
12. After the level in C-05 and C-16 bottom has come down close bypass of FV-82
and keep Crude column bottom and Vacuum column bottom under circulation
through the start up circulation line.
13. Stop circulation in F-01/F-51 & F-02 when the temperature comes down to
2500C.
Flush HVGO, LVGO, slop wax system reduced crude, vacuum residue system with
flushing oil, if failure is for longer duration. Check draw off tray levels of all the
products, if level is high bring it down by opening LV bypass and product FV
bypass.
14. Open V-017 water level control valve bypass (LV – 18 )
15. Open H.P.; M.P.; and LP condensate drums LCV (LCV –90, 92 and 95
respectively) bypasses to bring down the level.
16. For LP condensate drum (V–27) open PV–390B bypass slightly after closing
isolation valves to maintain 1.00 Kg /cm2 pressure.
(Actions in SGCU
Isolate H.P. steam block valves to 321-S-07
Isolate stripper, 321-C-05 and stabilizer, 321-C-06 bottom LCV isolation valves.
Isolate sponge absorber LCV-4 isolation valve.
Isolate product battery limits valve and keep it lined out to slop.

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9.6 LOSS OF FEED FROM RTF

Normally out of THREE sets of booster/main charge pumps, TWO sets of pumps
will be running for each train and third pump set would be standby on AUTO
mode.

CASE ONE
If out of two running sets of pumps, one running pump trips due to mechanical
breakdown, standby pump will automatically cut in and charge feed can be
maintained with slight disturbance.
CASE TWO
Out of 2 charge pumps if one pump fails and standby pump is not available,
reduce the throughput to 50% and adjust the unit operating parameters
accordingly.

CASE THREE

If total loss of feed occurred due to both charge and booster pump failure, feed
will not be available for long time then the following effects will be observed.

EFFECTS
1. Flash drum level (LI-005) would start dropping. Hence P-04 may cavitate after
some time if not stopped.
2. Crude column overhead pressure (PIC-005) will come down & hence PV-005A
will open to make up F.G. to V-12.
3. All draw off tray levels will start coming down in C-05
4. Ejector vapours will get diverted to flare (ESD –13 )
( Effects felt in SGCU :
In SGCU, flow of Unstabilised naphtha from 311-V-13 will come down, with the
result H. P. Receiver (321-V-01) level l-013 will start falling down. This would close
311-FIC-048 on unstabilised naphtha feed from 311-V-13 to U-321.
System pressure may come down which will close 321- PIC-004.)

ACTIONS

Manually trip the heaters F-01/F-51/F-02. Keep FD fan running for all the heaters.
Isolate APH.

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Continue to feed at reduced throughput F-01/F-51/F-02 to cool the coils, till the
time flash drum level comes down. Stop P-04 A/B/C when level (LI-005) in V-04
comes down to 10%.
Cut off MP steam to S-03
Isolate F-01/ F-51/F-02 individual FG, F.O. valves after flushing. Keep P-10A /B on
bottom circulation with start up circulation line routed in F-01 / F-051 inlet.
Cut off ejector and isolate MP steam block valve XV-91. Also isolate its manual
block valves.
Back up F.G. through PIC-62 to break vacuum.
Isolate stripping steam for C-05/C-16 and both the HAGO/Diesel side strippers C-
06/C-08.
Route all products to slops through respective fin fan coolers and keep watch on
rundown temperatures.
Open superheated steam vent from F-01/ F-051 to atmosphere. Stop boiler feed
water for desuperheater by closing TV-44/TV-45.
After 2-3 minutes stop turbulising steam flow through the F-02 passes.
Stop HAGO for S-16 and S-18 reboilers by closing FV-39 and FV-40 and opening
FV-38 on bypass.
When stripper level comes down stop stripper bottom pumps and close stripper
LCV’s.
Take normal shut down in SGCU, as there will be hold up in V-01 (H.P. receiver).
Route both stabilised naphtha and LPG to off spec header.
Flush column individual draw off tray by internal refluxing till draw off level comes
down.
If draw off tray level is not sufficient, take flushing oil make up. Continue flushing
till HAGO and RCO is sufficiently light..
Similarly flush vacuum column by taking flushing oil make up to P-21A/B suction
(LVGO pump) and continue flushing till LVGO and Vacuum column bottom looks
like Diesel.
If feed failure is for shorter duration keep bottom circulation in both heaters with
minimum firing. No need of flushing in both columns.

9.7 HEATER FAILURE

9.7.1 CRUDE HEATERS

EFFECTS
1. If the failure is due to tube leak (pinhole) in F-01/F-051, following things will be
noticed in heater
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Crude Complex Refinery Division Crude Distillers
Jamnagar

2. Hydrocarbons will come out from the leaky portion of the tube and start
burning in the fire box. If the leak is big & not burning, then there can be
explosion in the furnace.
3. If the hydrocarbons are coming out in the form of jet and falling on the nearby
tubes tube skin temperature would increase.
4. If leak is unnoticed for long time, it may increase and particular pass flow will
increase suddenly and FCV might start closing to maintain the flow.
5. Outlet temperature of the particular pass flow would increase.
6. Due to less flow tube would develop hot spots.
7. ID fan inlet temperature may increase & if it reaches trip value I.D. fan will trip
and stack damper will get opened.
8. O 2 /CO Analyzer readings would change
9. Black smoke will come out from the heater stack.

ACTIONS

1. Cut off all the burners. Keep one burner near the leaky tube lighted.
2. Reduce crude charge gradually and stop it fully
3. Start emergency steam in all passes. Initially flame will be bigger and
subsequently it will become smaller and smaller and finally it will be put off
when all the coil material is replaced by steam.
4. Trip the heaters F-01/F-51/F-02, isolate Pilot gas / Main FG/FO burners. Route
off gases to flare through XV-018.
5. Take normal shut down in Crude and Vacuum section.
9.7.1 VACUUM HEATER FAILURE

EFFECTS
1. If leak is towards the feed side, hydrocarbon will come out and get burned in
the fire box which will get noticed just like in F-01/F-51
2. If the leak is towards heater outlet side (at which there is negative pressure)
hydrocarbon will not come out, hot flue gases would be sucked in. COT will
increase and also flash zone pressure / temperature will increase.
3. There will be bubbling and hot spot around the leak.
4. Skin temperature will increase.

5. There will be sudden fall in Vacuum of Vacuum column.

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Jamnagar

ACTIONS

1. Cut off all the burners. Keep one burner near the leaky tube lighted.
2. Reduce crude charge gradually and stop it fully thereby reducing the flow of
reduced crude to the heater F-02.
3. Start emergency steam in all passes. Initially flame will be bigger and
subsequently it will become smaller and smaller and finally it will be put off
when all the coil material is replaced by steam.
4. Close the Pilot gas and vent gas to heater, divert off gases to flare.
5. Take normal shut down in Crude and Vacuum section.
9.8 CRUDE COLUMN BOTTOM PUMP FAILURE

EFFECTS

1. F-02 furnace will trip on low flow through the passes.

2. Crude column bottom level will increase.
3. Vacuum column bottom level will decrease.
4. All the draw off tray levels in Vacuum Column will come down.
5. Vacuum in C-16 will improve.

ACTIONS

1. Isolate the stripping steam to C-05 by closing control valve isolation valves
2. Changeover the crude column bottom pump to P-10B (turbine driven pump).
Till then reduce feed rate & firing in F-01/F-51.
3. Isolate the crude column bottom pump by closing discharge valve.
4. Close the individual burner isolation valves of F-02.
5. Take the pass flow control valves of F-02 in manual and adjust equal flow to all
the passes.
6. Inform Delayed coker unit about the lighters coming in along with the feed to
their unit.
7. Reduce the stripping steam to Vacuum column.
8. Reduce the ejector steam.
9. Open the vent of superheated steam from steam convection zone if the
temperature is above 230 oC. Inform the maintenance department about the P-
10A failure.

10. Once the pass flows have been established start firing in the heaters by
opening block valve in the FO/FG line and taking individual FO burner in line.
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11. Put HVGO, LVGO to Slops via Gas oil cooler.

12. (Note: Continue sending HAGO to VGO Unionfiner)
13. Inform U-361/362 about the reduction of feed from the unit.
14. Start raising the pass flow outlet temperatures to normal.
15. Put FG in cascade with pass flow outlet temperature.
16. Once the coil outlet temperature reaches to its normal value bring the stripping
steam flow to vacuum column to its normal value.
17. Once the HVGO, LVGO draw off tray temperatures are reached check the
sample and route them to U-361/362 after informing them.
18. When Crude column bottom level comes to normal introduce stripping steam in
C-05 after draining condensate.
19. Isolate suction valve of the failed pump, flush the suction and discharge line
and also the pump casing of the pump with flushing oil, routing it back to
vacuum column flash zone. Continue flushing till all RCO gets replaced.
20. Close steam tracing, drain the pump material to CBD and hand it over to
maintenance department.

IF BOTH PUMPS ARE NOT AVAILABLE

1. Go for emergency shutdown by closing FCV-091A&B and FCV-21/22 informing

RTF to stop crude charge and booster pumps. Trip F-01/f-51/F-02 & isolate all
the burners.
2. Route all products to Slop
3. Close stripping steam to crude column / Vacuum Column, Diesel and HAGO
strippers.
4. Close the feed level control valve of the strippers.
5. Close the IR of drawoff trays.
6. Stop the pumparound flows and put the Reflux to column to maintain the top
temperature.
7. Close stripper pump when stripper level comes down to 10 %.
8. If shutdown is for longer time stop the Ejectors and back up Fuel gas into
vacuum column upto 0.5 kg/cm2 and maintain that much pressure inside the
column.
9. Stop the feed going to Sat gas concentration unit.
10. Go for total circulation in sat gas unit
11. Cut off HP Steam to 321-S-07

9.9 VACUUM COLUMN BOTTOM PUMP FAILURE

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EFFECTS

1. Feed to Delayed coking unit will be stopped.

2. Vacuum column bottom level will increase.
3. Stripping steam in vacuum column will get cut off.
4. Vacuum column bottom temperature will rise as quenching will stop.
5. Vacuum will increase in vacuum column.
6. Load on F-01/F-051 will increase due to loss of vacuum residue.
7. F-01/F-051 Coil outlet temperature may come down.
8. Product draw off rates will be reduced.

ACTIONS

1. Route LVGO, HVGO to slops.

2. Inform U-361/362 about reduction of feed.
3. Inform Delayed Coker unit about the stopping of feed to their unit.
4. Close the pass flow control valves of F-02.
5. Divert RCO to Slops by sending RCO to off spec. tank through A-07 from P-
10A/B.
6. Flush the passes of F-02 with emergency coil purging steam .
7. Stop Turbulizing steam to all the passes.
8. Isolate vacuum column stripping steam isolation valves.
9. Reduce the crude throughput to crude unit to maintain the coil outlet
temperatures of F-01/ F-051.
10. If the P-18 failure is for longer duration go for shutdown of Vacuum Unit. CDU
section can continue to run by diverting RCO through S-15/S-515/S-10 & A-07
to Slops tank or VR storage tank.
11. Line out flushing oil to HVGO and Slop Wax section.
12. Close the product draw off control valves.
13. Stop Ejectors and back up fuel gas into the vacuum column upto 0.5 kg/cm2
and maintain this pressure till the pumps are handed over.

9.10 CRUDE COLUMN REFLUX PUMP FAILURE

EFFECTS

1. C-05 top temperature will increase.

2. V-12 hydrocarbon level (LI-13) will rise.

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3. V-13 level will come down due to which feed to SGCU will be reduced or
stopped.
4. Column pressure will increase which will lead to PV-005B opening to Flare.
5. All the draw off temperatures of crude column will go up.
6. Net gas compressor will trip on high level.

ACTIONS

1. Stop Net Gas Compressor. Isolate its suction and discharge valves.
2. Increase circulating Naphtha flow to reduce column top temperature.
3. Increase all pumparound flows and reduce return temperature set points to
reduce the draw off tray temperatures.
4. If pump is not available for a longer time go for emergency shutdown of
CDU/VDU/SGCU.

9.11 HVGO PUMP FAILURE

EFFECTS

1. HVGO tray level will increase

2. LVGO draw off tray level increase and temperatures will increase
3. Vacuum Column Top temperature will increase.
4. Vacuum will start deteriorating.
5. In vacuum overhead receiver slop oil level will increase.
6. CDU heater firing will increase (due to non availability of HVGO pump around).
7. Slop wax level will come down.

ACTIONS

1. If standby pump is not available, take shutdown of VDU. If HVGO pump is not
available for long time CDU also has to be stopped along with VDU.
2. Put flushing oil to IR line from IR filter in HVGO pump discharge.

9.12 EJECTOR CONDENSATE RECEIVER WATER PUMP

FAILURE

EFFECTS
1. Vacuum column overhead receiver level will increase which may lead to
breaking of Vacuum.
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2. Due to breaking of Vacuum all the draw off tray levels will come down.
3. Vacuum Residue to Delayed coker unit would be lighter & increase.

ACTIONS
1. Divert Ejector off gases to flare.
2. Start the standby pump.
3. Reduce the stripping steam to column.
4. Reduce the steam to Ejectors.
5. Check the current of P-22 as the water is going to go along with oil to slop
tank. If current is high then throttle the discharge valve.
6. Inform RTF that water is coming along with oil to slop tank.
7. Route HVGO, LVGO to off spec header.
8. Inform U-361/362 and RTF about routing of HVGO, LVGO from Train - I to
slops.
9. Inform Train-2 about routing of VGO from train-1 to slops through offspec
header.
(Note: A-07 being common for both trains train2 cannot use A-07 as material
from here is being diverted to slops while Train-2 material is good.)
10. If pump is not available for long time take shutdown of VDU unit and route
reduced crude through Vacuum bottom through A-07 to offspec. header.

9.13 NET GAS COMPRESSOR FAILURE

EFFECTS
1. Crude column Pressure (PIC-005) will start rising so to maintain Pressure PV-
005B will open to flare.
2. LPG production will come down in Sat Gas concentration unit.
3. Flow of Lean Gas to Amine treating unit will be reduced.

ACTIONS
1. Close Net Gas compressor discharge valve at A-06 inlet.
2. Keep watch on Crude column overhead pressure. When column pressure is
increasing more than that of 0.7 kg/cm2 even after PV-005B has opened 100%
then open control valve bypass to bring down column pressure.
3. Taking HIC-041 on manual and reduce output signal to zero.
4. Keep Lube oil / Seal oil pump running for at least half-hour.
5. Investigate the cause for compressor tripping.
6. Inform maintenance department for the same.
7. Inform ATU/LPG Merox unit for the reduction of feed from our unit.
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8. If duration is for longer period then try to switchover feed to AL or reduce the
throughput.
9.14 PROCESS CONTROL SYSTEM FAILURE (DCS)
Operator console failure
Effects
1. PROCESS GRAPHIC WILL NOT BE DISPLAYED ON THE CRT.
2. No action can be taken for process control.
3. Process parameters can not be assessed/ monitored.
4. Alarm status will not be displayed & audio will not be heard

Actions
1. Inform instrument Engineer about the problem.
2. Control the process parameters from other console.
3. If all control room consoles fails, control process parameters from PIB
Consoles after taking consent from instrument Engineer.
4. Once the problem is rectified, switchover controls from PIB to RCR console.

Keyboard is not working

Effects
Control of the process parameters can not be done from keyboard.

Actions
1. Check for loose cable connection of keyboard.
2. If not call instrument engineer.
3. Control the process parameters by touch screen operation of CRT.

Touch screen operation is not working:

Effects
CONTROL OF THE PROCESS PARAMETERS WILL NOT BE POSSIBLE FROM TOUCH SCREEN
OPERATION.

Action
1. Inform instrument Engineer about the problem.
2. Control the process parameters by track ball.
3. If not possible control from other consoles.

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Key board & track ball is not working

Effects
Control of the process parameters will not be possible from that Console.

Action
1. Inform instrument Engineer about the problem.
2. Control the process parameters from other console.
3. If not possible, control process parameters from PIB Consoles after taking
consent from instrument Engineer.

Audio alarm is not working:

Effects
Alarm can not be assessed from audio alarm system.
Action
1. Inform instrument Engineer about the problem.
2. Keep close watch plant parameters & match video alarms.
3. If required take help of site field Engineer.

System fault alarm is appearing:

Effects
System malfunctioning.

Action
Inform instrument Engineer about the problem.

Control card failure

Effects
Control of parameters for that particular loop will not be possible or bad
Measured Value will appear on CRT screen.
1. System faulty alarm will appear.
2. All controllers will go on manual mode.

Action
1. Inform instrument Engineer about the problem.

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2. Control the parameters from field by taking control valve on Manual mode &
observe parameters from local gauges.
3. If multi card failure is there, go for shutdown of the unit.

Power supply failure to DCS

There are two sources of power supply to DCS system.

a) 110 V AC power to control system.
b) 110 V DC power to SDV & ESD including solenoid valve
Effects
Emergency power supply Battery will go on load position automatically.

Action

If power failure is more than 2 hrs

go for normal shutdown of unit without which all ESD will get actuated

CHAPTER # 10

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Jamnagar

SPECIAL PROCEDURE

10.1 DESLUDGING OPERATION IN DESLATERS

1. TITLE:
Procedure for Desludging operation in Desalters (V02/V03 / V33/V34)
in Crude Distillers

2. SAFETY EQUIPMENTS:
a) Safety Shoes
b) Helmet
c) Safety Goggles.
3. PROCEDURE:
3.1 Pre-Start Check up:

1. Check the interface level in the desalter through trycoks.

2. Check brine sample for pH and presence of oil, sludge etc
3. Check the Desludging control valve (FV-015 / FV-809) is lined up
4. Inform Utility department for desludging requirement and get clearance

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3.2 Desludging Operation

 Inform Panel officer for desludging operation in particular desalter.

 Reduce the wash water to the desalter by 20 m3/h
 Open the isolation valve of control valve (FV-015 or FV-809)
 Open the valves in the desludging header entering into the individual desalter.
 Open the control valve for desludging (FV-015 or FV-809) very gradually and
set flow of 20 m3/h
 Monitor the interface level and transformer current and volts closely. Low volts
and high current reflect the water carry over in the desalter.
 Collect and check the effluent brine sample during desludging. Check for
clarity. If the sample is clear, then inform panel officer and stop desludging.
Never do the desludging longer than necessary as this could lead to poor
performance of the desalter.
 Close the desludging control valve and its isolation valve. Also close desluding
header valves at desalter.
 Inform Utility department that Desludging operation is over.
4. RESPONSIBILITY:
The responsibility for compliance of this procedure lies with SS (CDU)
5. REFERENCES:
CDU SOP Manual: CDU / PDN / 3041
6. RECORDS:
a) SSS Log Book
b) 311 / 312 SFE Log Book
c) 311 / 312 Field Operator log
d) 311 / 312 Panel Officer log

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10.2 A05 BUNDLE ISOLATION & HANDED OVER

1. TITLE:
Procedure for 311 / 312 – A05 Bundles (Crude Column Over head
condenser) isolation and hand over for maintenance jobs in Crude
Distillers.
2. SAFETY EQUIPMENTS:
d) Safety Shoes
e) Helmet
f) Safety Goggles.

3. PROCEDURE:

3.1 Pre-Start Check up:

5. Check the Utility water / Nitrogen / Steam lines (PCO-121 lines) to inlet and
outlet line bleeders of particular bundles are deblinded and kept ready.
6. Inform Utility department for additional requirement of Utility water,
Nitrogen and Steam.
3.2 A-05 Bundle Isolation Operation

 Inform SSM about isolation of bundles and throughput reduction for the same.
 Reduce the throughput of about 200 m3/h. Start idle fans in other bundles if
any.
 Close the first isolation valve inlet header (24”) very slowly. Monitor the crude
column parameters very closely during the isolation process and stabilize the
column.

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 After closing the isolation valve, close the vent valve to V12 in the bundles.
Keep wash water from P36 on to push the Naphtha to V12. Continue this
forward flushing for about 2 hours.
 After forward flushing isolate wash water from P36 and the second isolation
valve (16”) in the outlet header.
 After isolating inlet and outlet header, line up utility water to outlet header
bleeder and start back flushing. Keep inlet header bleeder open and flushing
on.
 Check the overflowing material sample for blackish particles, Naphtha etc.
Continue backward flushing till the material is free of Naphtha and Black
particles.
 Once the overflowing material is clear, stop back ward flushing and drain the
bundles.
 After draining the bundles, release for blinding. Blinds to be inserted in the
following locations.
 Inlet header
 Outlet header
 Vent to V12 line
 Wash Water lines
 After blinding the bundles, steam out the bundles using PCO-121 lines. While
steaming keep couple of plugs in all rows of supply and return header open for
LEL checking. Continue steaming for about 2 hrs.
 Stop steaming, drain all condensate and check for LEL in the opened plugs. If
LEL is still there, continue steaming still LEL comes Zero.

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 If LEL comes Zero, release bundle for maintenance jobs. LEL to be monitored
before actually starting the job and at frequent level when the job is in
progress.
4. RESPONSIBILITY:
The responsibility for compliance of this procedure lies with SS (CDU)
5. REFERENCES:
CDU SOP Manual: CDU / PDN / 3041
6. RECORDS:
e) SS Log Book
f) 311 / 312 SFE Log Book
g) 311 / 312 Field Operator log
h) 311 / 312 Panel Officer log

10.3 SOOT BLOWING OPERATION

1. TITLE:
Procedure for Soot Blowing operation in Crude and Vacuum
Heaters (F01 / F51 / F02)

2. SAFETY EQUIPMENTS:
g) Safety Shoes
h) Helmet
i) Safety Goggles.
3. PROCEDURE:

3.1 Pre-Start Check up:

7. The main MP steam isolation valve to soot blower is lined up.

8. Steam Trap down stream of main isolation valve is lined up and working.

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9. Puppet valves of all soot blowers are in their retracted position and the limit
switch is in contact.
10. Steam supply XV and Condensate XV are in Closed condition and indications
are healthy
11. Soot Blower panel is in energized condition
12. Conduct lamp test of Soot Blower Sequential control panel
13. Ensure that individual interlock switches for all the soot blowers (except
those are in maintenance) are kept in “ON” position
14. Inform CPP for additional steam requirement for Soot Blowing.
3.2 Soot Blowing Operation

 Inform Panel officer for soot blowing operation

 Open the Main Stack damper of the heater to 100% and cross check the
damper opening in the field.

 Stop ID fan and check in the field.

 Since the stack damper is opened fully, the APH will not have heating media
for pre-heating the air and hence adjust the firing of heater if it is not on
lead / lag control

 Switch on the main power to the Soot Blower and put sequence button in
“Auto”

 For first 5 min MP Steam XV and Condensate XV will open and condensate
blow off will be done. After condensate drain out, condensate XV will close.
Ensure in the local panel for condensate XV closure after condensate blow
off.

 Soot Blowing operation will start and it will take approximately 2.4 min for
operation of each soot blower.

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 While Soot Blowing operation, is any soot blower struck up inside, furnace
may pressurize which may lead to tripping of the furnace. Hence keep close
watch on the furnace draft.

 While in operation, check for flange, glands of Poppet valves.

 After the operation of all soot blowers is complete, Switch OFF the panel
power and take sequence button in “Manual”

 If a soot blower doesn’t retract to its normal position after 2.4 min and
struck up inside, “Excessive Elapse Time” lamp blinking will appear in the
local panel. If it happens, check the jammed / struck up soot blower at
convection section.

 Manually retract the soot blower and bring it to idle position by manual key
as early as possible, otherwise chances for damage of lancer, pressurizing of
furnace are there.

 After retracting, put individual soot blower interlock switch in the “OFF”
position.

 Reset soot blowing system by pressing Soot Blowing Reset Switch HS-103
and after that the next soot blower will be started automatically and hence
the sequence will be completed

 Inform panel operator that Soot Blowing is over and start ID fan and
normalize.
4. RESPONSIBILITY:
The responsibility for compliance of this procedure lies with SS (CDU)
5. REFERENCES:
Vendor information

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6. RECORDS:
i) SSS Log Book
j) 311 / 312 SFE Log Book
k) 311 / 312 Field Operator log
l) 311 / 312 Panel Officer log

10.4 LINE CHEMICAL CLEANING PROCEDURE

PURPOSE:

TO CHEMICALLY CLEAN THE PIPELINES MADE OF CARBON STEEL/CAST IRON/UPTO12%

CR STEEL/AUSTENITIC STAINLESS STEEL/CU – NI ALLOYS TO REMOVE IRON OXIDE
DEPOSITS AND SCALE.
SCOPE:

This activity is done during the initial startup of the unit at the time of pre-
commissioning.

PROCEDURE:

IT WOULD BE NECESSARY TO REMOVE THE LINE PIPING FROM THE VESSELS / COLUMNS
AND FORM THEM INTO LOOPS OF FEASIBLE SIZES. ALTERNATELY, A SUITABLE LOOP CAN
BE FORMED USING JUMP-OVERS AND CONNECTING SPOOLS. A BIG RESERVOIR WITH
ENOUGH SURGE VOLUME SHOULD BE USED FOR CHEMICAL SOLUTION FROM WHERE THE
CHEMICAL CLEANING PUMP TAKES SUCTION.

The procedure is divided into the following steps.

 Precautions
 Water Flushing
 Degreasing
 Rinsing.
 Acid Cleaning.
 Rinsing and Neutralisation.

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 Passivation and Final Rinse

Step-wise description of the procedure is given below.

PRECAUTIONS:

 Make arrangements to dispose the generated effluent. It is highly acidic and

may contain dissolved ferrous salts.
 Isolate all instruments.
 Do not use process pumps.
 Do not expose the control valve to the cleaning solution
 Do not use process Reboiler for heating the acidic medium. Use steam spargers
for heating or temporary coils.
 After the final rinse, the vessel lines should be thoroughly purged and dried
with nitrogen and then maintained in nitrogen atmosphere.
 Personal protective equipment like apron, PVC gloves and goggles should be
used.
 During acid cleaning step restrict liquid velocity to max. 0.5 m/sec for effective
inhibition

WATER FLUSHING:

 MAKE UP WITH CLEAN WATER, EITHER UTILITY OR COLD CONDENSATE AND

CIRCULATE. CONTINUE UNTIL RETURN WATER IS CLEAR.
 After circulating water is clear, raise temperature to 70oC in increments of 5oC
per hour and circulate for 2 to 3 hours

DEGREASING:

 When clear circulating water is at 70oC, add the following chemicals to the
specified concentrations:
 Caustic Soda -2.8%
 Trisodium Phosphate -1.2%
 Detergent -0.12%.
 Circulate for 6 – 8 hrs hours at 70 -80oC
 Monitor pH, alkalinity, and oil in return line.
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 When the alkalinity and oil content remain constant while solution is circulated,
degreasing is complete

RINSING:

 Drain caustic solution and flush with clean water.

 Makeup and circulate water at 40 to 50oC.
 Monitor pH and alkalinity.
 When PH and alkalinity of the solution are the same at the inlet and outlet to
the solution tank, stop the circulation.

ACID CLEANING:

 Inventory the system with cold condensate, circulate and heat to 70 to 80oC.
 ADD THE APPROPRIATE RHODINE 92.
 Add citric acid to make a 3.0 to 3.5% wt solution.
 Slowly add NH 3 to control PH at 3 to 3.5.
 Monitor PH, acid concentration and dissolved Iron. If acid concentration goes
below 0.5% wt , make up to 1.0%.
 When Iron concentration reaches 0.4% wt the solution should be dumped. The
equipment should then be rinsed

RINSING, NEUTRALISATIONAND PASSIVATION:

 Rinsing / Neutralisation and Passivation should be performed using a fresh

batch of Cold Condensate. Citric acid is added to a concentration of 0.5% wt
and circulated until the Iron concentration reaches equilibrium level. The pH is
then adjusted to 9.5 by adding NH 3 ( or alternatively sodium carbonate to avoid
ammonia odour )
 Add NaNO 2 to make a 1.5% wt solution. The solution is circulated for six
hours. Closely monitor pH and control at 9.5 by adding of NH 3 . ( or
alternatively sodium carbonate to avoid ammonia odour)
 Drain the system under inert gas (nitrogen). Refill with Cold Condensate and
circulate for 2 hours. Adjust pH to about 7.5 by adding NH 3 . ( or alternatively
sodium carbonate to avoid ammonia odour)

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FINAL RINSE:

 Makeup with clean water and circulate.

 Add hydrazine to a concentration of 50 ppm.
 Adjust pH to 7.5 to 8.5 by adding NH 3 .
 Circulate for one hour. Drain under nitrogen atmosphere.

REFERENCE:

 UOP specification 1-13-1 for chemical cleaning.

10.5 De-greasing & Passivation for Cooling Water Exchanger

Heat Exchanger details:

 Hx Cw volume: ___m3 + ___m3 Tank & Piping = ___m3

 Chemicals Required: MS6201 (Corrosion Inhibitor) 7500 PPM - ___kg
 SF5100: (Oil Dispersant) 500 PPM - ____ Kg
 DN2300: (Dispersant): 100 PPM - ____ Kg
 Sulphamic Acid: (pH correction) - _____Kg

Brief Description:

New and re tubed exchangers need to be thoroughly cleaned before being

passivated and put in service. Metal surface covered by oils and other dirt can not
be passivated so it is important to clean it chemically. So that metal becomes
active for the Passivation. If the metal surface is not prepared for Passivation, the
passive film is not formed properly and it can lead to heavy pitting and under
deposit corrosion. Passivation avoids excessive fouling by iron oxides. Passivity of
iron surfaces is brought about by strong oxidizing agents, all of which is capable of
oxidizing ferrous ion, thus permitting metallic iron to dissolve only in the ferric
state. These gives rise to a stable protective Passivation film, which protects heat
exchanger from corrosion, and hence extend equipment life.

Procedure:
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De-greasing:

 Prepare 250 PPM of SF5100 based on system volume and circulate for 1 hours.
 Drain the circulating solution completely.
 Once again add 250 PPM of SF5100 based on the system volume and circulate
for 2 hrs.
 Drain the circulating water completely.

Passivation:
 Prepare 7500 PPM of MS 6201 solution based on the system volume-
Passivation solution.
 Add 100 PPM of DN 2300 in the above solution and maintain pH 5.5- 6.0 by
addition of Sulphamic acid.
 Insert corrosion coupon in circulating tank to observe the Passivation film.
 Circulate the above solution for 8 hours.
 Drain the Passivation solution completely from the heat exchanger.
 After draining thoroughly flush the heat exchanger with cooling water.
 Immediately after thorough flushing, heat exchanger should be taken on-line
with cooling water within two days.

Monitoring:
 Checking of pH, turbidity, and iron levels of circulating water. (Frequency is 30
min. After stabilization of pH testing frequency is once in hour.)
 Testing of Corrosion coupon by Copper sulfate solution to check the
effectiveness / completeness of the Passivation.

Calculation:
Chemical Required (Kgs) = (System Volume x PPM dosage)/1000

Exchanger Volume : ____m3

Piping & Tank Volume : ____m3

Job Responsibilities: GE Betz will do testing & monitoring of Passivation

activity.
10.6 AIR PRE-HEATER
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General Description:

The heat exchange surface in the pre heater consists of cast-iron By-Cast tubes
type HTA (High temperature ) and LT (Low temperature) tube.

The cast iron HTA tubes have integral fins on the inside (air) and out side (flue
gas) surfaces. The LT tubes have fins on the outside surface and ribs inside (air
side)

The cast iron HTA and LT tubes are assembled in 5 superimposed blocks with axis
of the tubes horizontal. This APH has 3 air passes.

Flue gas enters at the top of warmest block (HTA) and flows vertically down over
the outside of HTA and LT tubes in series and leaves the pre heater at the bottom
of the coldest section (LT)

Air enters the pre heater on one side of the lower module (LT) and flows
horizontally through tubes LT (first pass). On leaving the LT tubes, the air is
returned through 180 degrees and flows horizontally through the HTA tubes of the
intermediate module ( 2nd pass). On leaving these HTA tubes the air is returned
through 180 degrees and flows horizontally through the HTA tubes of the
intermediate modules (3rd pass).
Then the air leaves the pre heater on the opposite side as to the air inlet side. A
static wash water system is installed on the top side of APH.

APH WATER WASH PROCEDURE

There are four manifolds provided with isolation valves for water wash. Water
wash minimum flow rate is 30m3/hr per manifold (total 120m3/hr). Minimum
water pressure at the inlet flange is 1kg/cm2 and maximum water pressure is 2
kg/cm2.

Following procedure should be adopted for washing:

 Barricade the APH area.

 Isolate APH by putting guillotines at inlet and outlet.

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 Before admitting water to the manifold check that the drain line below the
blocks is completely open. This line must be open to avoid the possibility of
filling up the connecting duct and thus causing damage.
 Open water inlet valve gradually for first manifold. Check the water flow
through the drain line.
 The end of effective water washing period can be simply determined by visual
examination of outgoing water. At the start this water is strongly discoloured;
the discolouration gradually disappears as washing proceeds. At the end the
outgoing water should appear the same colour as at inlet.
 Compare pH value at the inlet and outlet. The pH at the outlet should rise
during washing and reach a constant value when washing is completed.
 Close water inlet valve for first manifold.
 Open water for second manifold.
 Continue above procedure for all manifolds.
 Closing the inlet valve should be tight shut. Any leakage of water creates
further source of corrosion.

10.7 BLINDING PROCEDURE

Master Blind List of all the equipment’s have been made after discussion
with the Maintenance. The responsibility of insertion of blind and
removal of blind is fixed and mutually agreed upon by Operation,
Maintenance and Construction.

Ensure Following before Blinding: -

1. Complete blind list is made and available.

2. Blinding locations are to be checked both by Operation and Maintenance.
3. Mark up P&ID is available.
4. Blind list is clearly stating the nozzle or flange size, rating.
5. Mention regular spacer blind is available or not.
6. Mention the normal position (IN/OUT) of the blind nozzle/flange.

Blinding Procedure:
Number the blinds as per the blind list.
Ensure proper size and rating gaskets are ready.
Tag the blind as per the blind list.
Ensure that the line/equipment is isolated before blinding.

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Issue the work permit clearly stating the blind location and attach the mark up
P&ID for the same.
Sign the blind register after putting the blind along with date.
The total blind list is to be kept updated after putting the blind.
The blinds are to be removed when the job is over and to be boxed up with
permanent gasket.
After removing the blind fill up the blind register duly signed.
Ensure necessary leak test is carried out of the flanges, which are de-blinded
before start up.

10.8 Procedure for the shifting of 311/312 S 08

10.8.1 Shifting S-08 exchanger to u/s of the Desalter

1. Reduce the t’ put to 1800 m3hr.

2. Bypass the HK through the S-02 and reduce the S-03 MP steam to get the S-03

outlet temp around 135 Deg C.

3. Ensure Valve A1, C1, B1, B3 are in open condition.

4. Maintain high level in Flash drum around 75%

5. Reduce the Diesel flow through the S-08 Exchanger by opening the TIC-18B to

avoid sudden raise in Desalter temperature when the S-08 is taken in line.

6. Watch the COT and Diesel pump around temperatures when the Diesel is

bypassed through the S-08 exchanger.

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7. Once all valves are lined up gradually close the TIC-018B and increase the

Desalter temp very slowly.

8. Following is the sequence of opening the valves :

a. S-08 inlet valve A2 near the exchanger to be opened slightly (Flow will be

reduced AT fic 801 watch this tag) once the S-05 out let valve A1 is

opened.

b. Watch the flash drum pressure and temp V-04 keep like this for 10 min and

watch the temp at S-08 inlet valve .

c. Open the A-2 valve fully and watch FIC 81,FT-91AB, FIC 21&22 flows. FT-

802 flow will gradually come down.

d. PIC-002 will come down up to 3.9kg/cm2.

e. Slowly close the E-1 valve fully (now the flow is from S-05 out let to S-08

bypassing the desalters. Watch the Ft-802A Flow).

f. Now start throttling gradually S-05 out let to Desalter valve D1.

g. Keep FV-22 manual and slowly throttle the F1 and reduce the flow from

the FV-22 by 100 to 200 m3hr .

h. The same amount of crude to be taken through the S-08 Bypass by opening

the C2 valve.

i. Confirm The S-08 Shell side PSV isolation valve B4 is closed and blinded on

the d/s of B4.

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j. Slightly open the valve B2 and check for the temp to raise in the out let

line going to Desalter inlet.

k. Watch the FT-802A flow, and diesel return temp if the FT –802A flow starts

raising and the Diesel return temps increases starts.

9. Now start throttling gradually S-05 out let to Desalter valve D1.

10. Observe the temps and flows U/S and D/S of the Desalters for about 30 Mts.

temp TI 32 and 33 (flash drum inlet) ,TI 821&TI416,and flows FV 091A & B, FV

21 & FV 22.

11. Once the flows and temps are ok and Desalter temp is picking up,

Simultaneously, S-08 out let valve B2 to Desalter inlet valve to be opened

slowly.

12. Start Opening the S-09 inlet Valve C2 slowly and at the same time start

throttling the S-08 outlet F1 . FT-91B controller to be adjusted manually.

13. Slowly close F1, and open B2, C2.

Keep watch on FT-802, flow will be in increasing trend. Inlet temperature of V-

33/V-34 should not cross 150 degC. If the temperature is high then hold throttling

Valve F1, increase raw crude flow, bypass crude through TV-006 (HK PA), TV-018

(Diesel PA) and Naphtha PA TV-002/005

14. Hot bolting to be carried out for all the flanges.

15. Stabilise the system.

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NOTE- Initially ensure that the Desalter V-33 temperature does not go beyond 140
0
C. If necessary cut back S-03 steam to achieve this. Final tuning to be by

adjusting TV-18B/S-03 steam to achieve proper balance in furnace inlet

temperatures and column pump around duties.

Caution: Since we will not be keeping the PSV 800A/B for protection

against over pressurisation ensure that the DO NOT OPERATE tags are

placed on the S-08 In let and outlet valves (B1, B2 and B3).

OR

Keep these valves B1, B2 and B3 LOCKED OPEN.

10.8.2 Shifting of S 08 exchanger to D/ S of the Desalter

1. Reduce the t’ put to 1800 m3hr.

2. Maintain the HK flow through the S-02 .

3. Maintain the S-03 MP steam .

4. Maintain high level in Flah drum around 75%

5. Maintain the Diesel flow through the S-08 Exchanger . Keep open TIC-18B to

avoid thermal shocks to S-08 when it is taken in line D/S.

6. Watch the COT and Diesel pump around temperatures when the Diesel is

bypassed through the S-08 exchanger .

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7. Once all valves are lined up gradually close the TIC-018B to improve the

preheat.

8. Following is the sequence of opening the valves :

l. S-08 outlet F1 valve to be opened slightly and open fully (Watch FIC-

802flow).

m. Watch the flash drum (V-04 )pressure and temp keep like this for 10 min ..

n. Open Slowly S-08 inlet E-1 valve and open fully .

o. Slowly close the B2 valve watch FIC 802,FT-91AB,FIC 21&22 flows

and,flash drum inlet temps and FIC-802 flow (Now the flow is from S-05

out to S-08 and to flash drum bypassing desalters)

p. Slowly close Desalter out let to S-09 inlet valve C-2 valve fully .

q. Throttle the A1 valve and watch the FT-091 b flow and reduce it by 200

m3/hr (keep FIC91 in manual) .

r. Open the D1 vale now the FIC-802 flow starts increasing, also FT091B flow

increases.

s. Slowly close A1 and open D1 simultaneously and watch the flows.

t. Stabilise the system.

NOTE- Ensure that the Desalter V-33 temperature does not go down below 110 0C.
If necessary increase the S-03 steam to achieve this.

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Caution: Since we will not be keeping the PSV 800A/B for protection
against over pressurisation ensure that the DO NOT OPERATE tags are
placed on the S-08 In let and outlet valves (E1,F1). OR
Keep these valves E1,F1 LOCKED OPEN.

10.9 PIGGING PROCEDURE

Decoking of the tubes is done by pigging

For the Pigging operations , pigs of various sizes upto 7 % oversize

w.r.t the dia of the tubes will be used.

For F01 and F51 Heaters

Preparatory jobs: All the below mentioned jobs will be done after the
Decontamination job is complete.

For F01 and F51 heaters the Convection and Radiant tubes are of 6”
diameter.

 There are swing elbows which will be rotated so that the steam
line can be connected to the radiant tubes.

 Drop the steam valves in the line going to the radiant tubes .
These valves are located at the Steam Air Decoking platform.

 A fabricated spool of 6” will be connected in the steam line so

that the pig can be launched.

 The pig receiving will be at the pass flow control valves. For this
the C/v d/s spool will be dropped and a fabricated spool will be
fixed in the d/s spool of the c/v. This will be for receiving the pig.

 Water supply to the coils will be given at the following locations.

One at Steam Air Decoking platform and the other at the C/v inlet

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. Flexi hoses will be used for the water supply . The pump
discharge can be routed to the coils through the 3” line . There
are XV’s in these lines which can be operated from the panel
mounted in the machine by which the direction of the water can
be reversed. The attached diagram is self explanotary

In the pigging m/c there is a sump which has a partition for the clear
and the dirty water. The pump takes suction from the sump and the
coil return is routed to the dirty tank which has a strainer to remove all
the coke fines. The dirty water is routed to the storm water channel.
The fresh water make up is from the Fire water.

Operating Procedures:

 Once all the pigging equipments are hooked up in the circuit , filling
up of the heater coil with clean water will begin.

 Before the pigging operation , an initial flow test is done to measure

the flow rate at different ratings, e.g 100 psi, 200 psi and 300 psi.
With this flow the initial amount of flow rate achieveable in the tubes
is then determined.

 A full dia foam pig will be routed through the line to determine
deposit build up and too check for any restrictions. This step verifies
to the operator the size and type of studs to be used on the first
decoke pigg.

 The first decoke pigg is undersize , equipped with the correct studs
and assisted by a foam pigg. This pig can be utilised until the
pressure readings indicate the first layer deposit is removed.

 Continue with the pigging operations until a 95% to 98% diameter

pigg can pass through the coil without the aid of a foam pigg.

The sequence of how a pigging program works is as follows

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1. The first decoke pigg is under sized.

2. Using of varoius sizes of piggs and studs until 7% oversize pigg is

used. Then these tubes are considered clean.

3. The pigg profile is monitored by recording the pressure profile from

which the profile of coke deposits can also be determined.

4. Attention is given on the cleaning on the fouled heater sections ,

working back and forth only in the fouled area first to reduce the
cleaning time.

5. Direction of the pigg can be reversed by changing the direction of

water .

6. The location of the pigg in the heater is determined by using the

pressure recorder .

Air compressor of capacity 750 cfm will be used for Dewatering after
pigging.

F02 Heater
 Here also the pigging procedure is the same as done for F01 and
F51.

 The main difference here in F02 is that the Convection coils are of 5”
dia and the radiation coils sizes increasing from 5” to 10 “ by the
time it exits the radiant section .

 The water supply for the Convection tubes will be provided at the
Steam Air Decoking platform by reversing the swing elbow and
connecting it to the steam line.

 For the radiant section the outlet spool will be dropped and a
fabricated spool will be fixed for facilitating the pig launcher to be
fixed.

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 Water connection to the radiant section will be given by the hard

piping up to the radiant section platform.

 Pigs of various sizes right from 5” upto 10” will be provided from
the radiant outlet line.

 Direction of the pigg can be reversed by changing the direction of

water .

 The schematic diagram of the tubes are attached

CHAPTER # 11

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MAJOR EQUIPMENT

CHAPTER –11
11.0 MAJOR EQUIPMENTS

11.1 DESALTERS (V02&V03, V33&V34)

This is a horizontal vessel made of carbon steel. V-02 and V03 vessel have a
diameter of 3048 mm and a length of 17466 mm. V33 and V34 vessel have
diameter of 3048 mm and length of 23470mm. The whole vessel is heat
insulated.
Two series of two stage crude desalting (V02,V03 & V33,V34) system is used
for reducing salt content in crude oil to less than 1 pound (measured as NaCI)
per thousand barrels of crude oil (PTB). It employs electrostatic elements to
coalesce and separate water from oil, thereby reducing the salt content in
desalted crude oil such that it is within specified limit.
Crude oil brings along with it salts, particularly those of sodium, calcium,
magnesium etc., metals like arsenic, vanadium etc. and mud. Although these
are present only in small amounts, their presence can result in serious problem
in down stream equipment like heat exchangers, fired heaters and fractionating
columns. Hence the need for their removal is considered.
At high temperature, calcium and magnesium chloride decomposes and forms
hydrochloric acid, corroding trays in the top section of the column, overhead
condenser etc. The presence of calcium and sodium salts can cause plugging of

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heat exchanger and heater tubes and thereby rapidly reducing heat transfer co-
efficient. The presence of arsenic will poison platinum catalysts that are used in
down stream processing units e.g. Platforming Unit. Presence of these salts also
promotes coke formation in heater tubes that results in high-pressure drop as
well as less heat transfer rates. The excessive coke formation results in
increased number of hot spots, which can cause serious and disastrous
consequences due to heater tube failure etc.
Brine is associated with crude, both as a fine suspension of water droplets and
more permanent emulsion. To break this tight emulsion, the de-emulsifiers are
used. Application of a strong electric field hastens the process of coalescing and
therefore settling of all unwanted material.
Crude from S-03 and S-05 is at a temperature of 152 oC. Temperature as high
as 150 oC is favorable for heavier Crude Oils. The purpose of heating up crude
before it enters the desalters is to improve its fluidity or reduce its viscosity and
mix water thoroughly. The mixing valves PDV-100/101 and PDV-808/809 are
provided at the up-stream of desalter-V02/03 and V33/34 respectively. When
this crude oil-water mixture is subjected to high potential electric field, the tiny
droplets of water distributed between the electrodes start moving in zig-zag
manner. This makes it possible for these-tiny-droplets to coalesce, thus forming
bigger droplets of sufficient weight to settle down. The force of attraction
between two droplets must be of sufficient magnitude to break through the oil
film. Demulsifier added helps in reducing water carry over with desalted crude
oil and oil carry over with desalter effluent water.
When oil water mixture enters the high voltage electric field in the desalter, it is
separated into two phases. The oil phase floats on top and overflows, while
water phase with its dissolved salts, metals, mud, and Iron oxide settles down
at the bottom.
Thus oil from first stage Desalter-V02/V33 flows to the second stage Desalter-
V03/V34 after mixing with desalting water. Desalting water and oil flows from
one desalter to the next one in counter current mode. The oil from II-Stage
desalter flows to Desalted crude circulating Diesel & HK exchangers S-08 & S-11
respectively.
Below the electrodes, an interface is formed between hydrocarbon and water.
LIC-001 & LIC-804 control the interface level for I-stage Desalter-V02 &V33 and
that of II-stage Desalter-V03 & V34 is controlled by LIC-002 & LIC-805
respectively, by regulating desalter water effluent (i.e. brine) withdrawal from
these vessels. Brine from V02 is used to pre-heat desalting water in S-07 A/B,
and brine from V33 is used to pre-heat desalting water in S-27A/B, then routed
to Brine Cooler-A12. For further cooling it is sent to Plate and frame heat

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exchanger (Y08) and finally sent to effluent treatment plant for further
treatment.
Non phenolic stripped water, phenolic stripped water from Waste-Water-
Stripping-Unit (WWSU) and low pressure cold condensate are received the
water feed surge drum (V-01) & used as desalting water. Desalting water
surge drum level (LIC-004) is controlled by FIC-020 on non-phenolic-waste-
water. The flow of phenolic-waste-water is controlled by FIC-019, which is
cascaded with the level multiplier on the stripper at the WWSU. The flow of cold
condensate to V-01 is controlled by FIC-018.
Desalting water is pumped under flow control by FIC-016 using desalting water
pump P-02 A/B/C/D to second stage desalter V03/V34 after preheating in
exchanger S07/S27 A/B. Brine water from 2nd stage desalter-V03/V34 is
pumped under interface level control LIC-002/LIC-805 by desalting water
pumps P03/P40, to first stage desalter V02/V33.
Five sample cocks are provided for both desalters, each at different elevation of
the vessel. These are used to physically check interface level in the desalters &
match with corresponding LT. Sample points are provided on crude oil outlet
from desalters & on desalter water (brine) outlet.
All the desalters are having by pass facilities. At a time all the desalters can be
bypassed or any one of these can be bypassed. Two-safety valve PSV-122A/B
set at 42.5 kg/cm2g are provided on top of desalter V02. While PSV-810A/B set
at 41.1 kg/cm2g are provided on top of V33. Similarly PSV - 124A/B set at 42.5
kg/cm2g are provided on top of desalter V03 and PSV-811A/B set at 41.1
kg/cm2g are provided on top of Desalter V34. Discharge of these safety valves
is routed to crude column flash zone. Since this is a liquid discharge, safety
valve outlet line are free draining towards crude column so as to avoid liquid
pockets.
The material that collects at desalter bottom is a thick sludge that is corrosive
and often has a tendency to choke. This needs to be cleaned periodically. For
this purpose one 3” header is taken from desalting water pumps P-02 A/B/C/D
discharge through FIC-115. It is further divided into two branches, one for
desalter-V02 and other for desalter-V03. Both of these 3” de-sludging lines
divide into two 3” branches and enter the respective desalter. Same way it is
provided for V33 and V34. The Desludging water to V33/34 from P02 is
controlled by FIC-809 through 4” header. Each of these branches is associated
with distributors inside the desalter. Desludging is a batch process. When
desludging water is injected in the desalter through a distributor, it loosens up
the sludge / muck collected at the bottom, and facilitates easy removal from
bottom outlet. Meticulous care should be taken during this operation as a

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sudden jerk will upset oil-water-interface leading to water and salt carry over to
crude, & thus obviating the use of desalter.
Some of the parameters that are to be closely monitored to realize good
desalter operation & its performance are as given below:

A. Water injection rate and pressure drop.

B. Oil-water interface level
C. Mixing valve performance
D. Desalter temperature
E. Desalter pressure
F. De-emulsifier injection rate

Process Design Basis

The plant has been designed on the following basis:

Feed Characteristics

Crude type : AL-48%, AH-32%, Maya-20%

Flow rate : 1889.58 T/H
API gravity : 28.9
Viscosity CP : 24.31
Reid Vapour pressure @ 100 oF : 6.94 PSI

Feed Contamination

BS & W content ( % vol) : 1 (max)

: 0.3 (min)

Salt content PTB (expected) : 45

(Design) : 60
Operating Conditions

Operating temperature.0C : 125-145

Operating pressure Kg/cm2 : 20- 25
Mixing valve pressure drop + Static Mixer
Kg/cm2 : 0.35-1.76

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Crude Complex Refinery Division Crude Distillers
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Desalting system pressure drop

Kg/cm2 per vessel : 0.14-0.21 Comment [T1]:

Utilities Requirement

Wash water
Source : 1) Normal: Phenolic water from waste water
from waste water stripping unit U441
: 2) Make up: Non phenolic water from waste
water stripping unit U441
:3) Start-up: Cold condensate
Operating Parameter
PH : 8.0 to 9.5
Oil content ppm : < 200
Temperature oC : 58
NH4+ : 65 to 80
Cl 2 : 10 to 15 ppm
Flow rate : 5-8 Vol% on crude

Chemicals
De-emulsifier:
Type : PETROTEC 7570 or NALCO or eqvt.

Rate : Upto 5-15 ppmwt on Crude Oil per stage in case of

abnormal operation
:Normally 3-6ppmwt on crude is to be injected

Electrical :
Supply - power : 415 V, 3 Phase, 50 Hz
Power unit rating : 120 KVA each
Secondary Voltage : 16000/17600/19200 V for V02/V03
: 12000/16000/20000 V for V33/V34
Power consumption :

First stage Desalter : 40Kw max. during normal operation.

Second stage Desalter : 40Kw max. during normal operation.
Voltage transformer(VT) : 500V/100V 40VA CL 0.5
Current transformer(CT) : 400A/1A 40VA CL 0.5

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Crude Complex Refinery Division Crude Distillers
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Product Streams
Desalted Crude Oil
Crude type : Design Case-1
Flow rate : 1900.8 MT/hr
Salt content PTB : 0.5 PTB(max).
BS&W content % (Vol) : 0.2 (max).
Effluent Water
Flow rate : Dependent on feed contamination and wash
water flow rate.
Oil content ppm (vol) : Not specied (Method of analysis:Petreco C- 34)
The H 2 S content of effluent is expected to be
negligible.

Desalter Operation

Start – Up
The desalting system has been designed for operation as either a single stage
unit or a two-stage unit, and the start-up philosophy associated with this design
is set out in this section.
The following instructions are for the first start-up of the plant. Naturally the
usual precautions taken before the start-up of any new process units should be
observed, that is motors, pumps, safety valves, control valves, instruments, etc.
should be checked and approved for correct operation. Blind flanges and
temporary strainers should be removed from the lines. All utilities including
water, demulsifying chemical, caustic dosing chemical (future provision) and
electrical power should be connected and available.

Single Stage Operation

 Fill up the desalter with water to displace the air content of the vessel.

 Open the bottom drain on the vessel & displace the water in the desalter vessel
with crude oil by openining a 4” globe valve on filling line & the primary outlet
valve.

 Gradually close the crude side bypass of the desalters & route the crude oil
through the desalters.

 Raise the temperature of the crude oil to the desalters to 129 0C.
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 Inject the demulsifying chemical at the maximum rate (5-15 ppmwt on Crude
Charge). After commissioning, the chemical injection rate should be reduced
to the lowest possible, consistent with good effluent water quality.

 With the mixing valve fully open, allow the crude oil to flow through the plant
until all the operating conditions are steady (i.e Flow, temperature, pressure).

 Check the position of the transformer tap-changing switch to ensure that all the
switch is set at the same position. The position of the switch will be
determined by the Petrolite Engineer (during initial start-up).
 Close the circuit breaker ahead of the field control panel and energise the
electrodes by operating the `ON’ switch on the field control panel.
 Check that all the ammeters, the voltmeters and the pilot lights are activated
on the local control panels.

 Approximately 1 - 2 hours after starting chemical injection, commence

desalting water injection at a point immediately upstream of the mixing valve
at a flow rate of 5 - 8 % by volume of the crude oil flow.

 Observe the voltmeters and the ammeters for steady operation.

 Allow the unit to operate for 4-6 hours while the water level is being
established in the vessel and the level controller and valve is placed in service.
During this period samples of the treated crude oil should be taken and
analysed for BS &W, salt content at regular intervals.

 The Petrolite Engineer will then make recommendations for the optimisation of
the process variables. To assist the Engineer BS&W analysis should be reported
every two hours and salt analysis every four hours.

 After the desalting water injection rate is set, increase the mixing valve
pressure drop until the mixing is sufficient to reduce the salt content of the
desalted crude to specification. The pressure drop should be gradually
increased in 3 - 5 psi (0.2 - 0.35Kg/cm2) increments. Allow a sufficient time
for establishing equilibrium conditions after each change (45 - 60 minutes).
Take sample, analyse at each pressure drop setting.

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 The optimum mixing differential is impossible to predict accurately since the

emulsifying charecterstics of the mixture are influenced by the type of crude,
the operating temperature, the flow velocities in the crude lines, the method of
water injections, the process water quality, the type and the injection rate of
the demulsifying chemical, and other factors. In general, increasing the mix
valve pressure drop improves water / crude oil mixing and reduces the salt
content of the desalted crude oil.

 Care should be taken, however, not to over mix since this will result in an
emulsion which the desalter cannot break. Over mixing will be indicated when
the water content of the desalted crude oil and the oil content of the effluent
water start to increase. The correct settings for each crude oil must be
determined by experience.

 The interface water level should be checked frequently during the preliminary
days of operation by physical checks of the interface level through trycocks on
the vessel. The interface level should be controlled at about the middle
trycock (3rd trycock).

 When flow conditions have stabilised, samples of effluent brine should be

checked for pH. If the pH is below 5.0, the injection of a suitable alkaline
solution is recommended. The rate should be adjusted to maintain the effluent
water pH in the range of 5.5 – 6.5.

 During the preliminary start-up period, frequent analysis of the treated

crude oil should be made.

 Since it is sometimes difficult to get consistent salt analysis (with test

methods presently available) at the salt levels in the desalted crude oil, it is
recommended that a `salt balance’ be made around the desalter to help final
optimisation of the operating variables.

 The frequency of analysing treated samples of crude oil for B.S & W and salt
content is set out in the Chapter no. 17.

 Proper sampling procedures are necessary if the results of the analysis are to
be representative of the process, and since very small concentrations of

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impurities must be determined in salt analysis, it is urged that special

attention be given to the following :

a) Sample bottles should be clean and dry.

b) Sample lines, particularly for the desalted crude oil should be
thoroughly flushed before taking each sample.
c) A dedicated sample cooler should be used for desalted crude oil
samples.
d) Sample should be carefully bottled & labeled with the content,
the time , the analysis required, etc, before sending to the
laboratory.
e) Samples should be taken at about the same time each day,
preferably early morning, so that adjustments can be made
during the day if they are required.

 The unit is designed to run continuously and efficiently with a

minimum of operator attention during normal operation. However, when
the unit operating variables are being changed, such as a significant change
in the crude oil charge rate / change in type of Crude feed / desalter inlet
temperature / mixing valve pressure drop, it is recommended that samples
be taken and analysed at regular intervals so as to ensure good control
during the above period.

Two stage Operation

 Fill up both the desalters with water to displace the air content of the vessel.

 Open the bottom drain on the vessel & displae the water in the desalter vessel
with crude oil by opening a 4” globe valve on filling line & the primary outlet
valve. Fill up the first stage desalter & then the second stage desalter with
Crude Oil.

 Gradually close the crude side bypasses of the desalters & route the crude oil
through the desalters.

 Raise the temperature of the crude oil to the desalters to 129 deg C.

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 Inject the demulsifying chemical at the maximum rate. After commissioning,

the chemical injection rate should be reduced to the lowest possible, consistent
with good effluent water (i.e. brine) quality.

 With the mixing valve fully open, allow the crude oil to flow through the plant
until all the operating conditions are steady (i.e Flow, temperature, pressure)

 Check the position of the transformer tap changing switches to ensure that all
the switches are set at the same position.
 Close the circuit breaker ahead of the field control panel and energise the
electrodes by operating the `ON’ switch on the field control panel.

 Check that all the ammeters, the voltmeters and the pilot lights are activated
on the local control panels.

 Approximately 1 -2 hours after starting chemical injection, start desalting water

injection at a point immediately upstream of the mixing valve at a flow rate of
5 - 8 % by volume of the crude oil flow.

 Observe the voltmeters and the ammeters for steady operation

 The second stage desalter interface water level should be checked by

observing the level trycocks on the vessel. The level should be controlled at
the middle trycock by means of the second stage effluent water control valve
(LIC-002/LIC-805).

 With interface level stable in the second stage commence water injection to the
first stage desalter at a point immediately upstream of the mixing valve at a
flow rate of 5 - 8 % by volume of the crude oil flow.

 Observe the voltmeters and the ammeters for steady operation.

 The first stage desalter interface water level (LIC-001/LIC-804) should be

checked by observing the level trycocks on the vessel. The level should be
controlled at or about the middle trycock by adjusting the first stage effluent
water control valve.

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 Allow the unit to operate for 4 - 6 hours while the water level is being
established in the vessel and the level controller and valve is placed in service.
During this period samples of the treated crude oil should be taken and
analysed for BS &W, salt content at regular intervals.

 The Petrolite Engineer will then make recommendations for the optimisation of
the process variables. To assist the Engineer BS&W analysis should be reported
every two hours and salt analysis every four hours.
 After the desalting water injection rate is set, increase the mixing valve
pressure drop until the mixing is sufficient to reduce the salt content of the
desalted crude to specification. The pressure drop should be gradually
increased in 3 - 5 psi (0.2 - 0.35Kg/cm2) increments. Allow a sufficient time
for establishing equilibrium conditions after each change (45 - 60 minutes).
Take sample, analyse at each pressure drop setting.
 The optimum mixing differential is impossible to predict accurately since the
emulsifying charecterstics of the mixture are influenced by the type of crude,
the operating temperature, the flow velocities in the crude lines, the method of
water injections, the process water quality, the type and the injection rate of
the demulsifying chemical, and other factors. In general, increasing the mix
valve pressure drop improves water / crude oil mixing and reduces the salt
content of the desalted crude oil.

 Care should be taken, however, not to over mix since this will result in an
emulsion which the desalter cannot break. Over mixing will be indicated when
the water content of the desalted crude oil and the oil content of the effluent
water start to increase. The correct settings for each crude oil must be
determined by experience.

 The interface water level should be checked frequently during the preliminary
days of operation by physical checks of the interface level through trycocks on
the vessel. The interface level should be controlled at about the middle trycock
(3rd trycock).

 When flow conditions have stabilised, samples of effluent brine should be

checked for pH. If the pH is below 5.0, the injection of a suitable alkaline
solution is recommended. The rate should be adjusted to maintain the effluent
water pH in the range of 5.5 – 6.5.

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Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

 During the preliminary start-up period, frequent analysis of the treated crude
oil should be made.

 Since it is sometimes difficult to get consistent salt analysis (with test

methods presently available) at the salt levels in the desalted crude oil, it is
recommended that a `salt balance’ be made around the desalter to help final
optimisation of the operating variables.

 The frequency of analysing treated samples of crude oil for BS & W and salt
content is set out in the Chapter no. 17.

 Proper sampling procedures are necessary if the results of the analysis are to
be representative of the process, and since very small concentrations of
impurities must be determined in salt analysis, it is urged that special
attention be given to the following :

a) Sample bottles should be clean and dry.

b) Sample lines, particularly for the desalted crude oil should be thoroughly
flushed before taking each sample.
c) A dedicated sample cooler should be used for desalted crude oil
samples.
d) Sample should be carefully bottled & labeled with the content, the time
, the analysis required, etc, before sending to the laboratory.
e) Samples should be taken at about the same time each day, preferably
early morning, so that adjustments can be made during the day if they
are required.

 The unit is designed to run continuously and efficiently with a

minimum of operator attention during normal operation. However, when
the unit operating variables are being changed, such as a significant change
in the crude oil charge rate / change in type of Crude feed / desalter inlet
temperature / mixing valve pressure drop, it is recommended that samples
be taken and analysed at regular intervals so as to ensure good control
during the above period.

Shut Down

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It should be noted that once the desalting water injection to the desalting unit has
been discontinued, there is nothing about the operation of the desalter that could
cause upset to downstream processing equipment. To shut down the desalter
system the following procedure should be followed :

Shut-Down of Single Stage Desalter of either series in Operation.

 Stop desalting water to the desalter and Switch to another desalter.

 Fully open the mixing valve.
 When the crude oil flow through the desalter is discontinued, de-energise the
electrodes by operating the “OFF” switch on the local control panel and lock
the switch in the “OFF” position.
 Stop the demulsifier dosing to that desalter.
 When the vessel is to be emptied, lock the circuit breaker feeding the field
control panel in “OFF” position.
 Dump the water layer to the sewer.
 After disposing of the water layer, pump out crude oil & dump the desalter.
 Backwash the vessel with water & overflow.
 Dump the (back) wash water to the sewer.
 Open the manways.
 Use a high pressure fire water hose to wash any residual sediment from the
electrode parts and vessel.

Shut-Down of theTwo Stage Desalter system of either series in

Operation

 Stop the desalting water to that desalter.

 Fully open both the mixing valves.
 When the crude oil flow through the desalters has discontinued, de-energise
the electrodes by operating the “OFF” switch on the field control panel and
lock the switch in the “OFF” position.
 Stop the demulsifier dosing to that desalter.
 When the vessel is to be emptied, lock the circuit breaker feeding the field
control panel in “OFF” position.
 Dump the water layer to the sewer.
 After disposing of the water layer, pump out crude oil & dump the desalter.

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 Backwash the vessel with water.

 Dump the (back) wash water to the sewer.
 Open the manways.
 Use a high pressure fire water hose to wash any residual sediment from the
electrode parts and vessel.

11.2 NET GAS COMPRESSOR (SCREW TYPE)

The Net Gas Compressor is used to compress overhead vapors coming from Crude
column overhead receiver V-12. Basically the compressor is serving a dual
purpose. First it is reducing the Crude column pressure to get more yield. Secondly
recovering C 1 , C 2 , C 3 and C 4 components which otherwise would get flared.
The net gas compressor is an axial flow, rotary positive displacement type
compressor. It consists of two parallel impellers or rotors. One is called a male
rotor and other a female rotor. Male rotor has 4 lobes and female rotor has 6
matching cavities. Outside diameters of rotors are identical. Female rotor speed is
2/3rd of the male rotor speed. Male & female rotors are designed to mesh with
each other but touch neither each other, nor the casing. Synchronizing gear is
responsible for the rotation of male and female rotors without metal to metal
contact at all time. Male rotor and female rotor rotate in such a way that the lobes
and matching cavities separate on suction end. The separation of the lobes and
matching cavity creates an intake suction, which causes the inter-lobal space to fill
with gas. Further rotation isolates this space from the suction and the
intermeshing of the helical lobes, reduces its volume, & gradually compresses the
gas at the discharge end.
The construction of bearing and seals used in this compressor are such that any
leakage of lube oil from the bearing or seals would normally be routed to
atmosphere and not into the compressor chamber. The compressor housing is
jacketed for heat removal with cooling water.

PRE-STARTING PROCEDURE OF COMPRESSOR

Before starting the compressor for the first time or after a major overhaul, check
for the following:

 All lube oil and seal oil piping and internal parts of compressor are free from
dirt, moisture & any foreign material.

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 Remove paint and preservative coating from all moving parts.

 Check suction and discharge piping supports.

 Check auxiliary equipment, including safety alarm systems and interlocks of

compressor.

 Check for any condensate in the suction line by opening the drain at the inlet
silencer of the Compressor and also drain the casing from the compressor
casing drain.

 Flush the seal and lube oil systems properly and line up the Lube oil pressure
switches and Seal oil/ Reference gas differential pressure switches.

 Commission seal and lube oil system before an hour of initial start up.

 Ensure that all the valves internal to the unit are properly adjusted.

 Ensure all the lamps are O.K. on compressor local panel by pressing test push
button.
INITIAL STARTING PROCEDURE

1) Run compressor motor (MC-RD311/312-M01) without load

a) Disconnect coupling between motor and male rotor.
b) Run motor and check -
i) direction of rotation
ii) current drawn, and
iii) undue noise and vibration
2) Check hydrocarbon level LI-13 in Crude column receiver V-12. It should be
around 30%.
3) Ensure that sufficient Gas is available for running the Compressor.
4) Ensure that Naptha is routed to recontact drum V-13 from V-12.

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5) Line up PSV 134A/B on Compressor discharge and ensure that one PSV is in
lock open condition.
6) Run compressor on gas
a) Install a temporary strainer provided by the vendor between the
compressor and inlet silencer.
b) Bar male rotor to check
i) freeness of rotor
ii) any metallic sound or rubbing
c) Check alignment between motor and male rotor and couple them.
d) Check lube oil/seal oil temperature (TW/TG-29,30 ,31,32,33), flow (FG-
01to 08) and pressure (PG-21,22,23&24)
e) Ensure bypass valve of PV-05C is open.
f) Check compressor jacket cooling water flow, temperature and pressure.
g) Line up Reference gas / Sour oil system
h) Check nitrogen pressure & purge the compressor.
i) Open suction line isolation valve of compressor and discharge valve to A-06.
j) Keep V-13 pressure controller PIC-10 on auto with a set point at 0.5
kg/cm2g.
k) Start Compressor motor and gradually increase the rpm up to 935. Trip
compressor motor, observe the unit till it comes to a stop. Check –
i) any undue vibration or noise,
ii) freeness of rotor
iii) Note:- Don’t restart the motor atleast for 10 minutes after each
shutdown.
l) Restart the motor and bring unit up to minimum speed and run the
Compressor for 30 minutes. Check –
i) Any undue noise or vibration,

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ii) Operation of compressor, and

iii) Auxiliary equipment
iv) Ensure that differential pressure between the reference gas and seal oil
is being maintained around 2.07 kg/cm2g.
m) Stop motor, observe unit till it stops rotation. Check –
i) Freeness of rotors,
ii) Inlet strainer provided in the suction line of Compressor. (Clean it if
reqd.)
n) Restart the motor. Gradually, close bypass-valve of PV-005C and
simultaneously increase the set point of PIC-10. Bring the compressor to
design discharge pressure. Run for 30 min, and then check again
i) Any undue noise or vibration,
ii) Operation of compressor, and auxiliary equipment
iii) Check inlet strainer provided in the suction line of compressor. (Clean it
if reqd.)
o) Continue operation of unit for 30 minutes interval until inlet strainer is no
longer picking up dirt.
NORMAL STARTING PROCEDURES (Refer Net Gas Compressor SOP)

1) Ensure (PSV-25/26) on lube / seal oil pump and compressor (PSV-134A/B) are
commissioned.
2) For pre-lubrication, start main lube/seal oil pump (MP-RD311/312-P30A) before
30 minutes of compressor start up. Check -
a) Flow(FG-01,02,03,&04)
b) Temperature(TW/TG-29,30,31,32,33,34)
c) Pressure(PG-21,23,24)
d) level of oil reservoir
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3) Start cooling water to

a) compressor jacket
b) oil coolers
4) Check hydrocarbon level LI-13 in Crude column receiver V-12. It should be
around 30%.
5) Ensure that sufficient gas is available for running the compressor.
6) Ensure that Naptha is routed to recontact drum V-13 from V-12.
7) Check all valves in suction and discharge line.
8) Check nitrogen header pressure & purge the compressor
9) Bar the male rotor to check freeness.
10)Ensure that by pass valve of PV-5C is open.
11)Line up compressor discharge to A-06 by opening the block valve. Put V-13
pressure controller PIC-10 on auto with a set point at 0.5 kg/cm2g.
12)Start compressor motor (MC-RD311/312-M01)

a) Slowly bring the RPM upto 937.

b) Gradually close the by pass valve of PV-005C and pressurise the unit by
increasing the set point of PIC-10 upto 2.8 kg/cm2g.

c) If the flaring still persists from V-12 overhead receiver then increase the
compressor rpm gradually till the flaring stops.

d) Ensure that sufficient Naptha is routed to V-13 from V-12.

e) Maintain level in V-13 around 30%.

13)To ensure system is being lubricated properly, check -

a) Lube / seal oil temperature,
b) All lube oil pressure gauges

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c) Flow of Lube oil/Seal oil through the sight glass.

14)Check –
a) Any undue vibration or noise,
b) auxiliary equipment
15)Ensure that all parameters are within the operating range

SHUT DOWN PROCEDURES

1) Ensure that Crude column overhead pressure controller PIC-005 is in auto

mode with PV-005A selected from the selector switch PHS-005.
2) Gradually reduce the compressor rpm upto minimum i.e. 937 rpm.
3) Gradually decrease the set point of V-13 pressure controller, PIC-10 to reduce
the compressor discharge pressure to ½ of its normal operating pressure.
4) Stop the Compressor motor and close the suction, discharge.
5) Allow the lube oil / seal oil to circulate till the Lube oil/ Seal.oil return
temperature is around 500C.

CAUTION

1) Compressor pressure ratio should not exceed the design pressure ratio.

2) Compressor discharge temperature should not exceed 97 0C.

3) Lube oil pressure should not fall below 1.7 kg/cm2g.

4) Seal oil and reference gas differential pressure in the suction and discharge end
of the compressor should be maintained at 2.07 kg/cm2g.

Net Gas Compressor Process

Conditions.
Normal Maximum Minimum
Flow Rate, Kg/Hr 34681 43351 9975
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Cal. Molecular Weight 58.6 58.6 58.6

Inlet Pressure, Kg/cm2 a 1.35 1.35 1.35
Outlet Pressure, Kg/cm2 a 4.38 4.52 4.72
o
Inlet Temperature, C 55 55 55
o
Outlet Temperature, C 93 95 97
Speed, RPM 2570 3122 937
Absorbed Power, KW 763 1003 270
Cal. Cp/Cv value 1.086 1.086 1.086
Cal. Compressibility factor, Z1/Z2 0.977 0.977 0.977
Volumetric Efficiency 94.3% 97.0% 72.7%
Net Gas Compressor Mechanical
details
Model 200L4UD
Casing Construction Cast/Horizon
Casing Design Pressure, Kg/cm2 g 7.0 Test =
10.5
Design Temperature, max/min, oC 150 / 3
Max. Disc. Pressure, Kg/cm2g 7.0
Discharge Temperature, oC 95
Rotor Construction Machined from forging
No. of Lobes M4 / F6
Types of Construction Asymmetric
I-Critical speed, RPM > 120% normal
Max. Critical / Trip Speed RPM 3278 / 3590
RPM Max, Normal, Min 3122 2570 937
Power, KW Max, Normal, Min 1003 763 270
Cal. Cp/Cv value 1.086 1.086 1.086
Cal. Compressibility factor, Z1/Z2 0.977 0.977 0.977
Volumetric Efficiency 97.0% 94.3% 72.7%
Coupling type Flexible Dic
Thrust Bearing Tilting Pads
Seal Type Oil Buffered Mechanical
Operating seal leak, m3/day/seal 0.02
Noise level from 1 m distance 85 dBA
Net Gas Compressor ESD ( 311/312-SD–02)
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Jamnagar

The net gas compressor has the following seven interlocks for tripping the
machine during abnormal operating conditions :

1. Crude Column Receiver Level High (LT-079)

2. Compressor Discharge Temperature High (TI-076)
3. Compressor Manual Emergency Shutdown (XHS-037)
4. Compressor Shutdown Signal from UCP (XS-232)
a. Lube Oil Pressure Low (PSLL-030 A/B/C, 2 out of 3)
b. Seal Oil / Ref gas differential pressure at Suction End low (PDSLL-013 A/B/C)
c. Seal oil / Ref. Gas differential pressure at discharge end low (PDSLL-014A/B/C)
d. Compressor axial position should not exceed 0.15 mm.

11.3 CRUDE AND VACUUM HEATERS (311/312-F01/F51/F02)

11.3.1GENERAL DESCRIPTION:

There are three fired heaters in each crude train. MB-RD311/312-F01/F51 are
crude heaters which heat the crude coming from preheat exchanger train from 260
°C to 382 °C.
MB-RD311/312-F02 is the vacuum heater, which heats the reduced crude coming
from column bottom pump (P 10 A/B) from 369 °C to 392 °C.

CRUDE HEATERS F01/ F51

Crude distillation unit has two identical fired heaters MB-RD311/312-F01 and MB-
RD311/312-F51. Each heater has two cylindrical, vertical radiation zones with
independent firing controls and a common convection section. There are a total of
14 burners in each radiation zone. A typical burner assembly consists of a pilot
burner, dual fired main burner, off gas burner and an atomizing steam connection.
Heaters are balanced draft and have two forced draft fans and one induced draft
fan. Combustion air is preheated first in steam preheater using L.P steam and then
in air preheater using flue gases. Safe startup of the heater is ensured by burner
management system ‘BMS’. Lead lag control ensures that required parameters at
the heater outlet are met by suitable manipulation of variables like fuel oil/gas
pressures and flow of combustion air. Heater is safeguarded against hazardous
conditions that may result due to upsets during operation, by trip interlocks
(ESD’s)
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VACUUM HEATER F02

Vacuum heater has a single vertical cylindrical radiation zone and a
convection section. There are a total of 10 burners in the radiation zone.
Vacuum heater has all the features mentioned above except that there is
no waste gas burner.
Main features of crude and vacuum heaters are listed below:
Vacuum
Sr.No. Item Crude Heater
Heater
1 Duty (MMKcal/H) 105 35
2 Flow (Kg/H) 920880 1001160
Pressure Drop (Allowable)
3 13.85 8.59
(Kg/cm2)
Pressure
4 6.0
Drop(Calculated)(Kg/cm2)
5 Inlet Conditions
Temperature (°C) 251.9 368.4
Pressure (Kg/cm2g) 12.9 6.526
Liquid Flow (Kg/H) 920880 1001160
Vapour Flow (Kg/H) NA NA
6 Outlet Conditions
Temperature (°C) 386.1 409.5
Pressure (Kg/cm2g) 3.14 0.524
Liquid Flow (Kg/H) 543240 884160
Vapour Flow (Kg/H) 377640 122760
7 Percentage Vaporization 41.01 12.1

11.3.2 DETAILED DESCRIPTION:

The various sections of crude and vacuum heaters are described in detail below:
11.3.2.1 Process Loop
A. Crude Heaters F01/ F51

Process fluid coming from preheat exchanger train to crude heaters is first heated
in common convection section and then is heated to required temperature in two
separate radiation sections zone 1 and zone 2.

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 Convection section
Crude comes from Flashed crude/hot vacuum residue exchanger – S15/S515 A/B
and enters the heater convection section in 10 passes. Individual pass flow control
valves control flow of crude to each pass. Pressure in each pass can be read by
local pressure gauges located downstream of control valve. Each of the ten heater
passes has an MP steam connection through 1.5” lines, which are isolated from
the system by means of globe valves. MP steam would be used to purge the
heater passes during emergencies or shutdowns. Steam manifold and globe valves
are located 15 meters from the heaters for ease of operation during emergencies.
Swing elbows are located at inlet and outlet of each heater pass to aid the
decoking operations conducted during unit turnarounds. The heater convection
section can be broadly described in three sections.

The first section on the top consists of studded tubes arranged in four horizontal
rows (10 tubes / row).
The second section consists of studded tubes arranged in ten horizontal rows (10
tubes / row). This section is used to preheat the crude prior to heating it to the
final temperature in radiation section.
The third section consists of bare tubes arranged in three horizontal rows (10
tubes / row). These tubes act as a shock bank and separate convection section
and radiation section .

There are 16 fully retractable type soot blowers in the convection section for
knocking off the soot deposited on the convection section tubes. Soot blowers are
arranged in two rows with eight blowers in each row. They are designed for
vertical and horizontal coverage of 1220 mm or four tube rows. Soot blowers are
equipped with automatic sequential control with provision for remote operation of
any soot blower element and local push button control.

 Radiation Section
Crude heater consists of two cylindrical radiation sections, referred to as zone 1
and zone 2. Crude from common convection section enters the two zones of
radiation section in 5 passes each. Each pass consists of 22 vertical bare tubes
arranged at the periphery of the cylindrical radiation section. Thus the total
number of vertical tubes in each firing zone is 110. Four skin thermocouples are
located on each pass i.e. one each on 7th, 12th, 17th, 22nd tubes. Crude finally
comes out from each firing zone at 386 °C in five 10" lines. There is a temperature
transmitter with high temperature alarm located at each pass outlet. Temperature

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transmitter located on the common outlet header indicates the coil outlet
temperature, which is transmitted to heater firing control system.
B. Vacuum heater F02

Vacuum heater has all the features mentioned above except for the points detailed
below
 Convection section
Reduced Crude comes from column bottom pump - P 10 A/B and enters the heater
convection section in 10 passes. The heater convection section can be broadly
described in two sections.

The first section consists of studded tubes arranged in ten horizontal rows (10
tubes / row). This section is used to preheat the reduced crude prior to heating it
to the final temperature in radiation section.

The second section consists of bare tubes arranged in three horizontal rows (10
tubes / row). These tubes act as a shock bank and separate convection section
and radiation section.
There are 8 fully retractable type soot blowers in the convection section for
cleaning of the convection section tubes. Soot blowers are arranged in two rows
with four blowers in each row. They are designed for vertical and horizontal
coverage of 1220 mm or four tube rows. Soot blowers are equipped with
automatic sequential control with provision for remote operation of any soot
blower element and local push button control.
 Radiation Section

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Reduced crude from convection section enters the radiation section in 10 passes.
Each pass consists of 12 vertical bare tubes arranged at the periphery of the
cylindrical radiation section. Thus the total number of vertical tubes in radiation
section is 120. Four skin thermocouples are located on each pass i.e. one each on
10th, 11th tubes and two on 12th tube. There are provisions for injecting
turbulising steam into the 1 and 11 tube of each pass to minimize the chances of
Sr Item Crude Heater Vacuum Heater
.N
o
1 Convect Pass No of Row Type MOC Passe No of Row Type MOC
ion es tubes/ s s tubes/ro s
tubes row w
a Process 5 10 4 Studde 9Cr - - - - -
d 1Mo

b Process 10 10 10 Studde 9Cr 10 10 10 Studde 9Cr

d 1Mo d 1Mo

c Process 10 10 3 Bare 9Cr 10 10 3 Bare 9Cr

1Mo 1Mo
2 Radiant Pass No of Tota Type MOC Passe No of Tota Type MOC
tubes es/z tubes/ l s tubes/pa l
one pass tube ss tube
s s

a Process 2X5 22 220 Bare 9Cr 10 12 120 Bare 9Cr

1Mo 1Mo
3 Notes
a OD of tubes:
Convection section 6" 5"
Radiation section 6" 1 to 10 tube =5"
11 tube =6"
12 tube = 8" lower half & 10"
upper half
b Stud height 1" 1"
c Stud diameter 1/2" 1/2"
d Stud MOC. CS. CS.

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coking in the heater tubes. Tube nos. 10 and 11 extend out of the firebox so that
turbulising steam may be injected into the top of the 11th tube. Reduced crude is
finally heated to 404 °C in the radiation section. During the revamp shutdown
flame side of 8” and 10” tubes of radiation section of F02 is covered with heat
shields.

Main features of the radiation and convection section coils of crude and
vacuum heaters are listed below:
11.3.2.2 COMBUSTION AIR/ FLUE GAS LOOP
The heaters are balanced draft type and have two forced draft fans and one
induced draft fans. Combustion air is preheated first in steam preheater using L.P
steam and then in air preheater using flue gases.
A. Forced draft fans:
Combustion air is supplied to the burners by two motor driven forced draft fans,
one running and other serving as a standby. Each Combustion air fan is sized to
operate at 115% of design flow conditions with 132% of the design pressure
differential, when the heater is being fired at 25% excess air with the APH on line.
Each FD Fan is provided with variable inlet vanes at the suction and non-return
damper at the discharge.

For vacuum heater the inlet dampers on the two fans will control the discharge
flow via a common flow controller.
For crude heaters the FD fans supply combustion air to both the radiation zones.
Combustion air at downstream of APH is split into two streams. Venturi meters
located in each stream measure the flow of combustion air to each zone. Flow
control dampers located in the two streams receive the flow measured at the
venturi and control the flow of combustion air to each zone. The dampers located
at the inlet of FD fans control the pressure at the discharge of APH (Before the air
is split into two streams). Hence irrespective of the air requirement in any of the
zone, the pressure at the common APH discharge is maintained constant. This
ensures that flow and control of air to one zone has no influence on the other
zone.
There is provision of Automatic fan changeover to ensure the uninterrupted flow of
combustion air to the heaters at all times. Automatic fan changeover is triggered
by the following conditions:
 Low flow of combustion air
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 Power failure on the running fan

 Running fan’s speed falls 5% below the normal speed

All the above conditions are equipped with adjustable timer delays. Fans are also
equipped with vibration detectors, which will give a high vibration alarm on the
DCS. A manual gear operated guillotine blind is also placed on the outlet of each
fan to enable positive isolation and preventive maintenance.

B. Induced draft fans:

Heater is provided with one motor driven Induced draft fan sized to operate at
56°C above the calculated Air preheater outlet temperature at 125% of design
flow condition with 156% of the pressure differential, when the heater is being
fired at 25% excess air with the air preheater on line. The damper at the inlet of
the ID fan and the stack damper in split range, control firebox pressure. The Fan is
mechanically designed to operate at maximum temperature of 260 °C. High
temperature at the suction of ID fan causes the fan to shut down and stack
damper to open so that the flue gases are bypassed around APH & routed directly
to atmosphere. Stack height is sufficient to produce a draft of 3 mm of H2O at the
top of radiant section without ID fans in operation, & the heater operating at
130% of design case duty with 25% excess air at an ambient temperature of 41
(air pre-heater bypassed).
Main features of ID and FD fans of crude and vacuum heaters are listed
below:

Sr. Item Crude Heater Vacuum Heater

No.
Forced Induced Forced Induced
draft fan draft fan draft fan draft fan
1 Normal Flow (Kg/H) 164628 174190 55872 57941
2 Design Flow (Kg/H) 189288 217728 64260 72360
3 Design Temperature- Ambient 187 / 243 Ambient 194
normal/design (°C )
4 Static Pressure-
normal/design 424 / 512 202 / 311 375 / 504 215 / 331
(mmH2O)

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Sr. Item Crude Heater Vacuum Heater

No.
Forced Induced Forced Induced
draft fan draft fan draft fan draft fan
5 Absorbed Power- 200 / 304 192 / 375 67 / 102 68 / 132
normal/design (KW)
Forced Induced Forced Induced
draft draft motor draft draft motor
motor motor
1 Power (KW) 400 170
450 132
2 Voltage (V) 6600 6600
6600 415
3 RPM
1486 980
1480 1480

C. Steam / Air Pre-heater:

Steam air preheater is designed for preheating the combustion air from minimum
of 10°C(winterizing temperature) to 82°C (for 311/312-F02) and to 102°C (for
311/312-F01/F51) using LP steam on the tube side. It is provided with two inlet
steam headers with isolation valves to allow half of the exchanger surface to be
taken out of service. This will prevent overheating of the combustion air at steam /
air pre- heater exit, which may lead to lower heat recovery and high flue gas exit
temperature in the combustion air preheater. A 500-mm by 500-mm access
opening is provided to the steam coil for inspection and cleaning.

D. Combustion air preheater:

The air preheat system is designed to prevent acid condensation. The calculated
acid dew point is 135°C. The preferred minimum air preheater metal temperature
is 14°C above the acid dew point resulting in a minimum metal temperature of
149°C. Flue gases should exit the combustion air preheater at least 42°C above
acid dew point. Three skin thermocouples are provided on the flue gas side near
the combustion air inlet to measure the metal surface temperature. High
temperatures at the inlet of combustion air preheater causes the shut down of the
heater by tripping the fuel block valves. Two nos. 3” water wash connections are
provided in the top of the Air preheater to clean the Air preheater. The wash
system shall include a pipe grid with spray nozzles at the air preheat flue gas inlet.

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A cold air bypass around the air preheater is provided to control the stack
temperature during normal, design or turndown operation.

The heat exchange surface in the preheater consists of cast-iron BY-CAST tubes of
two types - HT (High Temperature) and LT (Low Temperature), with tube length
of 2154mm. The cast-iron HT tubes have integral fins on the inside (air) and
outside (flue gas) surfaces. The cast iron LT tubes have integral fins on the outside
(flue gas) surface and are smooth on the inside (air) surface. The cast iron HT/LT
and the LT tubes are assembled in 4 superimposed blocks with the axis of the tube
horizontal. Flue gas enters at the top of the warmest block (HT upper block) and
flows vertically down over the outside of the HT tubes in series and leaves the
preheater at the bottom of the coldest block (LT lower block). Air enters the
preheater on one side of the lower block (coldest block) and flows horizontally
through the LT tubes (first pass). On leaving the LT tubes the air is returned
through 180 degrees and flows horizontally through the HT/LT tubes of the
intermediate block (second pass). On leaving the HT tubes the air is returned
through 180 degrees and flows horizontally through the HT tubes of the
intermediate block (third pass). On leaving this block the air is returned through
180° and flows horizontally through the HT tubes of the upper block (warmest
block, fourth pass). Then the air leaves the preheater on the same side as the air
inlet side.
Main features of steam air preheaters and combustion air preheaters of
crude and vacuum heaters are listed below:
Sr. Item Crude Heater Vacuum Heater
No.
Steam air Combustion Steam air Combustion
preheaterair preheater preheater air
preheater
Air Steam Air Flue Air Stea Air Flue
gas m gas
1 Flow 16133 - 161336 17419 53665 - 53665 57941
Entering(Kg/H) 6 0
2 Bypass 3292 - 3292 - 1095 - 1095
quantity(Kg/h)
3 Temperature 10 177 115 311 10 177 91 391
entering (°C )
4 Temperature 115 141 258 187 91 141 355.2 187
leaving (°C )
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Sr. Item Crude Heater Vacuum Heater

No.
Steam air Combustion Steam air Combustion
preheater air preheater preheater air
preheater
Air Steam Air Flue Air Stea Air Flue
gas m gas
5 Mix Air 113 - 253 - 87 - 349 -
Temperature(°C
)
6 Allowable 50 - 140 140 50 - 150 150
pressure drop
(mmH2O)
7 Heat exchanged 4.11 5.67 1.056 3.544
(MMKcal/H)
8 Guaranteed fuel
efficiency with
APH @ 25% 93.8 92.8
exess air & fuel
oil firing
9 Guaranteed fuel
efficiency with
APH bypassed 86 78
@ 25% excess
air & fuel oil
firing
10 Minimum
allowable flue 187
gas
temperature (°C
)
E. Refractory & Refractory Anchors:

Heater Floor is lined with 200 mm thick insulating concrete LHV 1-2-4 (It is
obtained by mixing Luminite (cement) and Haydite and Vermiculate in the ratio of
1:2:4 respectively.) and 65 mm heavy duty fire bricks.

Shielded vertical walls are lined with 75 mm thick insulating concrete LHV 1-2-4
and 75 mm thick LHV 1-0-6. Refractory material will be fixed on the wall by means
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of 18/8 CrNi anchors (Y stud type).

Arch zone is lined with 75 mm thick insulating concrete LHV 1-2-4 and 100 mm
thick LHV 1-0-6. Refractory material will be fixed on the wall by means of 18/8
CrNi anchor (Y stud type).

Convection walls are lined with 75 mm thick insulating concrete LHV 1-2-4 and 50
mm thick LHV 1-0-6 Refractory material will be fixed on the wall by means of 18/8
CrNi and Carbon steel anchor (Y stud type).

Breaching zone is lined with 125 mm thick insulating concrete LHV 1-2-4.
Refractory material will be fixed on the wall by means of Carbon stee1 anchor (V
stud type).

Flue gas ducting from the heater stack to APH inlet and ID fan discharge to heater
stack is lined with 125 mm thick insulating refractory material fixed by Carbon
steel anchor (V stud type). Ducting from APH to ID fan is externally insulated with
75 mm thick mineral wool with Al cladding.

Combustion air ducting from Steam APH to combustion APH is externally insulated
with 75 mm thick mineral wool with Al cladding. APH and venturi are lined with 50
mm thick mineral wool with Al cladding. Ducting from venturi to burners is lined
with 50 mm thick LHV 1-2-4.

Stack is lined with 50 mm thick insulating concrete LHV 1-2-4. Refractory material
will be fixed by Carbon steel anchor (V stud type).
F. Flue gas Analyzers:

 OXYGEN ANALYZER:
THE ELECTROCHEMICAL CELL

The Working element of the gas sensor is a closed-end tube made of a ceramic
oxide, Zirconium Oxide (Zirconia). When it is hot, it becomes a conductor of
electricity because of the mobility of the oxygen ions in its crystal structure.

Cell Output:

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When the sensing cell is hot, a voltage is produced that is logarithmically

proportional to the ratio of the oxygen concentration of the gas on the reference
side of the cell (usually ambient air) and the oxygen concentration of the sample.
The percent oxygen value will appear on the microprocessor control display. The
sensing cell is a partial pressure device and responds directly to changes in sample
partial pressure.

When the two electrode coatings are in contact with gases (at the same nominal
pressure) that have different levels of oxygen concentration (or different partial
pressure), a voltage is produced that is dependent upon their ratio. If the oxygen
in one gas is known (the reference gas is normally air- 20.9% 02), the oxygen of
the other is indicated directly by the voltage from the cell.

CO Analyzer:

The Combustibles Detector is a dual element device; the element differs only in
that one is coated with a catalyst. The catalyst causes oxidation to occur at lower
than normal temperature. The temperature of the catalyzed element changes as
the combustible mixture burns. The temperature change causes the resistance of
the catalyzed element to change. The resistance is interpreted by the
microprocessor and the corresponding combustibles reading is displayed.

The Thermox catalytic combustibles detector will detect combustible gas present in
a sample. The sample must, however, contain enough oxygen to fully burn the
combustible present. The combustible responds to all unburned combustibles
gases. This includes gases such as CO and H2. The analyser is calibrated for CO
only.
11.3.2.3 BURNERS:
There are 28 dual fired burners in crude heater (10 in the case of vacuum heater).
The burners are supplied by John Zink - Model no. PSFRC – 20.
Main features of burners in crude and vacuum heaters are listed below:
Specification of fuel gas

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Sr. Item Normal –mole % Max –mole %

No.
1 Hydrogen 16.86 31.41
2 Methane 40.15 30.92
3 Ethane 20.4 22.56
4 C3+ 2.76 3.11
5 Other 19.83 12
6 LHV (Kcal/kg) 10673 11846
7 Molecular weight 19.66 17.39
8 Available pressure at burner kg/cm2g) 1.4
9 Available temperature at burner (°C ) 38
Specification of fuel oil

Sr. Item Value

No.
1 LHV (Kcal/kg) 9681
2 HHV (Kcal/kg) 10329
3 Specific Gravity (API) 13.3
4 Available pressure at burner 7.5
(kg/cm2g)
5 H/C wt. Fraction 0.1288
6 Viscosity at burner, (CP) 40.5
7 Sulfur content (wt%) 1.3
8 Nitrogen content (wtppm) 625.6
9 Nickel content (wtppm) 4.33
10 Vanadium content (wtppm) 10.46
11 Sodium content (wtppm) 17.14
12 Copper (wtppm) 0.65
13 Iron (wtppm) 3.06
14 Water (wt%) 0.03
15 Ash content (wtppm) 0.01
16 Atomising steam temp. at burner (°C ) 200
17 Atomising steam press. at burner 10
(kg/cm2g)

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Sr.
Item Crude Heater Vacuum Heater
No.
1 Location Floor
2 Number 2 x 14 10
3 Make of burners JOHN ZINK
4 Burner type Low NOx, Forced draft, Round flame
5 Heat release/burner-main (MMKcal/h) 3.871 (max) 3.605 (max)
6 Fuel type FO/FG
7 Excess air ( %) FO / FG 25 / 15
8 Allowable press. drop (mmwc) 130
9 Draught at burner level (mmwc) -18
Air temperature to burner- with APH
10 251 324
(°C )
NOX emission allowable
11 600 (FO) / 200(FG)
(mg/Nm3 dry, 3% O2)
CO emission allowable
12 150
(mg/Nm3 dry, 3% O2)
13 Allowable flame length (m) 12.6 11.5
14 Burner circle dia. (m) 5.9 4.89
15 Fuel gas consumption (TPH) 7.018 2.822
16 Fuel oil consumption (TPH) 7.666 (NNF) 3.083 (NNF)
17 Waste gas consumption (Kg/h) 20.93 -
18 Pilot type Fuel gas self inspirating type
19 Heat release/burner-pilot (Kcal/h) 25000
20 Igniter type Fixed electric
21 Flame detector type
Pilot Ionization detector
Main flame IR detector
22 Chamber temperature (°C ) 812 774

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1 Available pressure at burner 7.5

(kg/cm2g)
2 H/C wt. Fraction 0.1288
3 Viscosity at burner, (CP) 40.5
4 Sulfur content (wt%) 1.3
5 Nitrogen content (wtppm) 625.6
6 Nickel content (wtppm) 4.33
7 Vanadium content (wtppm) 10.46
11 Sodium content (wtppm) 17.14
12 Copper (wtppm) 0.65
13 Iron (wtppm) 3.06
14 Water (wt%) 0.03
15 Ash content (wtppm) 0.01
16 Atomising steam temp. at burner (°C ) 200
17 Atomising steam press. at burner 10
(kg/cm2g)

11.3.2.4 FUEL AND STEAM SYSTEMS

Fuel and steam systems in crude and vacuum heaters are explained in detail
below. Note that the Tag numbers mentioned in the description are of crude
heater 311/312-F01. For Tag numbers relevant to 311/312-F51 and vacuum
heater 311/312-F02 refer P&ID’s.

A. Pilot Gas:

Source: The pilot gas enters the crude unit through a 3” insulated steam traced
header provided with a single isolation valve, pressure and temperature gauges at
battery limit. Flow transmitter FT 234 measures and records the flow of pilot gas.
PFG pressure and temperature at battery limit are 3.9 kg/cm2g and 38 °C . Pilot
gas enters the pilot fuel gas KO drum RD311/312-V28 where condensables in the
line are separated and collected. The pilot fuel gas KOD is equipped with a
demister pad.

The level in the KO drum is indicated by LI-088. The condensabales are drained
periodically through a 2” line at the bottom, to oily sewer or to LP flare by
monitoring level in gauge glass. The vessel is safe guarded against excess
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pressure by two pressure safety valves PSV 148A/B (set pressure of 6.5 kg/cm2),
discharge of which is connected to LP flare. Pilot gas from top of KO drum enters a
3” main header from where it is further distributed to vacuum heater 311/312-F02,
and zone 1&2 of crude heaters 311/312-F01/51 through 2” insulated steam traced
lines.

Description : Pilot gas comes to crude heater in a 1 1/2” insulated steam traced
line and passes through two strainers connected in parallel. The down stream
pressure is controlled by a self regulating pressure control valve PCV-018 .
Pressure at upstream and down stream of PCV can be measured by local PGs.
There are two tight-shut-off valves (TSO’s) numbered XV-003 and XV-067 located
downstream of PCV. XV-003 is actuated by signals from ESD and BMS while XV-
067 is actuated by signal from BMS. In fail closed condition of the two TSO’s, vent
valve XV-066 located on bleed line between the two TSO’s is actuated
simultaneously by BMS, and FG trapped between the above two TSP’s is
depressurised by venting .

The fail close/ fail open operation is achieved by means of a three-way solenoid
valve. On receiving signal from BMS/ESD instrument air is bleed to atmosphere
causing the instrument air supply to be cut off to the XV. Pressure transmitters PT-
017A/B and PT-442 located downstream of TSO’s measure the pilot gas pressure.
PT-017A/B send signals to ESD, which is activated in the event of pilot gas
pressure falling below 0.35 kg/cm2g. PT-442 sends signals to BMS for pressure
holding leak test.

The pilot gas header to crude heater then connects to a 1 1/2” ring header. From
top of the ring header 3/4” insulated lines are tapped off for each pilot burner.
Each line has two ball valves. Downstream of ball valves is an eductor in which FG
flowing in the line inspirates the air required for combustion.

B. Fuel gas:

Source: Fuel gas enters the crude unit through a 10” insulated steam traced line
provided with a single isolation valve, pressure and temperature gauges at battery
limit. Flow transmitter FT 251 measures and records the total flow of fuel gas to
the crude unit. FG pressure and temperature at battery limit are 3.9 kg/cm2g and
38 °C . Fuel gas to the fired heaters comes through the Fuel Gas Knock out drum
311/312-V15 where condensables in the line are separated and collected. The FG
KOD is provided with a demister pad. The level in the K.O drum is indicated by LI-

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Crude Complex Refinery Division Crude Distillers
Jamnagar

016. The condensabales are drained periodically through a 3” line at the bottom to
oily sewer or to LP flare by monitoring level in gauge glass. The vessel is safe
guarded against excess pressure by two pressure safety valves PSV 136A/B ( set
pressure of 6.5 kg/cm2) , discharge of which is connected to LP flare. Fuel gas
from top of KO drum enters a 10” main header from where it is further distributed
to vacuum heater 311/312-F02, and zone 1&2 crude heaters 311/312-F01/51
through 4” insulated steam traced lines.

Description: Fuel gas comes to crude heater in a 4” insulated steam-traced line.

The flow of fuel gas to the heater is measured and transmitted by FT 052. The fuel
gas pressure is controlled by pressure control valve PV-015. Pressure transmitter
PT 015 located downstream of PV measures and transmits the fuel gas pressure to
the DCS. There are two tight-shut-off valves (TSO’s) numbered XV-002 and XV-
069 located downstream of PV 015. XV-002 is actuated by signals from ESD and
BMS while XV-069 is actuated by signal from BMS. In fail closed condition of the
two TSO’s, vent valve XV-068 located on a bleed line between the two TSO’s is
actuated simultaneously by BMS, and FG trapped between the above two TSO’s is
depressurised by venting. Pressure transmitters PT-016A/B and PT-443 measure
the fuel gas pressure. PT-016A/B send signals to ESD, which is activated in the
event of fuel gas pressure falling below 0.062 kg/cm2g. PT-443 sends signals to
BMS for pressure holding leak test.
The FG header for Crude heater then joins a 4” ring header. From top of the ring
header 2” insulated lines are tapped off for each main gas burner. Each line has
two ball valves such that they are operable from the sight doors on the platform.
C. Fuel oil:

Source: Fuel oil enters the crude heater through a 4” insulated FO supply header
which is provided with local temperature and pressure gauges to measure
temperature and pressure at battery limit. Flow transmitter/recorder FT/FR -253
measure and record the flow of fuel oil to the unit. FO supply pressure and
temperature at battery limit are 11 kg/cm2g and 120 °C. From the main supply
header the fuel oil is distributed through three nos. 2” lines to vacuum heater
311/312-F02, and zone 1&2 of crude heaters 311/312-F51/F01. Supply header is
connected to the return header through a 1” line having a return orifice FO-254.
Return header is a 2” line and receives fuel oil from individual return headers of all
heaters. There is a provision to steam out the supply and return headers. The
temperature and pressure of return fuel oil is measured by local temperature and
pressure gauges. Flow of return fuel oil is measured and recorded by flow
transmitter/recorder FT/FR -253 at the battery limit.
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Jamnagar

Description: Fuel oil comes to crude heater in a 2” insulated steam traced line.
The flow of fuel oil to the heater is measured and transmitted by FT-049. The fuel
oil pressure is controlled by pressure control valve PV-014. Pressure transmitter PT
014 located downstream of PV-014 measures and transmits the fuel oil pressure to
the DCS. Pressure differential transmitter PDT 094 measures and transmits the
differential pressure between fuel oil and atomizing steam to the pressure
differential valve PDV 094 located on the atomizing steam line. PDT 096A/B
transmits the differential pressure to the ESD, which is activated at a low value of
differential pressure. There are two tight-shut-off valves (TSO’s) numbered XV-020
and XV-070. XV-020 is actuated by signals from ESD and BMS while XV-070 is
actuated by signal from BMS. Pressure transmitters PT-350A/B measure the fuel oil
pressure, which send signals to ESD. ESD is activated in the event of fuel oil
pressure falling below 2.6 kg/cm2g. The temperature of fuel oil can be read from
local temperature gauge located downstream of TSO’s. From the supply header
3/4” insulated lines are tapped off for each main burner. Each line has two
isolation valves. At the downstream of the second isolation valve a cross over
steam connection is provided. Crossover steam is used to steam out the fuel oil
line to the burner, during its startup or shutdown. The fuel oil return line is of 1”
and has a globe valve, a non-return valve, and a TSO numbered XV 021 actuated
by signal from ESD.

D. Atomizing steam:

Source (MP steam): Steam for FO atomizing, soot blowing, emergency steam to
passes & steam air de-coking, required in the crude and vacuum heaters is taken
from MP steam header. MP steam enters the crude battery limit in a 16” insulated
header. There are local temperature and pressure gauges to measure temperature
and pressure at battery limit. Pressure and temperature at battery limit are 16
kg/cm2g and 232 °C. Flow
transmitter FT/FR-235 measures and records the flow of MP steam to the unit. MP
steam to the crude heaters F01 & F51 is supplied through a 12” sub header from
where steam is further distributed to zone 1&2 for atomizing (3” line), soot
blowing (4” line), emergency steam to passes (6” line), de-coking (6” line). MP
steam to the vacuum heater F02 is supplied through a 14” sub header from where
it is further distributed for atomizing (3” line), soot blowing (4” line), emergency
steam to passes (6” line) , de-coking (6” line), process steam (3” line)
Description: Atomizing steam comes to the crude heater in a 2” insulated line.
Atomizing steam pressure is controlled by pressure differential control valve PDV

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094, which maintains the atomizing steam pressure above the fuel oil pressure by
a set value (1.5 kg/cm2). Pressure differential transmitter PDT 094 measures and
transmits the differential pressure between fuel oil and atomizing steam to PDV
094. Steam traps are located upstream and downstream of PDV to continuously
discharge the condensate collected in the lines. PDT 096A/B transmits the
differential pressure to the ESD, which is activated at a low, value (0.5 kg/cm2) of
differential pressure. The header then connects to a 2” ring header. From top of
the ring header 3/4” insulated lines are tapped off for each main burner. Each line
has a isolation valve, NRV, a tapping for crossover steam followed by another
isolation valve. During startup and shutdown of the burner there is a provision for
draining the condensate from individual lines, through a 3/4” drain valve.

11.3.2.5 Special control loops:

A. Lead lag control:

In the normal operation of heater, the heat duty of the heater varies due changes
in process conditions or changes in the feed rate / feed type. The heat input to the
heater varies in accordance with the required coil outlet temperature. The heat
input to heater can be changed by either increasing or decreasing fuel flow to the
burners. While doing so it has to be ensured that sufficient excess air is always
available for complete combustion of fuel fired. To achieve this, whenever heater
duty has to be increased the flow of combustion air should be increased prior to
increasing the flow of fuel to the burners. Conversely when the duty has to be
reduced the fuel flow to the burners should be decreased prior to decreasing the
combustion airflow. In other words combustion air leads fuel in the case of
increase in firing requirement and lags the fuel in case of decrease in firing
requirement. Hence such a control is called “Lead –Lag” control. Such lead-lag
automatic control is possible only in case of balanced draft heaters where air
intake can be finely controlled and measured. With lead lag control, heaters can
operate with optimum excess air, which ensures that no unburned fuel is escaping
through the stack and hence enhanced safety, pollution control and maximum
thermal efficiency. If no unburnt fuel is left, then the chances of after burning in
the stack (in case of ingress of air) is considerably reduced. If the combustion air
is more than required for complete combustion, then the efficiency of heater
comes down as extra fuel is fired to heat the combustion air upto the flue gas
temperature.
Complete combustion of fuel is accomplished by introducing a low signal selector,
a high signal selector and a ratio-biased controller in to the system between the
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overall master i.e. the temperature controller and the final slaves i.e. the fuel oil /
fuel gas pressure and the combustion airflow controllers.
THE MAJOR ELEMENTS OF THE LOOP ARE SHOWN IN THE ATTACHED SKETCH AND EXPLAINED
BELOW:

1. FUEL TO AIR RATIO CONTROLLER - This instrument generates an output

which represents the amount of combustion air flowing to the heater corrected
for the amount of excess air which is required. The output signal goes to the
combustion air controller. When the instrument is in the remote mode it will
calculate the ratio of fuel and air currently being delivered to the heater.

2. COMBUSTION AIR CONTROLLER – This controls the flow of air into the heater.
The input to this controller is the output of the ratio / bias unit (Fuel to air ratio
controller). The output goes to the combustion air damper actuator. The set-
point for this controller comes from either the temperature controller (in the
case of increasing demand) or the total fuel controller (in case of decreasing
demand) via the high signal selector.

3. HIGH SIGNAL CONTROLLER – This takes the output of the temperature

controller and the process variable of the total fuel controller, compares them
and passes the higher of the two signals to be the set point for the combustion
air controller. This ensures that excess air is always available and that the
combustion air controller is taking the signal, which results in the highest
demand for combustion air.

4. FUEL OIL PRESSURE CONTROLLER – This controls the fuel oil pressure and
therefore the fuel oil flow. A pressure controller is used because the burners
are designed to operate with fuel oil pressure between 3 and 7 kg/cm2.
Pressure controller allows to set a limit on the set point so that operation is
within the allowable range of the burners. While in cascaded operation the set
point of these controllers will not go below 3kg/cm2. The set point comes from
the total fuel controller.

5. TOTAL FUEL CONTROLLER – This is a calculating as well as a controlling block.

First it calculates the total heating value of the fuels flowing into the heater (by
multiplying each of the flows by the design heating value and adding them
together). The set point of this controller comes from either the temperature
controller in the case of decreasing demand or the fuel / oil ratio bias unit in
the case of increasing demand via the low signal selector. A total fuel
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consumption process variable is used as one of the input signals for the high
selector.

6. LOW SIGNAL SELECTOR - This compares the output of the temperature

controller and the combustion air consumption and passes the lower of the two
signals as the set point for the total fuel controller. This ensures that excess air
is always available as the total fuel controller is working from the lower signal.

7. TRANSFER LINE TEMPERATURE CONTROLLER – This is the overall master of

the heater control scheme. The output of this controller will be set point for
either the total fuel controller or the combustion air controller depending on the
condition of the high and low signal selectors. In the case of need to increase
the temperature the output will be the set point of the combustion airflow
controller. When the temperature needs to be reduced the output of this
controller will be the set point of the total fuel controller.

B. Burner Management System

Burner management system (BMS) is a sequential logical program for safe start up
of fired heaters. The different logic steps carried out by the BMS are explained
below. Steps shown in ‘Bold’ require manual intervention, except for which all the
actions shall be automatic.
i) Leak Test

Sr. ACTIVITY IF " NO "

no.
1 Press push button " SYSTEM START "
2 Checks whether all Block / Bleed Valves are Goes back to heater stop
in Position
3 Lamp "LEAK TEST IN PROGRESS" Flashes
Closes Pilot bleed valve
Closes Main gas bleed valve
4 Checks if Pilot bleed valve has closed Lamp “PILOT VALVE
DISCREPANCY" Flashes
Press PB "RESET BMS"
5 Checks if Main gas bleed valve has closed Lamp “MAIN GAS VALVE
DISCREPANCY" Flashes
Press PB "RESET BMS"

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Sr. ACTIVITY IF " NO "

no.
6 Opens Pilot block valves
Opens Main gas block valves
7 Checks if Pilot block valves have opened Lamp “PILOT VALVE
DISCREPANCY" Flashes
8 Lamp “PILOT VALVE ENERGIZED" On
9 Checks if Main gas block valves have Lamp “MAIN GAS VALVE
opened DISCREPANCY" Flashes
10 Lamp “MAIN GAS VALVE ENERGISED" On
11 Starts timer X1
12 Checks if Pilot line press. > Po (At the end Lamp “PILOT GAS
of timer) PRESSURIZATION
FAILURE" On + Valves are
reset
Press PB "RESET BMS"
13 Checks if Main gas line press. > Po Lamp “MAIN GAS
PRESSURIZATION
FAILURE" On + Valves are
reset
Press PB "RESET BMS"
14 Closes Pilot block valves
Closes Main gas block valves
Opens Pilot & Main gas bleed valves
15 Lamp “PILOT VALVE ENERGISED" Off
Lamp “MAIN GAS VALVE ENERGISED" Off
16 Starts timer X2
17 Checks if Pilot line press. > Pl (At the end of Lamp “PILOT LEAK TEST
timer) FAILED" On
Lamp “LEAK TEST IN
PROGRESS" Off
Press PB "RESET BMS"
18 Checks if Main gas line press. > Pl Lamp “ MAIN GAS LEAK TEST
FAILED" On
"LEAK TEST IN PROGRESS" Off
Press PB "RESET BMS"

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Sr. ACTIVITY IF " NO "

no.
19 Opens second Block valves on Pilot and
Main gas lines for 5 sec.
20 Lamp “LEAK TEST COMPLETE" On
Lamp “READY FOR PURGE" On
ii) Fire Box Purging
Sr. ACTIVITY IF " NO "
no
.
1 Press push button " PURGE START "
2 BMS sends a signal to DCS and confirms.
Lamp “READY FOR PURGE" Off
3 Checks for a permissive signal from DCS Waits for permissive signal
4 Lamp “PURGING IN PROGRESS" Flashing
5 Starts timer X3
6 Checks if air flow > Fo Lamp “PURGING IN PROGRESS"
Off
Resets timer X3
Lamp “READY FOR PURGE" On
7 Checks if time is complete Goes to 6 ( continues purging)
8 Lamp “PURGING COMPLETE" On

iii) Pilot light up

Sr. ACTIVITY IF " NO "

no
.
1 Press push button " PILOT START "
2 Checks if Pilot ESD signal is healthy goes back to 1
3 BMS sends a signal to DCS and indicates
to adjust the airflow to min.
4 Closes Pilot bleed valve

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Sr. ACTIVITY IF " NO "

no
.
5 Checks if Pilot bleed valve has closed Lamp “PILOT VALVE
DISCREPENCY" Flashes
Press PB "PILOT START" OR
Press PB "RESET BMS"
6 Opens Pilot block valves
7 Checks if Pilot block valves have opened Lamp “PILOT VALVE
DISCREPENCY" Flashes
Press PB "PILOT START" OR
Press PB "RESET BMS"
8 Starts timer X4= 30 min.s
Lamp “PILOT VALVE ENERGISED" On
9 Operator to open individual pilot isolation
Valve on all burners and press
corresponding. igniter PB's
10 Checks if igniter X PB is activated Goes to 14
11 Igniter X is energized during 10 sec.
12 Checks for flame on burner X at the end of Goes to 14
10 sec.
13 Lamp “PILOT FLAME X" on
14 Checks for end of timer Checks if all "n" no pilots are lit
(if no: goes to 10 and continues)
if yes: goes to 16
15 Checks if N = n - 3 pilots are lit Block valves are closed
Bleed valve is opened
All individual pilot lamps are
switched off
16 Pilot light off is over Goes to " PURGING "
17 Press PB "MAIN GAS/FUEL OIL BURNER
START"

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Sr. ACTIVITY IF " NO "

no
.
18 Checks for activation of fuel oil PB Checks for activation of main
gas PB
(if no: Goes to 17)
Checks if main gas ESD signal
is healthy
(if no:Oper. to check: Goes to
17)
Goes to Main gas firing
19 Checks if fuel oil ESD signal is healthy Operator to check; Goes to 17
20 Goes to Fuel oil firing

iv) Main gas Burner light up

Sr. ACTIVITY IF " NO "

no
.
1 Closes Main gas bleed valve
2 Checks if Main gas bleed valve has closed Lamp “MAIN GAS VALVE
DISCREPENCY" Flashes
Press PB "MAIN GAS
BURNER START"
OR Press PB "RESET BMS"
3 Opens Main gas block valves
4 Checks if Main gas block valves have Lamp “MAIN GAS VALVE
opened DISCREPENCY" Flashes
Press PB "MAIN GAS
BURNER START" OR Press
PB "RESET BMS"
5 Lamp “MAIN GAS VALVE ENERGISED" On
6 Operator to open individual main gas
isolation
Valve on each burner

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Sr. ACTIVITY IF " NO "

no
.
7 Press PB "HEATER IN NORMAL
OPERATION " OR Press PB "FUEL OIL
BURNER START "
8 Checks for activation of normal operation Checks for activation of fuel oil
PB PB
(if no: Goes to 8)
Checks if fuel oil ESD signal
is healthy
(if no:Operator to check: Goes
to 8)
Goes to Fuel oil firing
9 Lamp “HEATER IN NORMAL OPERATION
"On
10 End of light off sequence

v) Fuel oil burner light up

Sr. ACTIVITY IF " NO "

no
.
1 Opens fuel oil Supply and return valves
2 Checks if block valves have opened Lamp"FUEL OIL VALVES
DISCRIPENCY" Flashes
3 Starts timer X6 .At the end of timer closes
return valve.
4 Lamp "FUEL OIL VALVES ENERGISED" On
5 Operator to open individual atomizing
steam / fuel oil isolation valves on each
burner
6 Press PB "HEATER IN NORMAL
OPERATION " OR Press PB "MAIN GAS
BURNER START "

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Sr. ACTIVITY IF " NO "

no
.
9 Checks for activation of normal operation Checks for activation of main
PB gas PB
(if no: Goes to 9)
Checks if main gas ESD signal
Is healthy
(if no: Oper. to check: Goes to
9)
Goes to main gas firing
10 Lamp "HEATER IN NORMAL OPERATION
"On
11 End of light off sequence
NOTE :
1) For startup and shut down procedures of the heater refer SOP’s
2) For emergency shut down, trip and interlocks of heaters refer chapter 15
3) For normal operating parameters refer chapter 5

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11.4 COLUMNS AND VESSELS

FLASH DRUM (V-04)

The flash drum is a vertical vessel constructed of carbon steel with level indication
and control covering approximately 75% of the vessel height. The vessel has a
diameter of 9600 mm and a height of 10400 mm. The whole vessel is heat
insulated.
Desalted crude after getting pre-heated to 192 oC in two symmetrical heat
exchanger trains is flashed in flash drum at approx. 4.9 kg/cm2g pressure where
water and light ends in the crude oil are flashed - off. The purpose of flash drum is
to lower the design pressure of the crude pre-heat exchanger trains down stream
of the desalter and reduce pressure drop across control valves, crude heaters, and
transfer line piping. In addition to this it reduces the heat duty of crude charge
heaters.
Flashed drum vapors are routed to crude column flash zone via control valve PV-
002. The backpressure controller PIC-002 controls the pressure of the flash drum.
Flashed crude is pumped by using P04 A/B/C, equally split and further pre-heated
in two symmetrical heat exchanger trains before entering crude heaters F-01 and
F-51. The pump discharge has two flow controllers, FIC-116 and FIC-117 for safe
guarding the pumps by ensuring minimum required flow.
Desalted crude enters the flash drum through FV-021 and FV-022. Flow controller
FIC-021 and FIC-022 control the flow of desalted crude to flash drum. The level
controller LIC-005 controls the flash drum level & cascaded the above flow
controllers. Upstream of FV-021 and FV-022 there are two sets of PSV-125A/B and
PSV-126A/B, which are set at 42.1- kg/cm2g pressure. Discharges of these PSV are
routed to flash drum through separate nozzles.
Two safety valves PSV-127 A/B set at 7.1 kg/cm2g protect the vessel against
overpressure. Discharge of these PSVs is routed through flashed vapor line to
crude column flash zone.

CRUDE COLUMN (C-05)

The crude column is constructed of killed carbon steel. The top section of the
column where possibilities of condensation of acidic solution are unavoidable is
lined with Monel (i.e. the section just above the circulating kerosene reflux return
to the top column including the top head is cladded with Monel). The top 4 trays in
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this section are also made of Monel. The other tray material is SS410. The bottom
section (i.e. from bottom of the column up to circulating diesel reflux line) of the
column is lined with SS410.
The crude column has a diameter of 9600 mm and height of 62700 mm. It
contains 49 multi -pass valve trays. Side draw-off is taken from chimney trays.
Tray 44 to 49 is replaced with packing 250Y Mellepack. There is a vortex breaker
in the bottom of the column to avoid vortex formation. 12 number of pilot
operated safety valves are located in the top vapor line to safe guard the column
against overpressure. All are set at 3.5- kg/cm2 pressure. There are nine
manways. New nozzle made in flash zone through which flash drum vapor from
PV-002 downstream enter to flash zone.
The following tray spacing apply to the crude column upper section.
Trays 1 – 3 2 spaces * 750 mm
Trays 3 - 4 1 space * 4900 mm
Trays 4 - 14 10 spaces * 650 mm
Trays 14 - 16 2 spaces * 4200 mm
Trays 16 - 23 8 spaces * 600 mm
Trays 23 - 24 1 space * 1400 mm
Trays 24 - 26 2 spaces * 750 mm
Trays 26 - 27 1 space * 3800 mm
Trays 27 - 31 4 spaces * 600 mm
The following tray spacing apply to the crude column bottom section
Trays 31 - 32 1 space * 1500 mm
Trays 32 - 34 2 spaces * 750 mm
Trays 34 - 35 1 space * 3400 mm
Trays 35 - 40 5 spaces * 600 mm
Trays 40 - 41 1 space * 1500 mm
Trays 41 - 43 2 spaces * 750 mm
Trays 43 - 44 1 space * 4300 mm
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Trays 44 - 45 1 spaces *5600 mm

Trays 45 – 49 4 spaces *600 mm

There is a top vent with a valve of 4" size located on the top manway. The whole
column is heat insulated

SIDE CUT STRIPPERS

The purpose of the side cut stripper is to allow the liquid from that section of
column to be stripped, removing the light ends from the liquid and returning
vapours of the light material to the main column to control the flash of that
particular product. The removal of light ends is accomplished with either a reboiler
action or steam stripping. HAGO and diesel strippers are steam stripped and heavy
kerosene, light kerosene stripper are stripped by reboiler action.

A) HAGO STRIPPER (C-06)

The HAGO stripper is constructed of carbon steel. The column has a diameter of
1200 mm and height of 7900 mm. There are 6 nos. of shell HI-FI trays. The tray
material is SS-410S. In the bottom of the column there is a vortex breaker to avoid
vortex formation. The whole column is heat insulated.
B) DIESEL STRIPPER (C-08)
The Diesel stripper is constructed of carbon steel. The column has a diameter of
2900 mm and height of 8550 mm. There are 6 nos. of valve trays. The tray
material is SS-410S. There are two man way. On the top manway a 3" vent line is
connected with a valve. In the bottom of the column there is a vortex breaker to
avoid vortex formation. The whole column is heat insulated. It is located on the
top of light kerosene stripper.
C) HEAVY KEROSENE STRIPPER (C-07)
The Heavy kerosene stripper constructed of carbon steel. The column has a
diameter of 2400 mm and height of 6800 mm. There are 6 nos. of valve trays. The
tray material is SS-410S. There are two man way. On the top man way there is a
3" vent line with a valve. The whole column is heat insulated. There is a vortex
breaker to avoid vortex formation.
D) LIGHT KEROSENE STRIPPER (C-09)
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The Light kerosene stripper constructed of carbon steel. The column has a
diameter of 3200 mm and height of 6400 mm. There are 6 nos. of valve trays. The
tray material is SS-410S. There are two man way and on the top manway there is
a 3" vent line with a valve. The whole column is heat insulated. There is a vortex
breaker to avoid vortex formation.
CRUDE COLUMN RECEIVER (V-12)

The purpose of this vessel is to collect hydrocarbon (vapour and liquid) and water
mixture that is coming from crude column over head after condensing (not fully) in
overhead condenser A05. This is a horizontal vessel with a boot. New feed inlet
device Scheponteter is given during revamp. The water will collect in the boot and
is pumped from the water boot area of the receiver. Part of water is recycled back
to the crude column overhead condenser A-05 for protection against NH4CL salts
deposition at the inlet to tube bundle & the balance water is sent to waste water-
stripping unit. The hydrocarbon is pumped from the main body of the receiver
partly as a top reflux to the column & net naphtha to recontact drum (V-13) after
joining with compressed gas from C-01 discharge through A-06 condenser /
cooler. In the top of the vessel there is vapor line through which non-condensable
gases from receiver will go to compressor suction. The vessel is constructed of
carbon steel. The overhead vessel (V-12) has a diameter of 3600 mm and length
of 11100 mm. The vessel has level indicators on the water boot and hydrocarbon
section. There are two liquid outlets on the vessel, first at the bottom of the water
boot and the second on the bottom of the main body. Both outlets have a vortex
breaker installed at the outlet nozzle. On the top of the vessel there are two PSV
set at 5 kg/cm2g.

RECONTACT DRUM (V-13)

The crude column receiver gas is compressed and then rejoins the crude column
receiver net liquid. This stream is then condensed and cooled in A06 before
entering the recontact drum. This drum allows separation of the hydrocarbon and
water phases of the incoming stream and provides surge capacity for the
unstabilized naphtha pumps, which transfer the liquid hydrocarbon from the
recontact drum to the saturate gas concentration unit. New feed inlet device
Scheponteter is given during revamp.

This drum is a horizontal vessel with a water boot that has level indication and
control on both the liquid hydrocarbon in the main body and the water phase in
the boot. The vessel is constructed of carbon steel. The drum has a diameter of
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3300 mm and a height of 11300 mm. There are two liquid outlets on the vessel,
one at the bottom of the water boot and the second on the bottom of the main
body. Both outlets have a vortex breaker installed in the entrance of the outlet. On
the top of the vessel there are two PSV set at 4.4 kg/cm2g

VACUUM COLUMN (C-16)

The vacuum column has four sections of different diameter and heights. Top
section of 5900 mm diameter and 9600 mm of height, middle section of 11000
mm diameter and of 24700 mm height, bottom section of 7500 mm diameter and
of 2300 mm height. It is 36600 mm tall. There are four packed beds for three
draw off cuts. The heights of four packed beds (from top to bottom) are 2100 mm,
500mm, 1100mm and 1850 mm respectively. FLEXI GRID type structural packing
of SS-410S is used here. All draw off trays except Slopwax are chimney type and
made of SS-410S. Slopwax draw off tray is double decker chimeny tray. In the top
of the column there is a demister pad to avoid liquid carry over in the overhead
vapor. The bottom section of the column is provided with a chimney tray just
below the flash zone, six sieve trays (Tray spacing 600 mm) and a coke trap. In
the top vapor line there are five Pilot operated PSVs for safe guarding the column
against overpressure. Out of Six PSV two are set at 2.11 kg/cm2g and others are
set at 2.21 kg/cm2g. The column is made up of killed carbon steel. It is lined with
SS-410S below 2nd bed (HVGO Packed section) i.e. 27.5 m from bottom tangent
line.

EJECTOR CONDENSATE RECEIVER (V-17)

The purpose of this receiver is to separate the steam condensate and any liquid
hydrocarbon and gases that have been carried overhead. This is a horizontal
vessel. It has a diameter of 2000 mm and a height of 5500 mm. The vessel is
constructed of killed carbon steel.

EJECTOR VAPOR KNOCKOUT DRUM (V-18)

The purpose of this vessel is to remove any entrained liquid from the vapor out of
the ejector receiver. The vessel is constructed of killed carbon steel and provided
with inlet distributor and level indication. The vessel has a diameter of 600 mm

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and a height of 2400 mm. In the top of the vessel there is a demister pad to avoid
liquid entrainment in the vapor outlet.

11.5 VACUUM EJECTOR SYSTEM

11.5 .1 DESCRIPTION:

In Vacuum column overhead system, two sets of three stage ejectors are provided
to maintain the desired vacuum. MP Steam is used as a motive fluid in ejectors.
Vacuum column overhead vapor line (74”) is routed to first stage ejectors (J 01
A/B). First stage ejectors outlets are joining a common header and which is routed
to shell side of 1st stage inter condensers (S 21 A/B). Uncondensed vapors from
inter condensers (S 21 A/B) are joining a common header and then routed to
second stage ejectors (J 02 A/B). Second stage ejectors outlets are joining a
common header, which is routed to shell side of second stage inter condenser (S
22). Uncondensed vapors from inter condensers (S 22) are routed to third stage
ejectors (J 03 A/B). Third stage Ejectors (J 03 A/B) outlets are joining a common
header which is routed to shell side of after condenser (S 23). Condensate streams
from inter-condensers (S 21 A/B & S 22) and after-condensers (S23) are routed
through barometric legs to Ejector Condensate Receiver Vessel (V 17). These
barometric legs are dipped in water the ejector condensate receiver (V 17) for
sealing purposes. Uncondensed vapors from third stage ejectors (J 01 A/B) are
routed back to the suction of first stage ejectors through PIC-062 for maintaining
vacuum & the uncondensed vapors from S-23 are routed to ejector condensate
receiver (V 17).

In crude distiller unit-1 J03C and J02C are installed in parallel with J03A/B and
J02A/B during revamp shutdown.

Ejector condensate receiver vessel (V 17) is having three compartments, separated

from each other by baffles. Middle portion is for receiving condensate form S-
21A&B/S-22/S-23. The condensate is a mixed phase of hydrocarbons and water.
In the middle portion of the vessel, the condensate separates into two phases and
flows to their respective compartment. Hydrocarbons phase settled in the middle
compartment overflows to other compartment of the vessel. This compartment is
having level gauge (LG - 69) and level transmitter (LT –19). These hydrocarbons
are pumped to off-spec-header by ejector receiver hydrocarbon pump (P 22A/B ).
This pump is getting signal from LI –19 for high-level start and low-level stop.

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Condensate water from the middle compartment flows under the first baffle &
then overflows over the other baffle into the third compartment of the vessel at
the other end. This compartment is having level gauge (LG - 70) and level
transmitter (LT –18). This condensate (non-phenolic water) is pumped to waste
water-stripping unit & Unsat. Gas conc. Unit (U-414), by ejector-receiver-
condensate-pumps (P 23 A/B). Non phenolic water to waste water-stripping unit is
on water level control (LV- 18) of V-17. This stream joins boot water stream of HP
receiver (321/322-V-01) and crude column receiver water pumps stream and
routed to waste water-stripping unit. P 23 A/B is provided with spill back control
valve FV-101 to take care of minimum flow requirement of the pump.

Cooling water is the utility on tube side in inter-condensers (S 21 A/B & S 22) and
after-condensers (S23). Cooling water supply header is of 30”. This main header
splits into two lines of 20” which supply CW to S-21A and S-21 B. Cooling water
return from S 21 A is routed to main cooling water return header, while cooling
water return from S 21 B is partly routed as cooling water supply to S 22 and S 23
and balance is routed to main cooling water return header. CWRs of S 22 and S 23
are also routed to main cooling water return. Hence cooling water supply
temperature to S-21A and S- 21B is 32 oC and 41.3 oC for S -22 and S- 23. New
14” tapping is taken from 30” line which supplies CW to S22 and S-23.

MP steam supply to ejectors is provided through a steam separator (Y 10), which

removes condensate if any in the steam. The XV–94 at Y-10 outlet is getting signal
from ESD 12 to close steam supply to ejectors in case the vacuum column level
(LI-35) is high. MP Steam pressure to ejector (PT–61) is controlled by PV-
61.Down stream of PV-61, pressure transmitter PT –104 is also provided which is
passing signals to EDS-13. On control panel MP steam pressure to ejectors is
indicated by PI- 104. Individuals ejectors are having gate valves on steam supply
line. In crude distiller unit-1 provision is made to use desuperheated HP steam for
ejector.

Vacuum column overhead line is having five pilot operated PSV’s (PSV–138
A/B/C/D/E) to take care of over pressure. Four PSV’s are to be kept in line at all
times. PSV 138 B/E are set at 2.11 Kg/cm2g and PSV 138 A/C/D/F are set at 2.21
Kg/cm2g. Discharge of these PSV’s is routed to LP Flare. Future provision of
ammonia injection is provided in vacuum column overhead line.

Fuel gas backup facility (2” line) is also provided on the spill back line upstream of
PV-62.

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To maintain desired vacuum at vacuum column overhead / flash zone one spill
back line (10”) from third stage ejector discharge manifold (J-03 A/B) to suction
line of First stage ejectors (J 01 A/B) is provided through control valve PV- 62
which is getting signal from selector switch PHS 62. Selector switch (PHS 62) is
provided to select Vacuum column top pressure from transmitter PT 62 (Normal
operating pressure 20 to 25 mm Hg absolute) or Vacuum column Flash Zone
pressure from transmitter PT-70 (Normal operating pressure 35 to 40 mm Hg
absolute) whichever is desired to be controlled. Vacuum column overhead line is
having three-pressure transmitter (PT– 65 A/B/C), which send signals to ESD -12.
In case of Vacuum column pressure high high (voting: two out of three PT –65
A/B/C voting), ESD 12 gets activated and closes MP steam to ejectors by closing
XV-94.

Vapors from ejector condensate receiver (V 17) are routed to ejector vapor
knockout drum (V 18). Two PSV’s are provided on condensate receiver (V 17),
which are set at 3.5 kg/cm2g and outlets of these PSV’s are routed to LP flare.
Ejector vapor knockout drum (V 18) is provided with a demister pad to knock off
any liquid from out-going vapors. Vapors from V 18 can be routed either to Crude
heaters F-01/F-51 through XV 16 via flame -arrestor and burnt in off-gas-burners
or to LP flare through XV 18. The XV- 16 and XV -18 are getting signal from ESD
13 for diversion of these vapors to LP flare from Crude heater in case of crude
heaters trip / manual shutdown is actuated. Manual diversion switch is also
provided for diversion of these vapors to LP flare instead of Crude heater. LG-71
and LI-17 indicates liquid level of ejector vapor knockout drum (V 18). Ejector
vapor knockout drum (V 18) can be drained into Ejector blow case (V-19) by
opening isolation valve.

Ejector blow case (V-19) is intermediate receiver of condensate from V-18. The
blow case (V-19) is having two PSV’s (PSV 140 A/B) set at 6.5 Kg/cm2g. Liquid
level and pressure in V – 19 is indicated by LG–72 and PG-272. Once enough level
is built in V-19, it can be transferred to ejector condensate receiver (V 17) under
fuel gas pressure.

Individual ejectors are provided with isolation block valve on process vapor inlet
side. The isolation valves are not provided on the discharge of ejectors.

11.5.2 UTILITY REQUIREMENTS:

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As mentioned above MP steam is a motive fluid in ejectors and cooling water is

condensing medium in inter condensers and after condenser. Summary of the total
utility requirements is given herewith.

I) MP STEAM REQUIREMENT

S.N Tag No. Description MP Steam requirement

. Flow Press. Temp. oC
Tons/h Kg/cm2g
1 J 01 A First stage ejector 10.05 14.3 to 17 260
2 J 01 B First stage ejector 20.10 14.3 to 17 260
3 J 02 A Second stage 1.71 14.3 to 17 260
ejector
4 J 02 B Second stage 3.42 14.3 to 17 260
ejector
5 J 03 A Third stage ejector 1.36 14.3 to 17 260
6 J 03 B Third stage ejector 2.72 14.3 to 17 260

II) COOLING WATER REQUIREMENT

S.N Tag No. Description Cooling water requirement

Flow Press. Temp. oC
Tons/H Kg/cm2a
1 S 21 A First stage inter 1516.5 4.5 32
condenser
2 S 21 B First stage inter 1516.5 4.5 32
condenser
3 S 22 Second stage inter 363.2 3.8 41.3
condenser
4 S 23 Third stage after 225.1 3.8 41.3
condenser

11.5.3 DESIGN CONDITION:

Two sets of Vacuum Ejectors are having different capacities. Set B is having
double vapor load capacities than that of Set A. In case of Arabian Heavy Crude
processing both Sets (Set A & Set B) of ejectors are to be kept in line to get
desired vacuum. While processing Arabian Light Crude only Set B will able to meet
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the desired vacuum level. Summary of the Ejector vapors load, pressures and
temperatures is given here.

I) DESIGNED VAPOR LOAD:

S.N Tag No. Description Vapor load, Tons/H

. Non- Water-vapor Total vapor
condensa load load
ble load
1 J 01 A First stage ejector 0.563 6.186 6.749
2 J 01 B First stage ejector 1.126 12.371 13.497
3 J 02 A Second stage 0.563 0.732 1.295
ejector
4 J 02 B Second stage 1.126 1.464 2.590
ejector
5 J 03 A Third stage ejector 0.563 0.275 0.838
6 J 03 B Third stage ejector 1.126 0.549 1.675

II) DESIGNED INLET/OUT LET CONDITIONS:

S.N Tag No. Description INLET CONDITION OUTLET

. CONDITION
Press.mm, Temp. Press. mm Hg
o
Hga C a
1 J 01 A First stage ejector 20 47 103
2 J 01 B First stage ejector 20 47 103
3 J 02 A Second stage ejector 91.1 41.6 310
4 J 02 B Second stage ejector 91.1 41.6 310
5 J 03 A Third stage ejector 288 52 894
6 J 03 B Third stage ejector 288 52 894

11.5.4 START UP OF EJECTOR SYSTEM:

To take ejector system in line & get the desired vacuum, the entire
system is to be checked for it’s fitness (Refer Ejector startup SOP for
checklist), availability of the utility (Cooling water for inter-
condensers and after condensers and MP steam for Ejector) and
Power (For P 22 and P 23 A/B) is to be ensured. All PSV’s should be in
line (PSV-139 A/B, PSV-138 A/B/C/D/E/F, PSV-140 A/B). Check the
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ESD-12 / ESD- 13 are active and in line. Ensure that no free water is
inside the Vacuum column. Ensure that feed to Vacuum column is got
heated up to 290oC to 300 oC (for VDU start up). Check The level (LG
69) in ejector condensate receiver (V-17). Check the lineup of steam
trap from steam separator of Y-10 to MP condensate header and drain
condensate if any.

Start cooling water to ejector condensers, S-21 A/B, S-22 & S-23. Open vent on
cooling waterside to remove air. In case of air locking in the condensers the
thermal efficiency would drop down very drastically. Line up one series of
ejector. (i.e. open the suction valve of 1st, 2nd and 3rd stage ejector (J-1B, J-2B
& J–3B). Open XV-18 to line up sour gas to LP flare. Take PIC-61 on manual
and open it about 40 %. Note down the pressure (PG-267). Take PIC-62 on
manual and keep it closed. Ensure that V-17 has enough level so that
barometric legs are dipped in it. In normal operation, this vessel will receive
level by condensing steam. Thus the above can be ensured by giving some time
for condensation after inter-condensers and after condensers are lined up.
Gradually open the steam supply to 3rd stage (J-3B) ejector. Gradually open the
steam supply to 2nd stage ejector (J-2B). Maintain the steam pressure to ejector
near design condition by increasing the opening of PV-61. Note down the level
of ejector condensate receiver (LG-69, LG-70). If HC level starts building (LG-
69) then line up off spec header/DUF Feed tank, start pump P- 22A/B and put
on auto mode. (Refer to pump start up SOP) after informing to RTF. If sour
water condensate level starts building (LG-70) then start pump P-23 A/B (Refer
to pump start up SOP) after informing to waste water stripping unit /
Unsaturated gas Conc. Unit.

Open gradually the steam supply to 1st stage ejector (J-1B). Maintain the steam
pressure by opening PV-61. Change it to auto mode when PV-61 is more than
30 % open after matching PV and SV. Monitor the column top pressure (PG-
266). When desired vacuum is achieved, PIC-62 can be changed to auto mode.
Select PHS-62 for PT-62 or PT-70 as per requirement. When Vacuum column
has normal operating conditions are established, open XV-16 and close XV-18 to
divert ejector vapor to Crude Heater (F-01 & F-51). Light the off gas burners in
the Crude Heaters.

Monitor the level (LI-17) of Ejector Vapor Knockout Drum (V-18). If this level is
increased above 50 %, then drain it intermittently in Ejector Blow Case (V-19).
Monitor the level (LG-72) of Ejector Blow Case (V-19). If this level is increased

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above 50 %, then transfer the liquid to Ejector Condensate receiver (V-17)

under Fuel Gas pressure.

11.5.5 SHUT DOWN OF EJECTOR SYSTEM:

Ensure that Vacuum in Vacuum Column (C - 16) is to be broken (While going

for plant shut down). Take PIC-61 on manual and throttle it. Take PIC-62 on
manual and keep it closed. Open XV-18 and Close XV-16 to divert Ejector sour
gas from crude heater ( F-01, F-51) to LP Flare. Isolate the off gas burners in F-
01/F-51.

Close steam valve on all the Ejectors starting from 1st, 2nd & then 3rd (J-1B, J-
2B & J-3B). Then stop cooling water supply to S-21 A/B, S-22 & S-23 as per
shutdown requirement. Stop HC Pump P-22 and sour water pump P-23 A/B
after bringing down the respective levels in V-17.

For fuel gas backup, open the 2” fuel gas injection valve up stream of PIC-62.
Monitor the column C-16 pressure. Stop fuel gas injection after C-16 pressure is
0.5 Kg/cm2g. Performing similar operation on A series of ejector can do
shutdown of A series of ejectors.

11.5.6 CHANGEOVER OF THE EJECTORS SET:

Ensure that standby “Ejector Set” is ready for startup. Take PIC-61 on manual
and open it. Take PIC-62 on manual and keep it closed. The ejector set A is to
be changed over with ejector set B as per the following procedure :

Gradually open MP steam supply slowly to 3rd stage standby element (J-3A).
Gradually open process inlet valve of 3rd stage standby element (J-3A).
Gradually close process inlet valve of 3rd stage ejector element (J-3B) which was
in line earlier. Close steam supply valve to 3rd stage ejector element (J-3B).

Then open steam supply to 2nd stage ejector standby element (J-2A). Maintain
the steam pressure by adjusting the opening of PV-61. Gradually open process
inlet valve of 2nd stage standby element (J-2A). Gradually close process inlet
valve of 2nd stage ejector element (J-2B) which was in line earlier. Close the
steam supply to 2nd stage ejector element (J-2B).

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Gradually open steam supply to 1st stage ejector standby element (J-1A).
Maintain the steam pressure by adjusting the opening of PV-61. Gradually open
process inlet valve of 1st stage standby element (J-1A). Gradually close process
inlet valve of 1st stage ejector element (J-1B). Close the steam supply valve to
1st stage ejector element (J-1B). Maintain the steam pressure by PV-61, put it in
auto mode. Now PIC-62 can be changed to auto mode.

The above change over procedure is for changing B to A series ejectors.

Following activity is to be done in field .

Monitor Vacuum Column Overhead Pressure Controller PIC 62 till it gets

stabilized. Monitor the level (LI-17) of Ejector Vapor Knockout Drum (V-18).
When this level is increased above 50 %, then drain it intermittently in Ejector
Blow Case (V-19). Monitor LG-72 (of V-19). When this level is increased above
50 %, then transfer the liquid to Ejector Condensate receiver (V-17) by Fuel
Gas pressure.

11.5.7 TROUBLE SHOOTING:

Malfunctions of ejectors can be difficult to analyze, unless a set-by-step

procedure is followed. Through the process of elimination of the likely causes
one by one, the problem area can be located and corrected. There are basically
five main areas that will cause an ejector to malfunction and these are:
(1) Motive Fluid conditions and properties different than design
conditions
(2) Cooling water properties to inter & after condensers are different
than design
(3) Ejectors over load conditions (i.e. vapor load more than the design
conditions)
(4) Ejector discharge conditions different than the design conditions
(5) Mechanical damage or wear.

1) Motive Fluid conditions and properties different than design: Motive

fluid (MP steam) should be condensate free and at the design temperature &
pressure. The steam trap of the steam separator should be in line and working
properly. If wet steam is used as a motive fluid in ejector then it can lead to
erosion of steam nozzle and ejector throat.

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2) Cooling water properties to inter & after condensers are different

than design: Cooling water flow and supply temperature should be at the
design condition. Also inter condensers and after condenser should be vented
properly to remove/displace air on cooling waterside. It should be checked
regularly on daily basis.

3) Over loading conditions: Increasing in the vapor load above its design will
lead to higher pressure than it’s designed pressure. The following reasons could
be lead to possible overloading of vacuum ejectors.
 Dissolved gasses in Reduced Crude to F-02.
 HAGO recovery in Crude Column is not good.
 Thermal cracking in Vacuum Heater (F-02 ).
 Steam to process coil in F-02 & stripping steam to vacuum column - is
excessive.
 LVGO reflux temperature and flow are not at their design condition.
 Coking in vacuum Heater coil (F 02).
 Air leakage into the system.

4) Discharge conditions: All ejectors are having compression ratio’s more

than 2.1 and hence all of them are critical ejectors. High discharge pressure
in critical ejectors can lead to higher pressure than it’s designed for.

5) Mechanical damage or wear: Nozzle and diffuser should be checked, and

if wear exceeds 7 % of the original design area, the parts should be
replaced. The steam nozzle and diffuser interior should be smooth and
clean. Leaks in steam chest will lead to higher pressure than the designed.
Clogging or fouling of cooling water supply and discharge line will lead to
inadequate flow of the cooling water, which would lead to overload
conditions for downstream ejectors. Fouling of the intercondensers and after
condenser will lead to the similar effect.

11.6 ABSORPTION SECTION

11.6.1 High Pressure Receiver (V-01)

The high pressure receiver (or separator) collects the liquid streams from several
units plus the primary absorber bottoms and the stripper overhead. Water is
separated from the hydrocarbon stream and collected in the boot. The sour water
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is pressured from the boot to the waste water stripping unit (U-441) on level
control, LIC-02. The hydrocarbon liquid stream is pumped to the stripper on level
control, LIC01, through P-01 A/B. The separated gas is sent to the primary
absorber, C-02. The primary absorber, C-01, floats on high pressure separator
pressure. The vessel is carbon steel. Design pressure is 16.5 Kg/cm2g. A pipe
distributor is provided to minimise liquid level disturbances due to the incoming
gas/liquid stream.

11.6.2 PRIMARY ABSORBER (C-02)

The function of the primary absorber is to absorb most of the C 3 and C 4

components in the rich gas stream from V-01. This column is a killed carbon steel
column. The trays are also carbon steel. Valuable light products such as LPG are
absorbed from the gas as it travels from the bottom to the top outlet. The tower
design uses an intercooler to remove the heat of gas absorption from the naphtha
as it travels down the tower. The temperature rise is approximately 11-14 0C. This
intercooler is located roughly at the midpoint of the tower. The circulating naphtha
is pumped through the intercooler, S-02. Stabilised naphtha is introduced at the
top of the column as "lean" oil. The naphtha from the bottom of the column is
pumped back to the high pressure condenser (S-01) by P-03 A/B while the
overhead gas is routed to the Sponge absorber, C-03.

11.6.3 Sponge absorber (C-03)

Depending of the absorption efficiency in the primary absorber, 5-10% of the

propane and heavier components can be lost to the fuel gas system if a sponge
absorber is not used. The sponge absorber is a "guard" tower which uses
circulating diesel oil from U- 311/312, to absorb any remaining liquid from the gas.
If any significant quantities of C 5 or C 6 remain in the gas stream, these will cause
problems with treating. If the gas is sent directly to the fuel gas system,
condensation of heavy material is dangerous, since it could cause the flame failure
in heaters.

The sponge absorber is typically half the size of the primary absorber. It is a killed
steel column filled with packing to provide intimate contact between the lean oil
and the gas. A mesh blanket, type 304 stainless at the top of the absorber, traps
any entrained liquid in the outgoing gas stream.

11.6.4 Lean gas knockout drum (V-04)

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The sponge absorber off gas enters the knockout drum in the upper one-half of
the vessel where any entrained liquid is separated from the lean gas with the aid
of the demister blanket installed in the upper section of the vessel. The vessel is
constructed of carbon steel. A mesh blanket, type 304 stainless at the top of the
drum traps any entrained liquid.

PIC-004 has been provided to control the pressure of the drum which in turn
controls the pressure of the full system, which includes Sponge absorber (C-03),
Primary absorber (C-02) and High Pressure receiver (V-01). The pressure on the
knockout drum should be kept at 13.9 Kg/cm2g normally.

11.7 DISTILLATION SECTION

11.7.1 Stripper (C-05)

The purpose of this column is to strip off the light ends(lighter than C 3 ) plus the
bulk of the H 2 S that is present in the liquid stream from the HP receiver. The
charger to the column enters through distributor, which discharges to the top tray.
The stripped vapour leave the top of the column. The heat input to the column is
controlled by the top vapour flow controller, FIC-09. The stripper bottoms liquid is
sent to the stabiliser on bottoms level control.

The stripper is made of carbon steel with 36 carbon steel trays. Tray fittings are
type 410 stainless. The reboiler is made of carbon steel.

11.7.2 Stabiliser (C-06)

The stripped naphtha from the recovery section is to be stabilised for vapour
pressure adjustment. In the stabiliser, a majority of the C 3 and C 4 components are
taken overhead. This is the LPG product stream which can be sent for further
treating to Saturated LPG Merox unit (U- 331) or Unsaturated LPG Merox Unit (U-
414).

The stabiliser is KCS with 40 carbon steel trays. Tray fittings are type 410
stainless. The overhead system is usually carbon steel, with inhibited admiralty
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tubes in the water condenser. The shell of the reboiler is carbon steel. The tubes,
tube sheet and floating headcover are 5% Cr 1/2% Mo/CS clad. Type 410 stainless
may be used instead of 5% Cr. Hot fluid is through the tubes.

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CHAPTER # 12

INSTRUMENTATION

 12.0 INSTRUMENTATION

 12.1 DCS DESCRIPTION

Distributed Control System for Jamnagar Refinery Complex is of Foxboro I/A series
50 and is capable of plant wide automation. The architecture of the system
accommodates both functional and geographical distribution of the hardware,
software, and database over the plant while allowing system wide access to the
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distributed data. The DCS utilises a modular architecture to permit a wide range of
system configurations and facilitates system flexibility and expandability.
The DCS hardware is state of the art microprocessor based design, which is fully
tested and reliable. It permits control and data acquisition functions to be
distributed to remote Plant Interface Buildings (PIBs) with operator-consoles
located in Plant Control Centre (PCCs).
As stated above all DCS hardware is in the PIBs, all field inputs are terminated in
the PIBs, all controllers are in the PIBs and field outputs are from PIBs only.

Monitoring and Control is by Operator Console located in the PCC which in turn is
connected to all the PIBs through Fiber Optic Plantwide Control Network (refer
Chapter no. 4 on Interconnectivity).

Foxboro I/A series 50: Following are the salient hardware features of the system :-

WP51B - Two-tier operator console with three 19” CRT’s, Keyboards, trackball and
touch screen. These are screens where plant operator (PO) observes and controls
the whole plant. These stations consist of a processor, memory cards and a
communication card. A printed circuit board with electronics mounted on it is
called a card. These stations are used to see the trends, alarms, graphics etc.

 CP30 & CP40 - Control processor for control and data

acquisition.

Control-Processor (CP) is the heart of the programmable controller. The logic built
is stored in its memory. This processor checks for the status of the inputs coming
from the input cards and executes the logic as written. On execution of the logic
some particular signal is sent to the output cards and then to field. It also controls
the communication, data handling and self-diagnostics. Diagnostics is a software
program that checks the healthiness of the system. In case of any unhealthy
condition it turns on certain LEDs to indicate the status.

· AW51C - Engineering Station for configuration of the system.

This station looks exactly similar to operator work stations, but the software
loaded is different. It is used to configure the requirements of the user like
building of graphics, tags, alarms, historian etc.

· FBM & FBC - Field I/O card.

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These are some electronic components on the Printed Circuit Board (PCB) which
basically perform the function of signal conditioning. They may either be input
type or output type. They have got channels and each signal going to the field &
coming from the field is terminated at one particular channel. They convert the
signal into a form acceptable by the controller. There is a diagnostic program
checking the status of each FBM. The FBMs are normally placed in the marshalling
room.

The hardware distribution and configuration of the Crude/Vacuum Distillation Unit

(311/312) and Saturated Gas concentration Unit (321/322) is as under:

 For Unit-311/321, CP 40, FBMs/FBCs are located in the PIB 6 and linked to
Refinery Plant Control Center with Fiber Optic Control Network.

 For Unit-312/322, CP 40, FBMs/FBCs are located in the PIB 7 and linked to
refinery Plant Control Center with fiber optic Control Network.

There are three operating consoles in the Refinery PCC dedicated for Train 1
Crude/Vacuum Distillation Unit (311) and Saturated Gas concentration Unit (321)
operated by one Panel Officer. Similarly three operating consoles are provided in
the Refinery PCC dedicated for Train 2 Crude/Vacuum Distillation Unit (312) and
Saturated Gas concentration Unit (322) operated by another Panel Officer.

Plant interface buildings (PIB) are located strategically throughout the complex to
house control system equipment. PIBs reduce the cabling costs as the field cabling
can be terminated here rather than having cabling right upto the plant control
center. PIBs are located in safe areas at a minimum 16 m away from any source
of hydrocarbon. PIB 6 will cater to Unit-311/321. PIB -7 will cater to Unit -312 /
322. PIB 6 & 7 are connected to Refinery PCC via fiber optic line. There are two
optic fibers with different route to take care of the damage to the optic fiber due
to Crane Movements / Excavation etc ( i.e. 100% redundancy for Optic Fiber is
provided)

 12.2 DATA FLOW:

The data flow right from the instrument to the screen on the operator-work-station
can be understood in two parts:

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 Data from instrument to controller.

 Data from controller to operator station.

 DATA FROM INSTRUMENT TO CONTROLLER

The controller has one main processor that performs the control function. All the
programs are written in such a way that the control sequence to be performed by
the controller is defined. There are input and output signal conditioning cards,
which are connected to this controller. The signal coming from the field is taken
into the input card and converted into the acceptable form for the controller. This
is called as the signal conditioning. Each input and output card is given a unique
identity number. The processor recognizes the card with reference to the ID
number given to each input / output cards. The instrument on the field is
connected to one of these input or output cards. The signal transmitted could be
in analog or digital form. Each input or output card is having a specific capacity or
number of channels they can handle. This puts an upper limit to the number of
instruments that can be hooked up to a card. Normally the card has 32 channels.
There is a network called field bus (FBS) on which all these cards are connected
and the data travels through the field bus to processor. The processor maps the
data into its memory and initiates action according to the user defined programs.
The output signal from the processor goes to the respective out put card. Imagine
the controller having a notebook and on each page it writes one ID number.
Hence the data for all the instrument tags coming from the field through the input
cards is written down by the controller in the page that contains that ID number.
This whole notebook forms the database of the controller. So the database has all
the values of the various process variables (i.e. level, temperature, flow etc.). This
set of database is then synchronized with a copy of database in the application
module.
 DATA FROM CONTROLLER TO OPERATOR WORK STATION:

When any graphic is called on the station the parameter of the graphic is updated
from the database available in the controller. Hence when the graphic shows some
level, temperature, flow etc. then its real value is coming from the controller. The
node (station) puts a query on the network to update its data at regular intervals.\

 12.3 DCS GRAPHICS

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The process graphics show process equipment, piping, instrumentation and

control. They are as per the Unit PFD’s and P&ID’s & arranged in four hierarchy
levels as given below:
 Plant-wide (Level 1)
 Complex (Level 2)
 Unit (Level 3)
 Detailed (Level 4)
At each of these levels, the graphics provide the means to move up and down the
graphic hierarchy, and also sideways.
The Plant-wide-graphics show an overview of the whole Refinery. It displays the
main plant areas, their status and primary plant data. There is no control or
process information at this level. The main purpose of this display is for navigation
to other displays.
The Complex-level-graphics show overview of each of the five complexes in the
Refinery. Only the major flows and other important data specific to each area is
shown. There is no process control from this level. Additionally, the Complex Level
graphics indicate whenever a fault occurs at any point within the process, which
allows the operator to choose & display a more detailed graphic.
The Unit-level-graphics show process equipment, piping and control loops, ESD’s,
alarms etc. All controllers, important process variables and general monitoring
parameters are indicated at this level. ESD trips are also indicated. Facilities are
provided for operator actions such as alarm acknowledgment, manipulation of
control loops, operation of valves, pumps etc. The plant unit is represented by
several unit level graphics. These graphics are as per the Unit PFD’s / P&ID’s. Unit
Level graphics are intended to be the ones that are used most of the time for plant
operations.
The Detailed Level graphics show all instrument functions implemented in the I/A
Series - indicating loops, monitoring functions, equipment status, trips, ESDs, etc.
Facilities are provided for alarm acknowledgment; access to all control loops,
faceplates, groups and trends. ESDs are indicated on these graphics. The
graphics at this level closely follow the Unit P&ID’s and indicate almost all P&ID
level information. This level of graphics is used to pursue detailed information on
the process and the instrumentation.
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 12.4 ESD SYSTEM GRAPHICS

ESD System graphics provide information on emergency shutdowns. These
displays appear in tabular formats and closely follow the Unit “Cause & Effect
Diagrams”. ESD trips and major shutdowns are included in these graphics.

There are two levels of ESD system graphics:

 ESD Overview (Level 1)

 ESD Detail (Level 2)

Facilities are provided to move from one level to the other and also sideways
within level 2 graphics.

The ESD Overview graphic lists all ESD's in the area and summarizes their
status. Each plant area has a level-1 ESD graphic.

In ESD Detail graphics, dynamic Cause and Effect information is depicted. This
includes status of the cause, the command and actual status of the effect (e.g.,
valve position, pump status etc.).

 12.5 WORKSTATION ACCESS

 Environments
Processors & Personal Workstations provide security through access levels for
different categories of system users. Password protection is configured for each
environment.
The environments configured for Crude are defined below:

Environment Access Authorization

Level
Field_Op_Env 1  Can view displays.
 Cannot change values (SP, Output, Auto-
Manual etc.).
 Cannot acknowledge alarms.
Ctrl_Rm_Op_En 2  All Field_Op_Env access.
v  Can change values (SP, Output, Auto-Manual
etc.).

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 Can acknowledge alarms.

 Cannot change alarm limits.
Supervisor_Env 3  All Ctrl_Rm_Op_Env access.
 Can change alarm limits.
 Cannot tune controllers.
 Cannot access configurations or maintenance
functions.
Maint_Engr_Env 4  All Supervisor Environment access.
 Can tune controllers.
 Can access configurations and make
configuration changes.
 Cannot access software management.
Soft_Engr_Env 5  All Maint_Engr_Env access.
 Can access software management to write
programs.
 Can access Password configuration and
change environment menus.

 12.6 ALARM MANAGER AND ALARM DISPLAYS

 Workstation alarm manager is used to alert the operator in case of process
alarms and to give direct access to user defined displays. The number of
alarms that can be displayed on a page can be configured. For Crude, the
option selected is 10 (default). The time for screen refresh can also be
configured to a value between 3 and 100 seconds. For Crude selected refresh
rate is 3 sec (default 10 sec). The system has default colours for each priority
of alarm. These defaults are applied to current alarm summaries and
faceplates.Alarm manager can display alarm information in up to six distinct
display windows

 Current Alarm Display (CAD)

 Most Recent Alarm Display (MRA)
 New Alarm Display (NEWALM)
 Acknowledged Alarm Display (ACKED)
 Unacknowledged / Return-to-normal Alarm Display (UNACK)
 Alarm History Display (AHD)

 12.7 Alarm Message Contents

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Generic alarm message text used is summarized below:

Sr Type of Alarm Alarm Text Return to Normal

no Text
1. Measurement High MEAS HI ALM MEAS HI RTN
2. Measurement Low MEAS LO ALM MEAS LO RTN
3. Deviation High DEVIATION HI ALM DEVIATION HI RTN
4. Deviation Low DEVIATION LO ALM DEVIATION LO RTN
5. Measurement High MEAS HI HI ALM MEAS HI HI RTN
High
6. Measurement Low MEAS LO LO ALM MEAS LO LO RTN
Low
7. Output High OUTPUT HI ALM OUTPUT HI RTN
8. Output Low OUTPUT LO ALM OUTPUT LO RTN
9. Bad Input INPUT BAD ALM INPUT BAD RTN
10. Bad Output OUTPUT BAD ALM OUTPUT BAD RTN
11. High Status HI ALM HI RTN
12. Low Status LO ALM LO RTN
13. High High Status HI HI ALM HI HI RTN
14. Low Low Status LO LO ALM LO LO RTN
15. Shutdown S/D ALM S/D RTN
16. Common Alarm COMMON ALM COMMON RTN
17. Common Trouble COMMON TROUBLE ALM COMMON TROUBLE
RTN
18. MAINTENANCE MAINTENANCE
Maintenance
Override OVERRIDE ALM OVERRIDE

19. Fault FAULT ALM

20. Failure FAIL ALM
21. Status Tap FAIL ALM
22. AC Transfer Switch FAIL ALM

 12.8 SCANNING AND DATA UPDATION

As process parameters change, it is to be updated in DCS for process control. Scan
time has been specified for each tag. Hence, sample collection group will collect
sample after specified scan time is over. Also the parameter dead band is specified
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due to which the object manager must detect before it updates the member point
data. Default setting for dead band is 2% of engineering value of the member
point, i.e. when the process parameter changes by 2% of its measurement range,
the member point will be updated before its scan time. At a same time, sample
collection group can take sample for minimum 600 and maximum 99,999,000
members. As per Project Application Specifications for Refinery, following scan
times have been configured.

 5% of total I/Os - 01 sec – For most critical tags.

 15% of total I/Os - 10 sec – For critical tags.
 80% of total I/Os - 1 minute– For all other tags.

The data retention span for the points configured in the Sample Collection Group is
24 hours.

Scan / update time for different types of signals is listed out in the following table:
-
Type of Signal Dead Update Update Time
Band Time open Closed loop
(% Of Loop
Eng.
Value)
FLOW 2 10 Seconds 1.0 Seconds
PRESSURE 2 10 Seconds 1.0 Seconds
LEVEL 2 1.0 Minutes 1.0 Seconds
TEMPERATURE 2 1.0 Minutes 1.0 Seconds
VIBRATION 2 10 Seconds 1.0 Seconds
ANALYSER 2 1.0 Minutes 1.0 Minutes
SPEED 2 10 Seconds 1.0 Seconds
OTHERS 2 10 Seconds 1.0 Seconds

 12.9 HISTORIAN
The Historian operates on an I/A series Application Processor (AP), Application
Workstation (AW) or a Personal Workstation (PW).
The Historian licenses for our complex as given in the following table: -

PCC Process Complex Historian Historian I/O

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Name License
Refinery Crude Train 1(PIB 06) 2000 1540
Refinery Crude Train 2(PIB 07) 2000 1540

 12.10 AIM* Historian

The Fox History (Loaded with Original Configuration during Commissioning of
Units) was replaced by AIM * Historian. AIM* Historian is a client/server
application that is used to collect, organize, and store historical data. AIM*
Historian accepts data from the I/A Series System and other types of automation
and control systems, such as DCS, PLC and SCADA. Historical data includes Real
Time Point (RTP) values and event messages such as process alarms.

The AIM* Historian operates on an I/A series Application Processor (AP 51),
Application Workstation (AW 51) and other network servers running Solarsis 2.5.1
or later or Network server running Windows NT 4.0 or later.

An AIM* Historian instance is made of Configuration and Database Files residing

on AIM* Historian Server. The AIM* Historian Configurator can be used to create,
configure and modify the AIM* Historian instances. Multiple AIM* Historian
instances can be configured in an AW/AP/NT Server. Each AIM* Historian instance
has one server component and one or more data collector components. Instances
names must be unique with in host computer.

AIM* Historian may include RTP (Real Time Points); Event Messages; Control
Groups; Data Reduction and Manual Data Entries.
 12.11 HARD WIRED ALARMS
In addition to the DCS alarms, the most critical alarms are provided in hard-wired
Annunciator panel adjacent to CRTs. This is to alert the panel operator to take
corrective action immediately in order to prevent plant upsets, emergencies &
plant shutdown.
 LIST OF HARD-WIRED ALARMS:
SR. TAG NO. DESCRIPTION
NO.
1 311/312FAL 091A CRUDE FLOW TO NAPTHA EXCHR - SO1
2 311/312FAL 091B CRUDE FLOW TO NAPTHA EXCHR - SO4
3 311/312FAL 116 FLASHED CRUDE FLOW FROM PO4
4 311/312FAL 117 FLASHED CRUDE FLOW FROM PO4

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5 311/312LAH 005 V04 FLASH DRUM LEVEL

6 311/312LAL 005 V04 FLASH DRUM LEVEL
7 311/312PAH 002 V04 FLASH DRUM PRESSURE
8 311/312FAL 131 FLASHED CRUDE FLOW TO CRD HTR - FO1,
( COM. ALM. ) ZONE 1, PASS 1-5 INLET
9 311/312FAL 135 FLASHED CRUDE FLOW TO CRD HTR - FO1,
(COM. ALM.) ZONE 2, PASS 1-5 INLET
10 311/312TAH 200 FLASHED CRUDE TEMP FROM CRD HTR - FO1,
(COM. ALM.) ZONE 1, PASS 1-5 OUTLET
11 311/312TAH209 FLASHED CRUDE TEMP FROM CRD HTR - FO1,
(COM. ALM.) ZONE 2, PASS 1-5 OUTLET
12 311/312FAL141 FLASHED CRUDE FLOW TO CRD HTR - F51,
(COM. ALM.) ZONE 1, PASS 1-5 INLET
13 311/312FAL145 FLASHED CRUDE FLOW TO CRD HTR - F51,
(COM. ALM.) ZONE 2, PASS 1-5 INLET
14 311/312TAH240 FLASHED CRUDE TEMP FROM CRD HTR - F51,
(COM. ALM.) ZONE 1, PASS 1-5 OUTLET
15 311/312TAH249 FLASHED CRUDE TEMP FROM CRD HTR - F51,
(COM. ALM.) ZONE 2, PASS 1-5 OUTLET
16 311/312TAH 053 CRUDE COLUMN (C05) TOP TEMPERATURE
17 311/312TAL 053 CRUDE COLUMN (C05) TOP TEMPERATURE
18 311/312PAH 082 CRUDE COLUMN (C05) FLASH ZONE PRESSURE
19 311/312TAL 051 REDUCED CRUDE TEMPERATURE
20 311/312PAL 028 COMBUSTION AIR PRESSURE TO CRD HTR – FO1
21 311/312PAL 047 COMBUSTION AIR PRESSURE TO CRD HTR - F51
22 311/312FAL151 REDUCED CRUDE FLOW TO VAC HTR FO2, PASS
(COM. ALM.) 1-10 INLET
23 311/312TAH284 REDUCED CRUDE TEMP FROM VAC HTR FO2,
(COM. ALM.) PASS 1-10 OUTLET
24 311/312PAH 070 VACUUM COLUMN FLASH ZONE PRESSURE
25 311/312PAL 062 VACUUM COLUMN C 16 TOP PRESSURE
26 311/312PAH 005 CRD CLMN CO5 TOP PRESSURE
27 311/312PAL 005 CRD CLMN CO5 TOP PRESSURE
28 311/312FAL 076 SLOP WAX FLOW FROM P-19 PMPS TO VAC HTR
FO2
29 311/312TAL 013 CRUDE TEMP TO 1 ST STAGE DESALTER VO2
30 311/312TAL 014 CRUDE TEMP TO 2 ND STAGE DESALTER VO3
31 NGC – VSD Com mon NET GAS COMPRESSOR VSD COMMON TRIP
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Trip
32 NGC VSD Temp High NET GAS COMPRESSOR VSD TEMP HIGH
33 ESD FAULT ESD PROCESSOR FAULT
34 311/312TAH 611 LP FLARE K.O COND COOLER A -11 O/L TEMP
35 311/312TAH 616 HP FLARE KNOCK OUT CONDENSATE COOLER A
–10 O/L TEMP

 HARD WIRED SWITCHES:

In addition to START/STOP switches in the field for all the drives, hardwired stop
switches for the Net Gas Compressor, Heater ID/FD Fans & RTF crude Charge
Pumps have been provided in the hard wired annunciator panel adjacent to CRT to
take immediate action during emergency.

Also the hard wired switches for manual shutdown of the fired heaters (F01, F51 &
F02), and ejector vapor diverting to LP flare have been provided in the annunciator
panel.

 LIST OF HARD WIRED SWITCHES FOR CDU/VDU:

Sr TAG No. Description

.n
o.
1 311/312XHS RTF Crude charge pump emergency shutdown.
235
2 311/312XHS 337 Net Gas Compressor emergency shutdown.
3 311/312XHS 013 Crude charge heater F01 emergency shutdown.
4 311/312XHS 019 Crude charge heater F51 emergency shutdown.
5 311/312XHS Crude heater F-01 ID/FD Fan emergency
015 shutdown.
6 311/312XHS 029 Crude heater F-51 ID/FD Fan emergency

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shutdown.
7 311/312XHS 028 Emergency Diverting to LP flare for ejector vapor
8 311/312XHS 035 Vacuum heater F-02 ID/FD Fan emergency
shutdown.
9 311/312XHS 034 Vacuum heater F-02 emergency shutdown.
10 311/312XHS 001 MOS Enable

CHAPTER # 13
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TROUBLE-SHOOTING

13.1 DESALTER
 WIDELY FLUCTUATING VOLTAGE
POSSIBLE CAUSES ACTION
1.High water level in the Water level is to be checked by the use of
vessel trycocks. If level is high, reduce water
injection rate & bring down the level.
2.Excessive water injection Check water flow rate. Shut off water if
controller is malfunctioning. Get the controller
checked & re-establish water injection to
normal rate as soon as possible.
3.Electrical arching at the This rarely occurs but if bushing or insulator
entrance bushing or insulator has become contaminated, arching along the
surface may result intermittently for several
minutes. If permanent damage occurs, the
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voltage will fall very low and bushing /

insulator must be replaced. This would involve
shut down of a desalter.

 LOW VOLTAGE
POSSIBLE CAUSES ACTION
1.High water level in the Water level is to be checked by the use of
vessel trycocks
2. Excess pressure drop Open mixing valve completely.
across Allow the voltage to return to a steady state
the mixing valve and optimum setting is to be re-established
slowly.
3. Sludge layer at interface Check trycocks. If sludge is indicated in upper
two trycocks lower water level as much as
possible and increase chemical rate. If layer is
not dissipated in 8 – 10 hrs., dump water and
sludge layer to sewer and re-establish level.
4. Excess water injection Check water flow rate. Shut off water if
controller is malfunctioning. Get the controller
checked & re-establish water injection to
normal rate as soon as possible.
 VERY LOW VOLTAGE
POSSIBLE CAUSES ACTION
1. Damaged entrance a) Open bushing housing and disconnect
bushing or electrode bushing from power transformer. Megger the
insulator bushing to ground. If shorted, remove bushing
and inspect, burning of traces on the surfaces
will be evident if arching along surface has
occurred. Install new bushing.
b) If bushing is not damaged, clean surface
thoroughly and replace.
c) After clean bushing replaced or new one
installed, megger to ground. If still shorted, an
electrode insulator is damaged. Vessel must be
emptied to replace the insulator
2. High water level in the Check water level by trycocks.
vessel

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3. Sludge layer at interface

Check trycocks. If sludge is indicated in upper
two trycocks, lower water level as much as
possible and increase the chemical injection
rate. If layer is not dissipated in 8 – 10 hrs.,
dump water and sludge layer to sewer and re-
establish level.
4. Excess water injection Check water flow rate. Shut off all water if
operation of water controller is questionable.
After repairs re-establish water injection to
normal rate.
5. Excess pressure drop Open mixing valve completely.
across Allow the voltage to return to a steady state
the mixing valve and optimum setting is to be re-established
slowly.
 OIL CARRY OVER IN DESALTER BRINE
POSSIBLE CAUSES ACTION
1. Water / oil interface level in a) Check and verify interface level
desalter is low b) Check pH & ammonium ion
concentration of the effluent brine. The
optimum range is pH =5.5 to 6.5. The
ammonium ion concentration should not
be more than 5 ppm in effluent brine.
2. De-emulsifier injection rate is Adjust De-emulsifier injection rate.
low
3. Desalting temperature is low Maintain temperature around 129 0c.
 EXCESSIVE SALT AND WATER CARRYOVER
POSSIBLE CAUSES ACTION
1. Mixing valve differential pressureAdjust mixing valve differential
too high or low pressure. Normal DP is 1-1.5 kg/cm2
2. Desalting water flow rate is not Check and verify oil-water ratio. If
enough. necessary increase water injection
rate.
3. Crude temperature too high or low Check and verify crude temperature.
Normal value is 129 0c.
4. Desalting water temperature too Check S-07 & S-27 for fouling.
low

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

13.2 HEATER
 ELECTRICAL PILOT WILL NOT LIGHT
POSSIBLE CAUSES ACTION
1. The ignition Check to make sure the power supply is correctly
transformer is not connected to the ignition transformer and that the
operating ignition cable (no more than 25 feet) is correctly
connected between the ignition transformer and
the spark plug on the pilot. Also check to see if
the spark is broken.
2. The ignition Check to make sure none of the ceramic insulator
transformer is arcing but on the pilot ignition rod is missing or have been
not at the tip. cracked or broken. Make sure the gap in between
the pilot tip and the ignition rod is sufficient to
allow an arc at the tip
3. The burner air inlet This could cause the pilot flame to “ blow out”
damper is more than 25% because of too high a level of air to stabilize the
open and /or the FD fan is pilot. Close the burner damper and /or reduce the
at greater than 25% of F.D fan rate and try again.
max. rate
4. The air register on the The suggested starting location of the pilot mixer
pilot mixer is not set air register is 50% open. If the mixer air register
correctly. is closed too far , the pilot may not be inspiriting
enough air for combustion and proper pilot
operation. If the air register is open too far , it
may be inspiriting too much air and therefore the
mixture too dilute to burn. Adjust the pilot air as
required.
5.The-mixer body is If the mixer body is plugged with a foreign object
plugged. or material, then it will not allow the fuel and air
to mix. Clean or replace the pilot mixer.
6. The pilot tip is plugged If the pilot tip is plugged with a foreign object or
material, then it will not allow the fuel and air
mixture to pass. Clean or replace the pilot tip.
7. The pilot orifice at the If the orifice is plugged with a foreign object or
base of the pilot mixture material, then it will not allow the fuel to pass.
is plugged Clean or replace the pilot orifice.
8. Fuel is not being Check to make sure all fuel supply block valves
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 Reliance Industries Limited
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Jamnagar

supplied to the pilot are open up to the pilot firing valve and that there
connection are no leaks in the piping system and that none of
the fuel lines are plugged.
 PILOT IS UNSTABLE
POSSIBLE CAUSES ACTION
1. The fuel gas pressure If the fuel gas pressure at the pilot is not within the
is not within the operating range shown on the data sheet, then it
operating range shown could be inspiriting too much or too little air to
on the data sheet. sustain combustion. The pilot orifice, mixer, or tip
could also be plugged causing this problem, see
points below.
2. The air register on the The suggested starting location of the pilot mixer
pilot mixer is not set air register is 50% open. If the mixer air door is
correctly. closed too far, the pilot may not be inspiriting
enough air for combustion and proper pilot
operation. If the air door is open too far, it may be
inspiriting too much air and therefore the mixture
too dilute to burn properly. Adjust the pilot air
register as required to stabilise the pilot.
3. The burner air inlet This could cause the pilot flame to “blow out”
damper is more than because of too high a level of air and not enough of
25% open and/or the FD a low pressure zone, gas to stabilise the pilot, or
fan is at greater than enough of an ignition source. Close the burner
25% of max. damper and/or reduce the FD fan rate until the
rate burner is in full operation and the heater is in full
operation and the heater is brought up to temp.
4. The mixer body is If the mixer body is partially plugged with a foreign
partially plugged or object or material, then it will restrict the flow of
damaged. the fuel and air mixer making the flame unstable.
Clean and replace the pilot.
5. The pilot tip is If the mixer body is partially plugged with a foreign
partially plugged or object or material, then it will restrict the flow of
damaged. the fuel and air mixer making the flame unstable.
Clean and replace the pilot.
6. The pilot orifice at the If the orifice partially plugged with a foreign object
base of the pilot mixer is or material, then it will restrict the flow of fuel
partially plugged or making the flame unstable. Clean the orifice &
damaged. replace.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

 BURNER WILL NOT LIGHT OR BECOMES UNSTABLE

POSSIBLE CAUSES ACTION
1. The pilot flame is Check the section above concerning the stability of
unstable and/or is not the pilot. If the pilot can not provide a strong
providing a good source source of ignition for the burner, it may not light off
of ignition to the burner. and/or may not remain stable in a cold furnace.
Also check the location of the pilot tip by confirming
the dimension shown on the burner drawing from
the pilot gas connection to the burner front plate.
2. Fuel is not being Check to make sure all fuel supply block valves are
supplied to the burner open up to the burner firing valves and that there
gas connection (S). are no leaks in the piping system and that none of
the fuel lines are plugged.
3. The burner air inlet This could keep the burner flame from remaining lit
damper is more than because of too high a level of air passing through
50% open and/or the FD the burner throat and not enough of a low pressure
fan is at greater than zone to stabilise the flame therefore causing the
50% of maximum rate flame to “blow out”. Close the burner damper
and/or reduce the FD fan rate until the burner lights
off and is stable. Once the furnace is in normal
operation and hot, this problem if present will
usually be eliminated.
4. The fuel gas tip and/or The fuel gas tip and/or risers are partially plugged
risers are partially with a foreign object or material, then it will restrict
plugged or damaged the flow of the fuel making the burner unstable. If
the tips and/or riser are damaged such that the gas
is allowed to bypass the ports drilled on the tip and
leak out through a crack or threads, then the
burner parts create a dangerous situation. Clean or
replace the gas tips and/or risers.
5. If the gas tips If the gas tips are not oriented correctly, the
orientation is incorrect. ignition and stabilisation ports will not be directed
towards the ignition source and low-pressure
stabilisation areas. Refer to the maintenance
section of this manual, for instructions on
disassembling and correcting the problem.
6. Insufficient air to Check the fire-box oxygen level to make sure there
support combustion is some excess O 2 in the heater.

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

If there is no excess oxygen present in the firebox

be careful. Never open the burner dampers, to
increase the combustion air flow, or shut off a
burner when the fire box is short of air; an
explosion may result.
Decrease the fuel rate in steps of 10%, allowing the
oxygen level in the firebox to stabilise between
each step, until the required excess air level is
achieved). Even if the O 2 analyser shows an excess
oxygen at the stack, the burner still could be short
of air due to leakage in the furnace. Carefully open
a burner damper or increase the FD fan rate to see
if it improves the flame. If the burner becomes
stable, then adjust other burners in the same
manner.
 FUEL PRESSURE DOES NOT MACH CAPACITY CURVES
POSSIBLE CAUSES ACTION
1.The fuel gas Check the fuel gas composition against that of the
composition does not original design fuel. An increase or decrease in
match that of the hydrogen content or other components will cause the
design fuel. heat content of the fuel to vary and therefore the fuel
pressure will change.
2.The-fuel pressure Make sure the pressure gauge is located as close to
gauge is not located the burner gas connections as possible and that there
correctly. are no valves between the gauge and burner. The
pressure shown on the capacity curves is for the
burner only and does not include any piping, valves,
fittings, etc. that may also be in the system.
3.The gas tips are not Check the ports on the gas tips against the drilling
drilled correctly information shown on the Data sheet. Match with the
number and size of the ports with the data sheet. If
over a period of time the ports have been enlarged
due to wear and do not match the information on the
data sheet, then contact JOHN ZINK company to
obtain replacements parts. If the drilling information
is not shown on the data sheet, contact JOHN ZINK.
4. The fuel gas tips If the gas tips and/or risers are partially plugged with
and /or risers are a foreign object or material, then it will restrict the

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Crude Complex Refinery Division Crude Distillers
Jamnagar

partially plugged or flow of the fuel & the pressure required for obtaining
damaged. a specified heat release would be higher than that
shown on the capacity curve. If the tips and/or riser
are damaged such that the gas is allowed to by pass
the ports drilled on the tip and leak out through a
crack or thread, then the burner may not release the
required amount of heat at the pressure stated on
the capacity curve and will give the false impression
that more pressure is required to make a certain heat
release, This could also cause serious damage to the
burner parts and create a dangerous situation. Clean
or replace the gas tips and/or riser.
5.The method or Check the accuracy of the instrument used to
measuring device used measure the fuel flow and fuel pressure. If the heat
to determine the heat release being used to check the operating pressure of
release or fuel flow to the burner is false, then the pressure will appear to
the burner is incorrect. be incorrect when it is actually not.
 CAN NOT ACHIEVE AIR FLOW CAPACITY
POSSIBLE CAUSES ACTION
1. The burner damper is If the burner damper is not open to the correct
not in the correct open position, then it will require more draft or a higher
position or is not open at F.D fan rate to pass the required amount of air. If
all and/or the FD fan is there is no more draft or F.D fan capacity
not operating at the available, then the burner will run short of air.
correct rate.
2.The draft at the floor ofIf the stack damper is not in the correct position
the heater is not at the and/or the I.D fan is not at the correct rate, the
correct level fordraft level at the floor of the heater could keep the
operation. burner from passing the amount of air required for
combustion.
3.Burner damper is Make sure that there is no debris blocking the air
blocked or plugged with a inlet to the burner. This will restrict the air-flow to
foreign material or the burner at the design conditions.
object.
4. The instrumentation This problem can be quite severe because the O 2
used to check the oxygen level in the stack is a false reading and actually the
level in the stack is not burners are running short of air. Check O 2 meter to
functioning properly make sure it is operating correctly and has been

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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

and/or there is leakage in calibrated properly. Check the sample line to make
the furnace sure it has no openings where air can be pulled in.
Check the heater for open sight doors or any other
openings, which would allow air to be pulled into
the heater at any location other than the burner air
inlet. Almost all cases where excess oxygen is
measured in the stack will have incorrect readings
due to leakage in the convection section.
 STACK TEMPERATURE TOO HIGH
POSSIBLE CAUSES ACTION
1. Too much combustion air Adjust combustion air

 EXCESSIVE STACK SMOKE

POSSIBLE CAUSES ACTION
1. Increased fuel rate Check lead lag system is working or not. If it is
without air adjustment not working then get it rectified by Instrument
Engineer.
 H. HIGH SKIN TEMPERATURE
POSSIBLE CAUSES ACTION
1. High skin temperature for the a) Presence of coke in the coil.
process coil. Inspect that particular coil & cut-off
the burner firing near that
particular coil
b) Flame impingement in the coil.
Adjust burner flame.
c) Low flow through the process coil.
Check & increase flow through the
coil.
13.3 CRUDE COLUMN
POSSIBLE CAUSES ACTION
1. Higher water content in a) Ask RTF to check water in crude tank.
crude to the unit during b) Reduce desalter water injection. Keep watch
tank change over on desalter interface level and check
trycocks.
c) Watch V-12 water boot level & drain for
water if required. Check NAPHTHA sample
for water content.
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Jamnagar

d) Reduce stripping stem to the crude column

(C 05).
e) Check HAGO and DIESEL PRODUCT for
color.
f) Reduce crude charge heater out let
temperature
g) If condition does not improve reduce
throughput.
2. Naphtha color hazy a) Check for water in top reflux. If naphtha
reflux is hazy & contains water, reduce the
reflux rate & immediately drain water from
V12 boot and check interface level.
b) Reduce stripping steam to crude column.
c) Reduce heater outlet temperature.
d) Check column-bottom level and maintain
column pressure.
3. High pressure drop The column could be flooded. Adjust the PA. IR
across a particular section streams & carry put the pressure survey again.
of the column The pressure drop in the particular zone could
be high due to trays / packing getting fouled
up.
4. Low temperature Possibility of flooding in that particular section.
difference across a Adjust product withdrawal rate, PA & IR reflux
particular section of the flows in that particular zone.
column
5.Low temperature & The trays in that particular section are dry.
pressure differential across Carry out the survey & increase PA / IR reflux
the particular section in stream flows. Reduce product withdrawal rate.
column
6. Failure of reflux pump a) Take flow control valve on manual and keep
about 40% open.
b) Reduce stripping steam in column.
c) Increase Naphtha PA flow. If necessary, run
both pumps.
d) Start standby pump and normalise flow.
7. Fouling of top trays a) Check for dew point on top section of the
trays
b) Check for V-12 boot water pH, chloride &
iron content
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 Reliance Industries Limited
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Jamnagar

c) Take corrective actions on desalter

operating variables
d) Adjust ammonia / Unicor C injection rate to
crude column top line
8. Product run down sample a. Check other products also for color. If other
is colored products are Okay, check for heat
exchanger leakage.
b. The product could be colored due to heavier
hydrocarbon entrainment also.
c. Reduce product withdrawal rate, flash zone
temperature & stripping steam rate etc.
13.4 NET GAS COMPRESSOR
 INSUFFICIENT CAPACITY
POSSIBLE CAUSES ACTION
1. Restriction in suction line. Clean suction line for scales.
2. Compressor rpm faulty. Check rpm of variable speed drive.
3. Dirty suction strainer at silencer Clean suction strainer.
inlet.
4. PSV-134A/B passing or lifting Remove, repair & recalibrate PSV-
prematurely. 134A/B for set pressure.
5. Excessive system leakage. Repair all leaks.
6. Excessive clearance. Replace worn parts. Adjust male rotor
to female rotor and rotors to casing
clearance.
7. Suction valve throttled. Open the suction valve fully.
8. PV-05B flare valve is passing. Get it attended by instrumentation
section.
9. Less vapor load from system. Run the compressor on minimum rpm.

 INSUFFICIENT DISCHARGE PRESSURE

POSSIBLE CAUSES ACTION
1. Excessive system leakage. Repair all leaks.
2. Compressor rpm incorrect. Check rpm of variable speed drive.
3. PSV-134A/B passing or lifting Remove, repair & recalibrate PSV-
prematurely. 134A/B for set pressure.
4. System demand exceeds Reduce back-pressure in V-13
compressor design capacity due to Run the compressor at maximum
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 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

high gas make speed i.e. 3122 rpm (Trip rpm 3505)
5. Faulty pressure gauge PG-009 on Repair or replace pressure gauge.
compressor discharge.
 EXCESSIVE DISCHARGE PRESSURE
POSSIBLE CAUSES ACTION
1. Compressor capacity greater than This could be due to high molecular wt
system demand. of the gas being compressed. Hence
put more fans in service in A-05 / A-06
to reduce V-12 equilibrium
temperature.
2. Faulty pressure gauge PG-009. Repair or replace pressure gauge.
3. Insufficient cooling in compressor Clean compressor jacket / cooling
jacket. water system. See cooling water
supply pressure and temperature.
4. Ambient air temperature high. Put more fans in service for A-05/A-06
 DISCHRGE GAS TEMPERATURE HIGH
POSSIBLE CAUSES ACTION
1. Excessive discharge pressure. See “Trouble shooting of Excessive
discharge pressure ”
2. Compressor malfunction. Check rotors for evidence of rubbing.
Reset clearances, if necessary.
3. Suction gas temperature high. Check air fin cooler A-05 .
There could be excessive fuel gas injection
in V-12 to maintain column pressure &
hence this should be arrested by reducing
the rpm of the compressor to match with
the gas make.
4. Insufficient compressor jacket Clean and flush compressor jackets and
cooling. adjust cooling water supply pressure /
temperature.
5.. Dirty strainer at the silencer Clean the strainer.
inlet.
 COOLING WATER DISCHARGE TEMPERATURE HIGH
POSSIBLE CAUSES ACTION
1. Inadequate cooling water supply. Clean and check cooling water supply
pressure.
2. Cooling water supply temperature Check ambient air temperature and

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Jamnagar

high. cooling tower fans.

3. Compressor running at more than See trouble shooting for “Compressor
the design capacity or compressor discharge temperature high”
discharge temperature is high due to
high Cp/Cv of the gas being
compressed.
4. Compressor malfunction. Check rotors for evidence of rubbing.
Reset clearances, if necessary.
 BEARING TEMPERATURE HIGH
POSSIBLE CAUSES ACTION
1. Lube oil temperature too high. a). Check cooling supply water pressure
and
temperature to S-24 A/B.
b). Check ambient air temperature.
C). CHECK RESERVOIR OIL TEMPERATURE TG-028
(ELECTRIC HEATER AUTO CUT-OFF ON HIGH
TEMP.)
D). CLEAN TUBE BUNDLE IN LUBE OIL COOLERS S-
24.
e). Check TCV-035
2. Lube oil pressure too low. a). Check lube/seal oil pump P-30A/B
discharge pressure. Check for the low
turbine speed ( i.e. due to MP steam
supply pressure low the turbine speed
would be low which in turn reduce the
discharge pressure of P-30A.
b). Check PCV-002 for malfunctioning.
Maintain reservoir level LG-001 in V-21.
c). Clean lube/seal oil pump suction
strainer.
d). Check differential pressure across
cooler and filter PDG-007 & clean the filter
if required.
e).Check pressure safety valve PSV-25/26
set pressure. If lube oil pressure gauge is
faulty reset or replace it . Check whether
these valves are passing.
3. Loss of lubrication qualities in Drain and refill the oil reservoir V-21 with

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 Reliance Industries Limited
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Jamnagar

lube oil. new oil.

4. Bearings damaged. Disassemble, remove, and inspect hot
bearing.
5. Excessive pressure-rise across Check for faulty suction or discharge
compressor. pressure controls.
 G. LOW LUBE OIL PRESSURE ALARM AND SHUTDOWN
POSSIBLE CAUSES ACTION
1. Malfunction in lube oil system. Check complete lube/seal oil system
and adjust or replace components
where necessary.
2. Malfunction of switch PSLL- Reset or replace switch.
30A/B/C.
3. Excessive pressure drop through Remove and clean filters F-01A/B.
lube/seal oil cooler S-24A/B and
filter F-01A/B.

 COMPRESSOR VIBRATES
POSSIBLE CAUSES ACTION
1. Rotor rubbing due to loss of Replace worn parts and adjust
clearance. clearances.
2. Piping improperly supported & Check & reset piping supports.
stressed.
3. Coupling misalignments. Check & realign.
4.Foundation bolts are loose. Tighten the foundation bolts
5. Improper grouting. Take corrective actions
6. Liquid carry over to compressor Drain liquid from suction silencer and
casing. check level LI-013/LI-079 in V-12.
Check V-12 temperature & put more
fan in service on A-05/A-06.

7. Bearing damage. Disassemble, remove, and inspect hot

bearing.
 LOW DIFFERENTIAL PRESSURE BETWEEN SEAL OIL/
REFERENCE GAS ALARM AND SHUT DOWN
POSSIBLE CAUSES ACTION
1. Seal oil pressure low. Check lube/seal oil pump P-30A/B
discharge pressure. Check for turbine
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Jamnagar

speed of P-30A.
Maintain reservoir level LG-001 in V-21.
Check lube/seal oil pump suction
strainer.
Check differential pressure across
cooler and filter PDG-007,
Check pressure safety valve PSV-25/26
for passing & set pressure.
Check pressure controller PCV-002 on
pump discharge.
If lube/seal oil header pressure gauge
PG-023 is faulty reset or replace it
2. Malfunction of switch PDSLL- Adjust or replace switches.
13A/B/C, PDSLL-14A/B/C
3. Malfunction of PDCV-003 / PDCV- Recalibrate & reset PDCV-003/ PDCV-
004 on suction & discharge end of 004.
the compressor.
4. Bypass of PDCV-003 / PDCV-004 Close MCV-02/MCV-03 properly.
(i.e. MCV-02 / MCV-03) partially
open.
5. Excessive seal oil leakage from Disassemble, remove, and inspect
mechanical seal. mechanical seal.
13.5 EJECTOR SYSTEM
 POOR VACUUM IN THE TOWER
External Problems Internal Causes
 Dissolved gasses in reduced crude  Erosion of ejector nozzle / diffuser
 HAGO product recovery in Crude  Clogging of ejector nozzle /
column is not good strainers
 Cracking in vacuum heater ( F- 02  Leaks in steam chest
)  Clogged or fouled water supply to
 Excessive turbulising steam to F- condenser
02 process coil  Clogged water outlet from
 Excessive stripping steam rate to condenser to hot well
vacuum column  Excessive leakage – cracked or worn
 Fouling of packed beds in the parts in ejector
tower  Inter condenser water nozzle
 Channeling in the packed bed erosion
 LVGO reflux temperature is high
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 LVGO reflux low flow

 Slop wax section plugged
 Cocking in vacuum heater coil
 Air leakage into the VDU
 Ejector steam quality poor /
inadequate quantity
 Cooling water low flow to ejector
condenser
 High cooling water temperature to
ejector condenser

13.6 CENTRIFUGAL PUMP

POSSIBLE CAUSES ACTION
1.Pump not developing a) Bleed/vent pump casing. Check the line up in
pressure the suction side.
b) Check the suction strainer for clogging.
c) Check liquid level from where the pump is taking
suction (physical verification).
d) Check pump coupling and rotation.
e) Check the foot valves (in case of vertical lift
pumps) for free movement of seat.
f) Check for any leakage in the pump suction line
or pump casing.

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2. Unusual Noise a) Check if coupling guard is touching coupling.

b) Check for proper fixing of fan and cover of the
motor.
c) Check for pump cavitation.
d) Check bearing temperature
e) Generally the bearing temperature up to 80 0 c
or 50 0 c above ambient whichever is lower can
be tolerated. Refer Vender’s instruction Manual.
f) Check lubrication & make sure oil level is OK.
g) Adjust cooling water to the bearing housing .
h) Stop the pump, if bearing temperature is high.
Call the technician.
3.High Gland a) Adjust cooling water.
Temperature b) Slightly loosen the gland nut.
c) Stop the pump and hand over to maintenance.
d) Arrange external cooling if pump has to be run
for sometime.
4. Unusual Vibration a) Check the foundation bolts.
b) Check the fan cover for looseness.
c) Stop the pump and hand over to maintenance.
In case of pumps connected with the system
operating under vacuum, pump vents shall be going
back to vacuum column flash zone through a
common line. Such vent system is necessary so that
a vacuum can be pulled on a pump casing before
the suction valve is opened for priming.
13.7 POSITIVE DISPLACEMENT PUMP
POSSIBLE CAUSES ACTION
1. Insufficient discharge a) Check up the line up on pump suction side.
pressure. b) Check the functioning of the safety valve and
pressure control valve from discharge to suction.
c) Check the suction pressure.
d) Check the strainer on the suction side.
e) Check & ensure sufficient liquid level in suction
vessel.
f) Check pump coupling and rotation.
Get the pump checked by pump technician.
2. Gland Leak a) Check for normal pump discharge pressure

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Jamnagar

b) Tighten the gland nut slowly.

c) Hand over the pump for replacing gland packing.
3. Unusual vibration a) Check the foundation bolts.
b) Check motor fan cover for looseness.
c) Stop the pump and hand over to maintenance.+
13.8 SAT GAS CONCENTRATION UNIT
Problem Cause Action
Primary absorber gas Low pressure set point on the Increase pressure
feed has high C 4 /C 5 lean gas knockout drum controller set point to
content. pressure controller (PIC-004) design (7.7 Kg/cm2g)
Low CW flow to high pressure Increase cooling
cooler. (S01 A/B) water flow rate.
High C 3 content in Primary absorber inter-cooler Increase the
the sponge absorber system not cool enough for intercooler flow or
"lean" gas. proper absorption cooling med flow rate.
Flow rate of "lean" oil to the Increase the flow rate
Primary and/or Sponge of the "lean" oil flow.
absorber.
Lean Oil flow to the primary Increase the cooling
and/or sponge absorber is not of the warmest "lean"
cool enough for proper oil flow or both flows
absorption. if necessary.
Low pressure set point on the Increase pressure
lean gas knockout drum controller set point to
pressure controller (PIC-004) design (7.7 Kg/cm2g)

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CHAPTER # 14

ELECTRICAL SYSTEM
AND EMERGENCY
POWER REQUIRMENT
14.0 ELECTRICAL SYSTEMS AND EMERGENCY POWER
REQUIREMENT
14.1 POWER DISTRIBUTION
CDU / VDU has two sub stations 300 – 10 and 300 – 20 for U-311/321 and U-
312/322 respectively. Sub station 300 – 10 is also feeding to Unit-351/361 &
similarly 300 – 20 is feeding to U-352/362. Thus, substations 300-10 & 300-20 are
feeding to Crude Train – 1 & Crude Train-2 respectively. These two substations are
getting power from MRS – 1 & MRS-2 through under ground cables at 33 kV
voltage level. At these sub stations, 33KV is stepped down to 6.6 kV by using 31.5
MVA transformers.

At each substation, there are two 31.5 MVA transformers feeding to 6.6 kV bus
and having a coupler between them so that when any of these transformers fails,
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then the other transformer will start feeding the loads of that side also through
Automatic Transfer Scheme (ATS).

From 6.6 kV switchboard, all HT motors (6.6 kV) of CDU/VDU and Hydrotreater are
being fed along with the Distribution transformers of 2 MVA. These distribution
transformers of 2 MVA then step down 6.6 kV to 415V which is supplied to all LT
motors, lighting loads etc. through PCC, PMCC & MCC. Automatic changeover
scheme is available in PCC also for better reliability of power.

There are 463 motors in both Crude trains out of which 72 are of 6.6 kV.

14.2 EMERGENCY POWER

In CDU/VDU, Emergency Power is made available through a PMCC for the most
essential electrical equipments. The emergency power to both Crude trains is fed
from MRS-1 by two DG sets (each of 3.81 MW at 6.6 kV) & one Emergency DG set
at Unit 351, through sub-station 300-11 in Unit-351. When total power fails, then
the Emergency DG will make power available within few seconds at the 6.6kV
switchboard available in substation 300-11. This 6.6KV power is stepped down to
415V by a small distribution transformer of 630 KVA located in each unit of the
both Train-1 & 2. The 415V supply is then automatically fed to different essential
electrical equipments of both trains.

SUMMERY OF ELECTRICAL LOADS

Units: 311/312/321/322
POWER CONSUMPTION DETAILS:
6.6KV BUS
Sub station 300-10 21.5 MW (Appox)
Sub station 300-20 21.5 MW (Appox)
CDU/VDU
Unit-311/321 12.5 MW (appox)
Unit-312/322 12.5 MW (appox)
EMERGENCY POWER REQ. 415V
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EC RD300-11 (Train-1) 0.390MVA (max)

EC RD300-28 (Train-2) 0.390MVA (max)

14.3 U. P. S
In CDU/VDU/ SGU there is one set of UPS per train. Each set is having two UPS
units, Rectifier, transformer, inverter, battery bank etc. and one bypass unit with
static switches. In normal condition, two UPS units share the electrical load
equally. When one of the UPS units fails to provide power due to internal fault,
then the other UPS unit will start giving power to all connected loads, keeping
faulty one isolated. Also when the normal power is not available to UPS, then with
the help of battery bank the UPS will provide uninterrupted power.

The load side is divided in two parts with a timer and bus-coupler. When normal
power fails then UPS will provide power as described above but only for 30
minutes to less important bus and for 6 hours to more important bus. The
electrical loads are distributed on either side of the bus according to their
importance.
The bypass unit will come into action when both UPS units fail to provide power.
Bypass unit has been provided with a stabiliser to give regulated power supply.
Manufacturer GUTOR, SWITCHERLAND
INPUT 415 V +/-10%, 3 Phase, 4 Wire, 50Hz+/-5%
Output 115V AC+/-1%,1 Phase, 2 Wire, 50Hz+/-1%
UPS POWER LOAD DESCRIPTION
Load for six hours
1. Telecom feeder ‘A’
2. Telecom feeder ‘B’
3. Fire and gas feeder ‘A’
4. Fire and gas feeder ‘B’
Load for 30 minutes
1. DCS / ESD feeder ‘A’

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2. DCS / ESD feeder ‘B’

3. M/c Monitoring Panel ‘A’
4. M/c Monitoring Panel ‘B’
5. Distribution Board 1
6. Distribution Board 2
7. Distribution Board 3
8. Distribution Board 4
9. Analyser House feeder ‘A’
10. Analyser House feeder ‘B’
11. Analyser House feeder ‘B’
12. Analyser House feeder ‘D’
13. JP-RD311-C01 A
14. JP-RD311-C01 B
15. JP-RD311-C02 A
16. JP-RD311-C02 B
17. JP-RD311-L01 A
18. JP-RD311-L01 B

Electrical Loads (415 V) connected to the

EMERGENCY PMCC
Plant : CDU / VDU
Unit : 311
Sl TAG NUMBER EQUIPMENT DESCRIPTION ABSORBED POWER
No (kw)
1 ME-RD311-M10-01 to 2 HP Flare KO condensate cooler 22
2 ME-RD311-M11-01 to 2 LP Flare KO condensate cooler 37
3 ED-RD300-01B 220V DC SUPPLY to sub-station 300- 9
10
4 EK-RD300-E01 Emergency lighting D B Sub-station 36
300-10
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5 EK-RD300-E03 Emergency lighting D.B. PIB -6 36

6 EK-RD311-E01 Emergency lighting D.B. Piperack 36
(N/S)
7 EK-RD311-E02 Emergency lighting D.B. Piperack 36
(N/S)
8 EK-RD311-E03 Emergency lighting D.B. Piperack 36
(N/S)
9 EK-RD311-E04 Emergency lighting D.B. Piperack 36
(N/S)
10 EK-RD311-E05 Emergency lighting D.B. Piperack 36
(N/S)
11 EU-RD300-P01B UPS 15
12 EU-RD300-P01C UPS 15
13 MA-RD300-X03B HVAC for PIB-6 36
TOTAL LOAD ( in Kw ) = 386

Unit : 312
Sl TAG NUMBER EQUIPMENT DESCRIPTION ABSORBED POWER
No (kw)
1 ME-RD312-M10-01 to 2 HP Flare KO condensate cooler 22
2 ME-RD312-M11-01 to 2 LP Flare KO condensate cooler 37
3 ED-RD300-02B 220V DC SUPPLY to sub-station 300- 9
20
4 EK-RD300-E02 Emergency lighting D B Sub-station 36
300-20
5 EK-RD300-E04 Emergency lighting D.B. PIB -7 36
6 EK-RD312-E01 Emergency lighting D.B. Piperack 36
(N/S)
7 EK-RD312-E02 Emergency lighting D.B. Piperack 36
(N/S)
8 EK-RD312-E03 Emergency lighting D.B. Piperack 36
(N/S)
9 EK-RD312-E04 Emergency lighting D.B. Piperack 36
(N/S)
10 EK-RD312-E05 Emergency lighting D.B. Piperack 36
(N/S)
11 EU-RD300-P02B UPS 15
12 EU-RD300-P02C UPS 15
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13 MA-RD300-X04B HVAC for PIB-7 36

TOTAL LOAD ( in Kw ) = 386

CHAPTER # 15

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UNIT SAFEGUARDING
SYSTEM

15.0 CDU/VDU SAFEGUARDING SYSTEMS

 CDU/VDU SAFEGUARDING FLOW SCHEMES

 The principle components for safeguarding the CDU/VDU are set out in Process
Safeguarding Flow Schemes (Refer G55-RD-311/312-001/ 011) following a
SAFETY / HAZOP analysis. Process Safeguarding Flow Scheme identifies /
summarises those protective devices which are installed to avert the release of
toxic and/or flammable materials.

 The intent of the safeguarding is to ensure that plant is safe in all respects and
the protection systems are not complicated by excessive installations without
compromising the safety.

15.1 ROVs AT PUMP SUCTION & SPILLBACK FLOW

CONTROLLERS AT PUMP DISCHARGE
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 Where large quantities of hazardous liquid (7.5 m3 or more) may be released

due to pump seal failure, positive isolation should be provided by a ROV for
each pump so that plant operation could continue with spare pump. Vessels
containing 7.5 m3 or more of inflammable liquid from which centrifugal pumps
take suction shall have positive isolation through a remote operated valves,
when any of the following conditions is met :
1. Pumping liquid is LPG or any other light hydrocarbon
2. Pumped liquid is above its auto-ignition temperature
3. Pumped liquid temperature is greater than or equal to 250°C
4. Pump service is prone to frequent seal leak
 The attached Table no.15.1 indicates the list of such ROVs & their location /
service.

 These ROVs are located on pump suction and replace the normal pump suction
valves. These ROVs are provided with a local switch for opening and closing
during normal operation and an emergency shutoff switch at a distance of 15
meter (minimum) from the pump and within line of sight of the pump. In order
to protect the pump from cavitation, the corresponding pump drive could be
stopped by means of a valve stem limit switch when ROV is less than 80%
open. The ROVs are fail in position type in case of instrument air failure.

 ROVs are operated by double acting actuators so that the plant operator has
control at all times and valves do not move on failure of the driving
mechanism.

 Also the CDU/VDU pumps are provided with spill-back control valves to meet
minimum continuos flow requirement of the pump at all the times & thereby
safeguard the pumps against blocked flow conditions.

15.2 PRESSURE SAFETY / RELIEF DEVICES:

 The various Vessels, Columns, Shell & Tube Exchangers, Net Gas Compressor,
Turbines, Dosing Pumps & pipelines etc in CDU/VDU are protected, by installing
PSV / PRV devices, against overpressures resulting from possible plant upsets /
abnormal operating conditions such as blocked flow / external fire etc . These

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devices with their location & purpose in CDU/VDU are as summarised in Table
No. 15.2.

 Also the u/s & d/s isolation valves for these PSV / PRV are oriented in such a
way that their stems are in a horizontal plane / position.

 The flare header valve at the unit B/L is a gear-operated valve installed in such
a way that its spindle is horizontal.

 The discharge of these PSV / PRV valves is free draining without any liquid
pockets. Also these valves are installed as close to the equipment as possible to
protect it against additional over pressurisation due to back-pressure.

15.3 EMERGENCY SHUTDOWN SYSTEM

 Emergency Shutdown System (ESD) will provide safeguarding for major

equipment such as Desalters, Net Gas Compressor, Crude Charge Heaters &
Vacuum Heater, Crude & Vacuum Column, Ejector System & a few critical
pumps such as HAGO & HVGO pumps, LP condensate return pump etc. in
CDU/VDU. In case of upset in process or utility systems, ESD will act
automatically to protect equipment / unit. The list of ESDs for CDU/VDU is as
per Table no.15.3. For details of these ESDs refer the “Cause & Effect
Diagrams” as summarised in Annexure 15.1.

15.4 LOCK OPEN VALVES:

 The isolation valves, marked as CSO (Car sealed open) or LO (Locked open)
are these valves whose hand wheel is kept in locked open position. Whereas
for LC (Locked close) valves hand wheel is kept closed. Locking of hand wheel
is done by means of a lock & key. There is no difference between CSO & LO
valve besides functional authority. For CSO valves the SS (shift superintendent)
has the authority to operate whereas for LO & LC valves prior approval of Plant
Manager is required. This measure has been taken to ensure the safety of the
equipment and the plant.

 Isolation valves of the PSV / PRV (which is inline) are kept Locked open to
ensure free path for the relief discharge. The upstream isolation valve of the
spare PSV is kept LC to isolate the spare PSV / PRV, whereas downstream
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isolation valve is kept LO to ensure that there is no pressurisation in the PSV /

PRV downstream line due to the passing upstream isolation valve. For steam
services PSVs / PRVs are not provided with any isolation valve as per IBR
regulation.

15.5 THE SAFEGAURDING SYSTEM FOR PUMPS :

 The pumps in CDU.VDU have been provided with various facilities as given
below :

1. Auto Start / Auto Stop

2.DCS Start / DCS Stop
3.Indication for Current Drawn / Vibration / Seal Trouble / Common Trouble
4.Indication for Running Hours / Run Indication etc.

 The attached Table no. 15.1 summarises the above facilities in CDU/VDU
pumps.

15.6 THE SAFEGAURDING SYSTEM FOR FIN FAN

COOLERS :

 All the fin fan coolers in CDU/VDU have been provided with vibration sensing
element (VE) for the fans. In case of high vibrations the high vibration switch
(VSH) would be actuated, sound high vibration alarm in the control room &
give signal in MCC to trip the concerned motor. Also the fin fan motor running
lamp indication is provided in the DCS control room.

15.7 THE SAFEGAURDING SYSTEM FOR HEATERS :

 Heaters are protected against abnormal and emergency situations by ESD’s as

mentioned above in point 15.3. Under normal operation the advanced lead lag
control ensures that optimum air to fuel ratios are always maintained. This in
turn ensures complete combustion of fuel at all times and safegaurds the
heaters from situations like after burning in the stack. Startup of heaters is a
critical activity and safe startup of heaters is ensured by a PLC based logic
sequence namely - Burner management system ‘BMS’. For details on lead lag
control and BMS refer chapter 11 section 3.

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CHAPTER # 16

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CHEMICALS USED & CONSUMPTION

S. UNIT FEED RATE SYSTEM DOSING CHEMICALS CONSUMED
NO KGS/HR RATE / MONTH
1 U311 C-05 ovhd C-O5 0.12 to ANH.AMMONIA- 875 kgs
stream= OVHDS 1.18 Kgs / NEUTRALISER
160000 Hr for each
train
2 U 311 C-05 ovhd C- 05 6 ppm wt/ UNICOR C – 1600 lits
stream= OVHDS OHDS CORROSION
160000 STREAM INHIBITOR
3 U311 1324000 CRUDE OIL 27.5 ppmwt PF 100( 27000 kgs
on Crude oil POLYFLO) –
ANTIFOULANT
4 U311 2648000 CRUDE OIL 3- 5 ppmwt DE 9930Lits
(I.e 450000 on Crude & EMULSIFIER- (I.e 9850 kgs,
bpsd) in EACH DESALTER Sp Gr =.992,)
DESALTER CHEMICAL
5 U312 C-05 ovhd C-O5 0.12 to ANH.AMMONIA- 875 kgs
stream= OVHDS 1.18 Kgs / NEUTRALISER
160000 Hr for each
train

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6 U 312 C-05 ovhd C- 05 UNICOR C –

6 ppm wt/ 1600 lits
stream= OVHDS OHDS CORROSION
160000 STREAM INHIBITOR
7 U 312 1324000 CRUDE OIL 27.5 ppmwt PF 100( 27000 kgs
on Crude oil
POLYFLO) -
ANTIFOULANT
8 U 312 2648000 CRUDE OIL 3-5 ppmwt DE 9930Lits
(I.e 450000 on Crude & EMULSIFIER- (I.e 9850 kgs,
bpsd) in EACH DESALTER Sp Gr =.992,)
DESALTER CHEMICAL

Note: For Chemical injection systems & details refer Chapter No. 5.

CHAPTER # 17

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LABORATORY SAMPLING
SCHEDULE

17.0 LABORATORY SAMPLING SCHEDULE

17.1 GENERAL

 Samples should be taken on a regularly schedule basis by authorized personnel

having knowledge of the process.

 Minimum operator equipment required during sampling typically includes

rubber gloves and protective shields. All personal protective equipment
required by operator’s facility should be shown.

 For gas samples, 500 ml stainless steel sample cylinders are preferred.

 All samples leaving the process area for the laboratory should be tagged with
the information like sample description, sample source, analyzers requested,
date and time sample.

 For quality analyzers list refer table –17.1

17.2 TEST METHODS

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 The following general test methods are collected from the literature with the
intention of giving idea of test procedures. However refinery may adopt
different test methods.

 Vapour pressure of petroleum products

 Reid method (ASTM D 323)

 This test covers the procedures for determination of vapour pressure of

gasoline, volatile crude oil, and other volatile petroleum products. The liquid
chamber of vapour pressure apparatus is filled with the chilled sample and
connected to the vapour chamber that has been heated to 37.8 0C in a bath.
The assembled apparatus is immersed in the bath until a constant pressure is
observed.

 Significance: - The determination of vapour pressure is another means of

assessing the volatility of gasoline, particularly its tendency towards vapour
locking. The latter is caused by excess of low boiling components, which under
critical circumstances of temperature and pressure tend to boil off in the fuel
supply system. The bubbles of vapour thus formed impede the flow gasoline to
the carburetor, thereby causing rough engine operation, reduction in power
output and in severe cases stopping the engine.

 Gasoline vapour pressure depends critically on its butane content, and the final
adjustment of vapour pressure to meet the specs. is often met by butane
injection.

 Vapour pressure (ASTM D 1267):

 For LPG, vapour pressure is an indirect measure for the most extreme low
temperature conditions under which initial vaporization can be expected to
occur.

 Significance: determination of vapour pressure of LPG is important for

safety reasons to ensure that maximum operating design pressures of storage
handling and fuel systems and their components shall not be exceeded under
normal operating temperature conditions.
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 Weathering test: -

 This test indicates the presence of higher boiling constituents in LPG. 100-ml
sample is collected in weathering tube. THE 95%EVAPORTION OF THE
PRODUCT AT 2 OC DENOTES THE CHARACTER OF THE SAMPLE. IN CASE THE
TEMPERATURE IS ABOVE 2 OC IT MEANS LPG IS HEAVIER AND IT MAY CONTAIN
C5+ HYDROCARBONS. THIS TEST IS INTENDED TO FIND OUT THE PRESENCE
OF HEAVIER HC IN LPG. WHICH MAY NOT READILY EVAPORATE.

 Copper strip corrosion tests (ASTM D 1838): -

 A cleaned and smoothly polished copper strip is immersed in the sample, which
is then maintained at the specified temperature for the specified length of time.
This strip is removed from the sample and examined for etching, pitting, or
discoloration.
 Significance: This test gives an indication of the corrosiveness of the
product to the metallic parts of the system in which the product is used.

Residue: -
 When LPG is vaporized, it is undesirable to leave behind non-volatile materials
that can plug up equipment or cause controls to operate improperly. The
residue test is an indicator of the non-volatile materials present in LP gas. A
100-ml sample is weathered in 100-ml centrifuge tube. The volume of residue
remaining at 37.80 C is measured.

 Distillation: -
 ASTM and true boiling point (TBP) analytical distillations are used to
define the volatility characteristics of petroleum fractions. Both are
batch distillation, which differ mainly in degree of fractionation
obtained during distillation. Atmospheric ASTM distillations are run in
flask without any reflux and no packing is employed. ASTM
distillations are standardized and more commonly used.

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 TBP distillations are performed in columns with 15 to 100 theoretical plates at

relatively high reflux ratios. The high degree of fractionation in this distillation
gives accurate component distribution for mixtures.

 ASTM D-86:

 This test method covers the distillation of natural gasoline, aviation gasoline,
ATF, special boiling point spirits, Naptha, white spirits, kerosene, gas oils,
distillate fuel oils and similar petroleum products.
 A 100-ml is distilled under prescribed conditions that are appropriate to its
nature. Systematic observations of temperature against volume of condensate
recovered are made and from these data results are calculated.
 Initial boiling point (IBP): - The thermometer reading that is observed
at the instant that the first drop of condensate falls from lower end of
condenser tube.
 Final point (FBP): Final boiling - The maximum thermometer reading
obtained during the test. This usually occurs after the evaporation of all liquid
from the bottom of the flask.

 Percent recovered: - The volume in ml of condensate observed in the

receiving graduate, in connection with a simultaneous thermometer reading.

 Fifteen-five (15/5) TBP distillation (ASTM D 2892)

 A laboratory batch distillation is performed in a fifteen theoretical plate-
fractionating column with five to one reflux ratio. A good fractionation results in
accurate boiling temperature. This distillation corresponds very closely to the
type of fractionation obtained in the refinery.

Motor Gasoline: -
 The most commonly used boiling points in the distillation tests are
temperatures at which 10,50 and 90% of gasoline is evaporated, indicating
front-end, middle and tail end volatilities respectively. Gasoline volatility
controls its performance for starting, vapour lock, warm up and crank case
dilution. About 10% of gasoline in the fuel air mixture must evaporate and
reach the cylinder as vapour in order to give prompt starting. The controlling
volatility requirement for starting is shown by the 10% evaporated temperature
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from the distillation test. The temp. for 50% point is a broad indicator of warm
up and acceleration performance under cold starting conditions. The lower the
50% evaporated temperature, the better the performance high 90%
evaporated temperature contributes to fuel economy and resistance to knock.
If this 90% point and FBP are very high, they can cause poor mixture
distribution in the intake manifold and combustion chambers, excessive
chamber deposits etc. in the engine.

SKO: -
 When superior kerosene is used in vaporizing burners, it is essential that the
fuel contain sufficient volatile components to ensure the ignition and flame
stability. In addition the volatility of the fuel must be uniform from batch to
batch if frequent resetting of burners is to be avoided. A recovery of 20% v
minimum at 2000C is therefore the limit set for kerosene.
 Distillation of Petroleum Products at Reduced
Pressure (ASTM D-1160)

 Some petroleum products decompose when distilled at atmospheric pressure.

This distillation method is for determination of distillation characteristics of such
products.

 This test covers the determination, at reduced pressures, of the range of

boiling points for petroleum products that can be partially or completely
vaporized at a maximum liquid temperature of 4000C (7520F). Both a manual
and automatic method are specified.
 The sample is distilled at an accurately controlled pressure between 0.13 and
6.7 kPa (1 and 50 mm Hg) under conditions that are designed to provide
approximately one theoretical plate fractionation. Data is obtained from which
the initial boiling point, the final boiling point, and a distillation curve relating
volume percent distilled and atmospheric equivalent boiling point temperature
can be prepared.

 Flash point (ASTM D 93) Standard test by

Pensky - Martens closed cup tester
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 Flash point is the lowest temperature at which application of the test flame
causes the vapour above the sample to ignite. This test method is applicable to
liquids with viscocities of 5.5 centistokes or more at 400 C.
 A 75-ml is heated at slow constant rate with continual stirring in brass test cup
with a cover of specified dimensions. An ignition source is directed into the test
cup at regular intervals with simultaneous interruption of stirring. The flash
point is the lowest liquid temperature at which application of ignition source
causes the vapour of the test specimen of the sample to ignite.
 This is used primarily as an index of fire hazards. This test is therefore made
mandatory by government regulations. Flash point can indicate the possible
presence of highly and flammable materials in a relatively non-volatile or non-
flammable materials. For example, an abnormally low flash point on a sample
of kerosene may indicate gasoline contamination. The sample is deemed to
have flashed when a large flame appears and instantaneously propagates itself
over the surface of the sample.
 Fire point is the minimum temperature at which the oil ignites and continues to
burn for 5 seconds.

 Cold flow properties (cloud point; CFPP;

pour point)
 CLOUD POINT, CFPP & POUR POINT OF FUELS FOR DIESEL ENGINES AND COMBUSTION
EQUIPMENT ALL RELATE TO THE PERFORMANCE OF THE FUEL UNDER COLD TEMPERATURE
CONDITIONS AND IN THE CONSEQUENCE THE ABILITY OF THE ENGINES OR PLANTS TO OPERATE
SATISFACTORILY IN COLD CONDITIONS.

 Cloud point (ASTM D2500)

 TEMPERATURE AS EXPRESSED AS MULTIPLES OF 10C AT WHICH CLOUD OR HAZE OF WAX

CRYSTALS APPEARS AT THE BOTTOM OF THE TEST JAR WHEN OIL IS COOLED UNDER
PRESCRIBED CONDITIONS. CLOUD POINT HAS BEEN REGARDED AS THE LOWEST TEMPERATURE
FOR PUMPING THE FUEL AND THEREFORE THE OPERATION OF THE VEHICLE.

 Pour point (ASTM D-97)

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 THIS TEST METHOD IS INTENDED FOR USE ON ANY PETROLEUM PRODUCT. AFTER PRELIMINARY
HEATING THE SAMPLE IS COOLED AT A SPECIFIED RATE AND EXAMINED AT INTERVALS OF 3 0C
FOR FLOW CHARACTERISTICS. THE LOWEST TEMPERATURE AT WHICH MOVEMENT OF THE
SPECIMEN IS OBSERVED IS RECORDED AS THE POUR POINT. POUR POINT IS A USEFUL GUIDE
TO THE LOWEST TEMPERATURE AT WHICH A FUEL CAN BE USED/PUMPED. IT ALSO INDICATES
THE WAXY NATURE OF THE OIL.

 Cold filter plugging point – CFPP (IP – 309)

 The highest temperature (expressed as a multiples of 10C) at which the fuel,

when cold under prescribed conditions will not flow through the filter or require
more than 60 sec for 20 ml to pass through or fails to return completely to the
test jar.

 Colour
 Saybolt Colour of petroleum products (ASTM D-156)

 IT IS DETERMINED BY MATCHING THE TRANSMITTED LIGHT FROM THE OIL SAMPLE WITH THE
SPECIFIED GLASS STANDARD.
 This test covers the determination of colour of refined oils from gasoline, jet
fuels, naphtha, and kerosene. The height of a sample column is decreased by
levels corresponding to Colour numbers until the Colour of sample is
unmistakably lighter than that of the standard.

 ASTM Color of Petroleum Products: (ASTM D-1500)

 This test method covers the visual determination of the color of a wide variety
of petroleum products such as heating oils and diesel fuel oils lubricating oils
and petroleum waxes.
 Using a standard light source, a liquid sample is placed in the test container
and compared with colored glass disks ranging in value from 0.5 to 8.0. When
an exact match is not found and the sample color falls between two standard
colors, the higher of the two colors is reported.

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 Determination of the colour of petroleum products is used mainly for

manufacturing control purposes and is important quality characteristic since
colour is readily observed by the user of the product. In some cases the colour
may serve as an indication of the degree of refinement of the material. When
the colour range of a particular product is known, a variation outside the
established range may indicate possible contamination with other product.

 Carbon residue:
 It is a measure of carbonaceous material left in the fuel after all volatile
components have vaporized in the absence of air. Carbon can deposit on
injector nozzles, which disrupts the mixture formation and consequently
combustion. Since residual fuel oils contain high amount of carbon, this test in
diesel can give indication of possible contamination of diesel with residual fuel
oil.

 Conradson method (ASTM D-189):

 This test covers the determination of the amount of carbon residue left after
evaporation and pyrolysis of oil and is intended to provide some indication of
relative coke forming properties. This test method is generally applicable to
relative non-volatile petroleum products, which partially decompose on
distillation at atmospheric pressure.

 A weighed quantity of sample is placed in a crucible and subjected to

destructive distillation. The residue undergoes cracking and coking reactions
during a fixed period of severe heating. At the end of the specified period, the
crucible containing the residue is cooled in a desiccator and weighed. The
residue remaining is calculated as percent of the original sample, and reported
as Conradson carbon residue.
 Since residual fuel oil contains high amount of carbon this test in diesel can
give an indication of possible contamination of diesel with residual fuel oil.

 Ramsbottom method:

 The sample after being weighed into a special glass bulb having a capillary
opening is placed in a metric furnace maintained at 5500C for 20 + 1 minute.
The sample is thus quickly heated to the point, at which all volatile material is
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evaporated out of the bulb with or without decomposition while the heavier
residue remaining in the bulb undergoes cracking and coking reaction. After a
specified 20 minutes heating period, the bulb is removed from the bath, cooled
in a desiccator and again weighed. The residue remaining is calculated as a
percentage of the original sample and reported as Ramsbottom carbon residue

 Ash from Petroleum Products (ASTM D-482):

 Knowledge of the amount of ash-forming material present in a product may

provide information as to whether or not the product is suitable for use in a
given application. This gives an idea of the ash forming impurities in oil or
inorganic components.

 This test covers the determination of ash in the range 0.001-0.180 mass
percent, from distillate through crude oils and waxes, in which any ash forming
materials present are normally considered to be undesirable impurities. The
test is limited to petroleum products, which are free from added ash-forming
additives, including certain phosphorus compounds. The sample contained in a
suitable vessel is ignited and allowed to burn until only ash and carbon
remains. The carbonaceous residue is reduced to an ash by heating in a muffle
furnace at 7750C (14270F), cooled and weighed.
 Heat of combustion of liquid hydrocarbon
fuels (ASTM D240)
 It is the amount of heat produced by combustion of unit quantity of fuel with
oxygen. The heat of combustion is a measure of energy available from fuel.
Knowledge of this value is essential when considering the thermal efficiency of
the equipment for producing either power or heat. It is expressed in Btu/lb. or
cal/g or J/g. There are two heats of combustion or calorific values for every
petroleum fuel - gross or net.
 The difference between the two calorific values is that the gross includes the
heat given by the water vapour in condensing while the net value does not
include this heat.

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 Heat of combustion is determined in this test by burning a weighed sample in

an oxygen bomb calorimeter in controlled conditions. The heat of combustion is
computed from temperature observations before, during and after combustion
with proper allowance for thermochemical and heat transfer corrections.
 The heat of combustion per unit mass of fuel, is a critical property of fuels
intended for use in weight- limited craft such as airplanes, surface effect
vehicles, and hydrofoils. The range of such craft between refueling is a direct
function of the heat of combustion and density of the fuel.
 Calorific value can also be calculated by the formula
Q V = 12400-2100d2
Q V caloric value gross cal/g
d = density at 150C

 API gravity (ASTM D-287)

 GRAVITY (WEIGHT PER UNIT VOLUME) OF CRUDE OIL OR OTHER LIQUID HYDROCARBON, AS
MEASURED BY THE API (AMERICAN PETROLEUM INSTITUTE). API GRAVITY BEARS A
RELATIONSHIP TO TRUE RELATIVE DENSITY BUT IS MORE CONVENIENT TO WORK WITH THAN
THE DECIMAL FRACTIONS, WHICH WOULD RESULT, IF PETROLEUM WERE EXPRESSED IN
SPECIFIC GRAVITY
 This test covers the determination by means of a glass hydrometer of the API
gravity of crude petroleum and petroleum products normally handled as liquids
and having a Reid vapor pressure of 180 kPa (26 psig) or less. Gravities are
determined at 15.560C (600F), or converted to values at 15.560C (600F), by
means of standard tables.
 This test is based on the principle that the gravity of a liquid varies directly with
the depth of immersion of a body floating in it. The floating body, which is
graduated by API gravity units in this method, is called an API hydrometer. The
API gravity is read by observing the freely floating hydrometer and noting the
graduation nearest to the apparent intersection of the horizontal plane surface
of the liquid with the vertical scale of the hydrometer.
 API Gravity deg C = 141.5 / Sp. Gravity (15.5/15.50C) –131.5

 API gravity of crude oil is used for pricing structure. Higher API gravity means
higher light and middle distillate content in crude oil.
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 Characterization factor: -
This is an empirical relationship used to correlate some of the important
characteristics of crude oil
K=3 TB/S
TB Mean average boiling point in degree rankine
S = Specific gravity @ 15.5 deg. C
 Kinematic Viscosity of Transparent and
Opaque Liquids

 (ASTM D-445)

 This test specifies a procedure for the determination of the kinematic viscosity
of liquid petroleum products, both transparent and opaque, by measuring the
time for a volume of liquid to flow under gravity through a calibrated capillary
viscometer. The dynamic viscosity can be obtained by multiplying the
measured kinematic viscosity by the density of the liquid.

 The time is measured for a fixed volume of liquid to flow under gravity through
the capillary of a calibrated viscometer under a reproducible driving head and
at a closely controlled and known temperature. The kinematic viscosity is the
product of the measured flow time and the calibration constant of the
viscometer.

 Viscosity is used for pump design. Pump clearances are adjusted according to
the viscosity and if it is out of range it will result in pump seizure. Many
petroleum as well as non-petroleum material is used as lubricants for bearings,
gears, compressor cylinders, hydraulic equipment etc. The proper operation of
equipment depends upon the proper kinematic viscosity of the liquid.

 For ATF viscosity at low temperature is limited to ensure that adequate fuel
and pressure are maintained under all operating conditions and that fuel
injection nozzles and system controls will operate at lower design temperature
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conditions. For diesel high viscosity can cause poor atomization, large droplets
and high spray jet penetration in diesel engines. As a result the fuel is not
distributed in or mixed with air required for burning. This results in poor
combustion, accompanied with loss of power and economy.

 Low fuel viscocities result in a spray, which is too soft and does not penetrate
far enough in the combustion chamber for good mixing. Combustion is
impaired and power output and economy are decreased. Wear of fuel system
components may increase because lubricating properties of fuels tend to
decrease with viscosity.

 Acid and Base Number by Color-Indicator

Titration (ASTM D-974):

 This test covers the determination of acidic or base constituents in petroleum

products and lubricants soluble or near soluble in mixtures of toluene and
isopropyl alcohol. It is applicable for the determination of extremely weak acids
or bases. Acidity is responsible for the corrosive properties of the product.

 To determine the acid or base number, the sample is dissolved in a mixture of

toluene and isopropyl alcohol containing a small amount of water, and the
resulting single phase solution is titrated at room temperature with standard
alcoholic base or alcoholic acid solution, respectively, to the end point indicated
by the color change of the added p-naphthol benzein solution (orange in acid
and green-brown in base). To determine the strong acid number, a separate
portion of the sample is extracted with hot water and the aqueous extract is
titrated with potassium hydroxide solution, using methyl orange as an
indicator.

 Doctor test (ASTM D235)

 Standard procedure in refinery operations, using the doctor solution to ensure

that the distillate products have a sweet odour as distinguished from the sour
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odour imparted by mercaptan sulphur compounds. The mercaptans are

converted to silver mercaptide by reaction with silver nitrate, the excess of
which is then determined by titration with ammonium thiocyanate.

 Aniline point
 Aniline point of oil is the lowest temperature at which the oil is completely
miscible with equal volumes of aniline.
 Equal volumes of sample and aniline (5ml) each are heated or cooled with
stirring in a jacketed test tube and the lowest temperature at which complete
miscibility occurs is noted.
 High aniline point indicates that fuel is highly paraffinic and hence has high
diesel index and a very good ignition quality. In case of aromatics the aniline
point is low and the ignition quality is poor.

 Cetane Number of Diesel (ASTM D-613):

 Ignition quality of diesel is usually expressed in cetane value as determined by

a mixture of normal cetane C 16 H 34 which has a high ignition quality, 100 cetane
no. and hepta methyl nonane which has a low ignition quality having 15 cetane
No. The percentage of cetane in the reference fuel by volume is termed as
cetane no. This can be determined in a standard CFR engine.
 The calculated cetane index or diesel index is a useful tool for estimating ASTM
cetane no. where a test engine is not available for determining this property.
 Higher the Cetane no. the lower the temperature at which the engine can be
started and lesser the engine roughness.
 Other empirical formulae e.g. Cetane index and diesel index can indicate
approximate cetane No. of fuels which do not contain cetane improver.

 Cetane Index of Distillate Fuels (ASTM D-976):

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 The Calculated Cetane Index formula represents a means for directly

estimating the ASTM cetane number of distillate fuels from API gravity and
mid-boiling point.
 Diesel index uses API and aniline point. Higher the diesel index better is the
ignition quality. It is normally used as a guide to ignition quality of diesel fuel in
the absence of engine for testing cetane no.
 Diesel index = Aniline point in deg F x API / 100

 Antiknock quality:

 This is most important performance property of gasoline imparting resistance

to knock or ping in the engine. Antiknock quality of gasoline is normally
expressed in octane no. Two laboratory methods have been standardized for
obtaining octane no. of motor fuels by comparing their knock tendencies in the
standard test engines with reference fuels blended from normal heptane and
iso-octane. The percent volume of iso-octane in the reference fuel, which
matches the knock tendency of the fuel under test, is termed as octane no.
 Research method for octane No. (RON) and motor method for octane no.
(MON) use the same basic engine but operate under different conditions.
 RON is accepted as a better guide of antiknock quality of fuels when vehicles
are operated under mild conditions associated with low engine speeds. MON
becomes of greater importance when operation is at high engine speed or
under heavy load conditions.
 The differences in the methods are as follows.
Research Motor
RPM 600 900
Mixture heating No Yes.

 Octane no. requirement of gasoline engine depends on their compression ratio

and if the fuel meets the minimum requirements in respect of octane no. It
ensures trouble free operation. Apart from being a nuisance the knocking in

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engine may result in loss of energy and at times may cause severe damage to
the engine.

 Smoke Point Luminometeric No. Naphthalene

content for Aviation Turbine Fuels (ASTM D-1322):

 Smoke point test alone is not universally accepted as a reliable criteria for
combustion performance. This test covers the determination of the smoke point
of an aviation turbine fuel. There is a good correlation between luminometer
number and smoke point, which is presented as part of the method.

 The sample is burned in an enclosed wick-fed lamp that is calibrated daily

against pure hydrocarbon blends of known smoke point. The maximum height
of flame that can be achieved with the test fuel without smoking is estimated
to the nearest millimeter.

 Smoke point provides indication of the relative smoke producing properties of

kerosene and ATF in diffusion flames. The smoke point is related to the
hydrocarbon composition type of such fuels. Generally more aromatic the fuel
the smokier the flame. A high smoke point indicates a fuel of low smoke
producing tendencies. Smoke point is greatest with paraffins considerably low
with naphthenes and lowest with aromatics. The smoke point and the
luminometric no. with which it can be correlated is qualitatively related to the
potential radiant heat transfer from the combustion product of the fuels.
Because radiant heat transfer exerts a strong influence on the metal
temperature of the combustion liners and other hot section parts of the gas
turbines, the smoke point provides the basis for the correlation of fuel
characteristics with the life of these components.

 Salts in Crude Oil (Electrometric Method) ASTM

D-3230:

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 This test method covers the determination of salts in crude oil. The accepted
concentration units are pounds NaCI per 1000 bbl of crude oil.
 This test method is based on the conductivity of a solution of crude oil in a
polar solvent when subjected to an alternating electrical stress. The sample is
dissolved in a mixed solvent and placed in a test cell consisting of a beaker and
two parallel stainless steel plates. An alternating voltage is impressed on the
plates and the resulting current flow is shown on a millimeter. The salt content
is obtained by reference calibration curve of current versus salt content of
known mixtures.
 The knowledge of salt content is important in deciding whether or not the
crude needs desalting. Excessive salt left in the crude frequently results in
higher corrosion rates in refining units.

 Sulphur in petroleum products (ASTM D-129)

 This is determined by lamp method or wickbold procedure for volatile

petroleum products and by bomb method for heavier products. Sulphur in the
sample is oxidized by combustion and is estimated volumetrically after
absorption in H 2 O 2 or by gravimetric methods after converting to barium
sulphate.

 This test method provides means of monitoring the sulphur level of various
petroleum products or additives. Sulphur in any form creates corrosion
problems and hence its tolerance is limited. Sulphur content can be used to
predict performance, handling or processing properties, and potential corrosion
problems. There are also regulations promulgated in federal states and local
agencies which restrict the amount of sulphur present in some fuels.

 Hydrogen Sulfide in Gases by the Tutwiler

Method (UOP-09):
 This method determines hydrogen sulfide in gas mixtures. Mercaptan sulfur
and carbonyl sulfide, if present, are determined as hydrogen sulfide.

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 A known constant volume of sample is drawn into a Tutwiler burette, replacing

a starch solution. A volume of starch solution, retained in the burette, is
titrated with standard iodine solution until the starch solution assumes a faint
permanent blue color. The concentration of hydrogen sulfide is calculated from
the volume of iodine solution used and its known molarity. Hydrogen Sulfide,
Mercaptan Sulfur, and Carbonyl Sulfide in Hydrocarbon Gases by Potentiometric
Titration UOP-212:
 This method is for determining hydrogen sulfide, mercaptan sulfur, and
carbonyl sulfide in gaseous hydrocarbons and in liquefied petroleum gas (LPG)
of ordinary properties. Also covered is the determination of mercaptan in non-
ordinary LPG, which may contain a wide range of hydrocarbon types from
ethane to gasoline boiling range hydrocarbons. The hydrogen sulfide
concentration range, which can be determined, is from 0.03 to several
thousand grains per 100 cu ft (0.03 to several thousand wt-ppm). The method
is also applicable to LPG samples containing as little as 1.0-ppm mercaptan
sulfur.
 The sample, taken either form a sample cylinder or directly from a refinery
stream, is scrubbed first through a potassium hydroxide solution and then
through a monoethanolamine solution. The potassium hydroxide solution
contains Unitest 212 solution, which inhibits the oxidation of sulfur compounds
by chelating heavy metals. A Potentiometric titration of the absorbed hydrogen
sulfide and mercaptan sulfur follows, using either an aqueous or an alcoholic
silver nitrate solution. The monoethanolamine solution, which contains the
absorbed carbonyl sulfide is titrated potentiometrically with alcoholic silver
nitrate in an acidic titration solvent. The electrode system for both titrations is
glass vs. silver-silver sulfide. The concentration of each item sought is
estimated from the titration curve. Either an automatic recording or a manually
operated titrator may be used.

 Trace Metals in Oils by Wet Ash (UOP-389):

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 This method is for determining iron, nickel, vanadium, lead, copper, sodium,
and other metals in crude, gas oils, and fuel oils. Most of the elements can be
determined within the concentration range of 0.02 to 200 mass-ppm when a
50g sample of oil is ashed. Higher or lower concentrations can be determined
by ashing appropriate sized samples. The method is sufficiently flexible to add
more elemental determinations if needed.

 The oil sample is coked with fuming sulfuric acid, ignited and ashed at 5380C
(10000F). The residue is then treated with aquaregia and after evaporation is
dissolved in dilute hydrochloric acid containing scandium and lithium as internal
standard and spectroscopic buffer, respectively. The resulting sample solutions
are then aspirated into a computer controlled, Inductively Coupled Plasma-
Atomic Emission Spectrometer along with appropriate standards.
Concentrations are determined by comparison of the sample emission signals
to the computer-generated calibration curves.

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CHAPTER # 18

FIRE AND SAFETY

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18.0 FIRE AND SAFETY

18.1 LOSS PREVENTION AND SAFETY PHILOSOPHY
The principal objectives of loss prevention & safety philosophy are to ensure
safety of the plant & facilities to:
 Minimize the risk and consequences of an accident
 Minimize the potential for hazardous occurrences
 Ensure a safe working environment for the personnel
 Ensure adequate means of escape are provided
 Provide appropriate fire protection systems to rapidly bring under control
and extinguish any reasonably foreseeable fire which could develop
during normal operations

 HAZARD:
 Hazard is considered as an inherent property of a substance or a process that
has a potential to cause loss, damage or injury to the property, environment or
person.

 ACCIDENT:
 Accident is defined as an occurrence resulting from uncontrolled development
in course of industrial activity, which causes or has the potential to cause a
serious damage to the persons, property or the environment.

18.2 BRIEF INTRODUCTION TO HAZOP AND HAZAN

STUDIES:
 Hazard operability (HAZOP) and hazard analysis (HAZAN) studies are defined
as “ The application of a formal systematic critical examination to the process
and engineering intentions in order to assess the hazard potential due to the
mal-function of the individual item of equipment effect or facility as a whole”.

 HAZOP:
 The application of guide words in a systematic & critical manner to the process
& engineering intentions so as to discover conceivable & meaningful deviations,
search for their causes, visualize their consequences & hazard potential and try
to eliminate or mitigate hazards by suggesting suitable hardware or software
modifications in the system is called as HAZOP study.

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 The various guide words are no flow, less flow, reverse flow, less temperature,
high temperature, low pressure, high pressure, as well as, other than etc. The
guide words are used to stimulate the imagination of the persons to discover
deviations from the design & operating intentions of the plant / system.
Standard HAZOP sheets are used to carry out the study, record the findings &
give recommendations.

 A team usually consisting of a Project Engineer, Process Engineer,

Instrumentation Engineer, Commissioning Manager and several others who
possess the required technical expertise and experience in the Process Industry
carries out Hazop.

 Their job starts from the conceptual stage of design and continues till the
normal operations of the plant are resumed. However, the Hazop studies will
be conducted even on the running plants to identify the near misses that might
have occurred during the design or commissioning stages.

 HAZAN:
 Hazard Analysis is the term used to describe the application of the numerical
methods to safety problems.

 It consists of three stages:

1. Estimating how often the incident will occur (probability)
2. Estimating the consequences of the incident on the employees , plants
and profit
In both (1) and (2), estimates should be based, whenever possible on
past
experience.
3. Comparing the results of (1) and (2), action is taken to minimize the
probability
of occurrence or consequence the hazard.

 Fault tree and Event tree analysis is employed in HAZAN studies. Both the tree
analyses list the probable causes for a hazardous event. By estimating the
probabilities of occurrence of individual causes and by using appropriate
arithmetical expressions the frequency of an event can be worked out.

 ACCIDENTS:
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 Most of the accidents in hydrocarbon industry are caused by various types of

fires or explosions as discussed below. There are three basic requirements for a
fire or an explosion to take place, namely fuel, air & source of ignition. Also for
the fire to take place & sustain, fuel & air should have proper the
stoicheometric ratio. This ratio depends upon the type of fuel involved.

 AUTO-IGNITION-TEMPERATURE :
 All the hydrocarbons have a tendency to ignite on their own at or above a
particular temperature called “AUTO-IGNITION-TEMPERATURE”. When the
hydrocarbons are at or above their auto-ignition temperature, no external
source of ignition is required. The heavier the hydrocarbon, lower is its auto-
ignition temperature.

 LEL (or LFL):

 The minimum concentration (expressed in % volume) of fuel in fuel-air-
mixture so as to catch fire & sustain the flame is called as low explosive limit of
the fuel or low flammability of a fuel. When the fuel concentration is below LEL,
it would fail to catch & sustain fire, since it will starve for fuel.

 HEL (or HFL):

 The maximum concentration (expressed in % volume) of fuel in fuel-air-
mixture so as to catch fire & sustain the flame is called as high explosive limit
of the fuel or high flammability limit of a fuel. When the fuel concentration is
above LEL, it would fail to catch & sustain fire, since it will starve for air.

 TYPES OF FIRES & EXPLOSSIONS:

 Oil Pool Fire :
 The oil pool fires are generally associated with tankfarm. The release of a non-
boiling liquid from a tank results in spreading of the leaked oil. Thus the leaked
oil can form a pool. The area of the pool can be taken equal to the area of
confinement (i.e. tank bund). If by any chance it catches fire the intensity of
the fire depends upon the type of liquid, wind velocity, area of the pool, height
flame, distance from the fire.etc.

 Flash Fire:
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 When a leaked hydrocarbon travels certain distance & meets the ignition
source downstream, it catches fire. This fire has the tendency to travel back
towards the source of hydrocarbon leak & is called as flash fire. In a flash fire,
the gas burns, but does not explode. The heat radiation or the flames can
cause severe burns. It can also cause sudden depletion of oxygen and could be
fatal.

 Fire ball :
 When the vapor cloud formed catches the source of ignition outside, the cloud
boundaries, it results into a fireball.

 UCVCE (Un-Confined Vapor Cloud Explosion) :

 The cause for UCVCE is the ignition of proper mixture of hydrocarbon vapor
and air. The source of the vapor may be a leak in the pipeline, valve or a
storage tank. The emission rate has to be fast enough to preclude dispersal or
dilution of the atmosphere and the mixing should be turbulent enough for
proper mixing rather than forming a vapor “pan-cake”. In case of “pan-cake”
formation the vapor may travel considerable distance from the source of
release and cause damage to other places (for e.g. near-by residential areas
may become the victims).

 UCVCE causes wide spread damage to life and property more because of the
overpressure (blast wave) rather than the fire itself.

 BLEVE (Boiling Liquid Expanding Vapor

Explosion)
 This phenomenon occurs when a pressure vessel containing light hydrocarbon
liquid ruptures on exposure to intense heat.

 For example consider the LPG storage tank. The gas is liquefied under high
pressure and if additional heat is applied the liquid starts boiling forming
vapors. The hydrocarbons have high liquid to gas expansion ratio. This creates
very high pressure within the tank and when the design limits are crossed the
tank ruptures. The liquid when released into the atmosphere undergoes rapid
vaporisation and covers a large area. If this vapor gets ignited wide spread
damage will be inevitable. The fragments of the tank that are thrown off are
also capable of causing severe damages.

 Toxic Gases :
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 The release of toxic gases can occur due to

1. Accidental or sudden failure of the system:
-the material released may cause explosion or fire OR
-the toxic / poisonous gases may endanger human beings
2. Continuous release from the system are normally expected to be within
limits

18.3 TAMING OF HAZARDS:

 Design and Layout:
 A sound design and good layout of the plant solves most of the impending
problems. This subject is taken up during HAZOP studies and efforts are put to
maximize safety and production.

 SOP’s :
 By following standard operating procedures the potential dangers involved in
operation a plant can be minimized.

 Employee Training:
 Employees are trained to make them aware of the safety procedures both
during the normal operations and emergencies. Fire Mock Drill is one example
of practical kind of training.

 Safety Audits:
 Safety program auditing is an important tool to evaluate the effectiveness of
the safety system. It is a part of HSF&E Practices to ensure that critical
operations are carried out in a profitable, efficient and safe way.

 Fire Fighting Facilities:

 The RPL complex possess facilities to rapidly bring under control and extinguish
any foreseeable fire, which could develop during normal operation and
emergencies.

18.4 FIRE INDICATION AND FIRE FIGHTING:

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Jamnagar

 PASSIVE FIRE PROTECTION:

1) Structures: Primary structures, supports for vessels containing
hydrocarbons and critical supports for pipe racks are considered for fire-
proofing to prevent the structural collapse.

 Control rooms, sub-stations and other buildings within the process plant area
are blast proof to protect them from overpressures. The location of flares and
atmospheric vents are positioned so as to pose minimum danger to the plant.

2) Fire and Gas Detection System :The system helps to detect fire or
gas release, and automatically initiate audible and visual alarms in the main
control room and in the vicinity of the hazard so that preventive/shutdown
actions at an early stage can be initiated to mitigate the consequences of the
accident / hazard.

 Types of Fire Detectors:

 Combined UV-IR Detectors :
0. Principle: A burning substance gives out radiation’s that fall between the
UV-IR range. In the process industry the flammable materials can be arranged
on the type of flame they produce. Hydrogen and Coke form the two extreme
ends of such a category. Whether the flame will be colorless or smoky depends
upon the H/C ratio of a fuel. Lower the value of the H/C ratio of a material,
greater is the smoke generated. Hence Hydrogen burns with a colorless flame
while the coke gives a smoky flame.
 Hence the UV-IR detectors installed in process areas detect flame of any
kind except the smoky kind.
 No voting is necessary, as they are highly reliable.

 Smoke Detectors:
 There are two kinds of smoke detectors: -1) Ionization type & 2) Optical type

 They are placed in control rooms, switch-gear areas, laboratories, warehouses,

stores etc where the flame will be of smoky nature. The smoke generated
hides the actual flame and hence makes the UV-IR detectors ineffective.

 Heat Detectors:
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 These kinds of detectors are placed in only specific areas like kitchen.

 They are of three types:

1. Fixed Type: These kinds of detectors give alarm only if the temperature of
the surrounding place reaches or goes beyond the pre-determined
temperature. Usually the fixed temperature is 79o C.

2. Rate of Rise Type: These kinds of detectors give alarm only if the rate of
rise in temperature reaches or goes beyond the pre-determined value. Usually
the value stored in the detectors is 10o C/sec.

3. Fixed cum Rate of Rise Type: These kinds of detectors have both the
features of the detectors explained above. These kinds of detectors are being
used extensively in our refinery.

 Types of gas detectors:

 Flammable gas detectors (LEL type): These kinds of detectors help in detecting
leakage’s of flammable gases .The detectors give alarms if the flammable gas
vapors are a certain percentage of their LEL (Lower Explosive Limit). The
percentage varies between 40% to 60% depending upon the nature of the
hydrocarbon.

 The commonly used ones are:

1) Point Type: To detect the leaks in the seals of the individual pumps.
2) Beam Type: To detect leaks in the pipelines.

 Toxic gas detectors: These kinds detect the presence of toxic gases such as
SO 2 and CO. They are of semi-conductor type and hence can protect
themselves from being poisoned by the toxic gases.

 The detectors are placed at a height of 1.5 meters as it is considered to be the

breathing zone for human beings. Portable types of gas detectors are also
available which can be fixed to the waist like a pager.

18.5 ACTIVE FIRE PROTECTION:

 A general introduction to various fires fighting equipments is given below:
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1. Fire Hydrants: These are located along the battery limits of a unit. The
distance between any two hydrants is 30 meters. Additional hydrants are
installed within the process areas. The height of the hydrant is 1 meter from
the ground as this is most comfortable in fixing a hose during any emergency.
Hoses are placed in separate cabins called FHC (Fire Hydrant Cabins) which are
placed strategically in the field. The diameter of the outlet is 63mm, the
pressure of the hydrant is 5.25kg/cm2 and the volumetric flow rate 600 lit/min.
In the open fields the hydrants have twin openings while the ones in the
buildings (sub-station, control-room etc) have only a single opening. These are
used to fight only major fires.

2. Fire Water Hose Reel: This is primary fire fighting equipment employed
to fight minor fires. It consists of a drum installed on a concrete wall and a
hose is wound on the drum. One end of the hose is connected to the water
source and the other has a nozzle. The hose is made up of fire resistant
neoprene material, which has a length 30 meters, and a diameter of 40mm.The
nozzle has the arrangement either to give spray or jet of water.

3. Fixed Type Water Monitor: This kind of equipment is employed to fight

major fires usually the tank and vessel fires. Fighting such fires takes long time
and employing a fire hydrant will be tiring. Hence they are located around
vessels and tanks. The main advantage of a monitor is, it can be rotated 360o
in a horizontal plane and 95o in a vertical plane (+ 75o to –15o). Moreover the
jet emerging from the monitor has a pressure of 7 kg/cm2 (flow is 2400 lit/min)
and reaches a height of 45 meters (under still air conditions).

4. DCP (Dry Chemical Powder): It’s a primary fire fighting equipment

and placed in open field (process area) to fight small fires (A, B & C type of
fires). They are not used in offices because the chemical powder might
contaminate the electronic goods and at times the problem of low visibility in
confined areas may occur. The chemical extinguishing agent shall be a
potassium-based agent (Purple K or Monnex Powder).

5. CO2 Extinguishers: It’s also a primary fire fighting equipment and used
to fight small fires in buildings (control room, labs, and offices etc). The danger
of electronic goods getting contaminated as in case of DCP is obviated and in
addition house keeping will not be a problem. However, one should be careful
enough not to use this in confined areas, because CO 2 being heavier than air
replaces air and may lead to sudden depletion of O 2 .In open fields even a small
breeze will drastically reduce the efficiency.
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6. Deluge and Sprinkler Valves: This system is installed near hot oil/high
pressure pump.
 Manifolds handling flammable liquids
 Transformers
 LPG Spheres
 Non-insulated vessels containing more than 7.5 m3 of flammable liquids

 The D.V. skid for relevant area are provided with a foam concentrate storage
tank sized for 30-min. duration of foam solution application. The foam
concentrate is induced into the main deluge header via an inductor at 3%
proportioning rate.

 In addition to Passive and Active fire fighting equipments there are several
Miscellaneous Safety equipment which aid in the fire fighting process. Some of
them are listed below:
 Breathing Apparatus
 Stretchers
 First Aid Kits
 Wind Socks
 Safety Signs
 Eye wash / Shower Units
 Portable Multiple Gas Detectors

18.6 Details of different fire fighting equipment:

 Unit 311/312/321/322

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Jamnagar

FIRE FIGHTING EQUIPMENTS Nos.

Dry Chemical Powder 285X2=570(10kg cap)
6X2=12 (75kg cap)
CO 2 Extinguisher 6X2=12 (4.5 kg)
Foam Trolley with hose NIL
Foam Extinguisher NIL
Breathing Apparatus 3+4=7
SCBA 1+1=2
Safety showers 6X2=12
Eye bath 6X2=12
First Aid Cabinets NIL
Stretcher NIL
Wind Sock 5X2=10
Hydrant Points 53X2=106
Water Monitors 18X2=36
Hose Reel 4X2=8
Deluge System (Water spray) 7X2=14

Reliance Industries Limited

Jamnagar
Material Safety Data Sheet
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Jamnagar

Crude Oil

1. CHEMICAL IDENTITY
Chemical Name: Chemical Classification: Hydrocarbon
Crude oil

Synonyms: Crude oil Trade Name: Crude oil

Formula: Mixture of C1 to C.A.S. No: N/A U.N. No: N/A

Heavier Hydrocarbon Paraffinic
and Bitumastic Materials
Shipping Name: N/A
Codes/Label: Flammable Liquid Hazchem No : N/A
Regulated Identification
Hazardous Waste: Acrid smoke and irritating fumes

Hazardous Ingredients: C.A.S. No: Hazardous Ingredients: . C.A.S. No: N/A

N/A

1 None 3 None

2 None 4 None

2. PHYSICAL AND CHEMICAL DATA

Boiling Range/Point 93 to Physical State: Liquid Appearance: dark brown liquid
316 C

Melting/Freezing Point: -65 Vapour Pressure Odour: crude oil

C N/A

Vapour Density: Solubility: Insoluble in water

(Air = 1)

Specific Gravity: 0.6738 to 0.9497 pH: N/A

(Water = 1)

3. FIRE AND EXPLOSION HAZARD DATA

Flammability: Yes LEL N/A Flash Point: 83 C Autoignition
Temperature: N/A
UEL N/A
Explosion Sensitivity to Impact: Hazardous Combustion Products:
None May produce toxic and flammable gases

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Hazardous Polymerisation: None

Combustible: It burns readily once involved in a fire and highly

combustible.
Explosive Material:
Explosive hazard when exposed to heat, flame.
Corrosive Material:
None

Flammable Material: It can be ignited by sparks, a small flame and

when heated..

Pyrophoric Material: No Organic Peroxide: N/Appl.

4. REACTIVITY DATA
Chemical Normally stable
Stability:

Incompatibility Readily ignited by contact with oxidising chemicals.

with other
Materials:

Reactivity: None

5. HEALTH HAZARD DATA

Routes of Entry: oral

Effects of Exposure/Symptoms: Moderately toxic.

Emergency Treatment: Medical advice should be immediately sought.

TLV (ACGIH) N/A STEL N/A

Permissible Exposure N/A Odour: N/A ppm mg/m3

Limit orl-rat LD 50 Threshold LD 50
.
NFPA Hazard
Signal Health: 1 Flammability: 3 Reactivity: 0
Special:

6. PREVENTIVE MEASURES
Personnel Protective Wear protective gloves for general containment
Equipment:

Handling and Storage Store in a cool, dry, well ventilated location. Inside storage

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Precautions: should be in a standard flammable liquids storage warehouse,

room, or cabinet. Separate from oxidising materials. Storage
tank should be stainless or mild steel, High Density Polyethylene,
glass (small quantities).

7. EMERGENCY AND FIRST AID MEASURE

EMERGENCY HANDLING OF: Media: Dry chemical, foam, carbon dioxide, or water spray

Special Procedures: Flame proofing equipment are needed

FIRE:
Unusual Hazards: None
First Aid Measures: Seek medical help
EXPOSURE:
Antidotes/Dosages: Seek medical help

Steps to be Eliminate all ignition sources. Stop or control

taken: the leak, use water spray to cool and disperse
SPILLS
vapours.

Waste Disposal Absorb in a noncombustible material

Method: for proper disposal.

8. ADDITIONAL INFORMATION/REFERENCES
1. SAX-Dangerous Properties of Industrial Materials.-(8th Edition)
2. Fire Protection Guide on Hazardous Materials. NFPA (1985 Edition) NFPA-325.

ACGIH = American Conference of Governmental Industrial Hygienists

orl = Oral route
STEL = Short Term Exposure Limit
TLV = Threshold Limit Value

9 MANUFACTURER/SUPPLIER DATA
Name of firm: RELIANCE INDUSTRIES LIMITED. Fire Department,
RIL
Village Padana/Meghpur, Taluka Lalpur, Jamnagar
Pin 361 280 Dist. Jamnagar, (Gujarat),
INDIA Phone:( 0288)291191
Telephone: (0288) 292929

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 Reliance Industries Limited
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Jamnagar

10 DISCLAIMER

Reasonable care has been taken in the preparation of the information contained
in this Material Safety Data Sheet and is given in good faith. However, Reliance
Industries Limited, Jamnagar. assumes no responsibility as to the accuracy or
suitability of such information and no warranty, expressed or implied, is made.

LIQUIFIED PETROLEUM GAS

( LPG )
A. Important Safety Data
 Colourless, highly flammable gas. Mixture of propane/butane,etc.
 Odour: Mild, unpleasent.

B. Health Hazard
 Avoid inhalation.
 Asphyxiant in high concentration.

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 Causes mental dullness, drowsiness, nausea & unconsciouness.

 Frostbite, in case of direct contact with skin.
 PPE : Safety goggles, protective hand gloves & overall.

C. Fire / Explosion Hazard

 Highly flammable gas.
 Fire : Shut off supply. If this is not possible, let it burn keeping surroundings
cool with water sprays.
 Auto ignition Temp: > 365 oC
 LEL %V : 1.6 – 1.9 Flash Point : - 104 to – 60 deg C
UEL % V : 9.5

D Emergency / First aid measures

 If inhaled, remove the victim to fresh area.
 Give artificial respiration if required.
 In case of frostbite wash the skin immediately with plenty of water.
 Get medical help.

E In case of emergency contact

 Security : 100 Fire : 101 Medical : 111

F  NFPA Hazards Ratings

Health: 1 Flammability: 4 Reactivity: 0

Reliance Industries Limited

Jamnagar
Material Safety Data Sheet
Naphtha
1. CHEMICAL IDENTITY
Chemical Name: Chemical Classification: Hydrocarbon
Light Naphtha

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Synonyms: Naphtha Trade Name: Light Naphtha,

Formula: Mixture of mainly C.A.S. No: N/A U.N. No: N/A

C5/C6
Shipping Name: N/A
Codes/Label: Flammable Liquid Hazchem No : N/A
Regulated Identification
Hazardous Waste: Acrid smoke and irritating fumes

Hazardous Ingredients: C.A.S. Hazardous Ingredients: . C.A.S. No:

No: N/A N/A

1 None 3 None

2 None 4 None

2. PHYSICAL AND CHEMICAL DATA

Boiling Range/Point 93 - Physical State: Liquid Appearance: Colourless liquid
149 C

Melting/Freezing Point: <- Vapour Pressure Odour: Sweet aromatic

10 C @ 38 C: 0.7691 kg/cm2 smell

Vapour Density: 3.75 Solubility: Insoluble in water

(Air = 1)

Specific Gravity: 0.75 pH: N/A

(Water = 1)

3. FIRE AND EXPLOSION HAZARD DATA

Flammability: Yes LEL 0.9 % Flash Point: 15 C Autoignition
Temperature: 232 -
UEL 6%
260 C
Explosion Sensitivity to Impact: Hazardous Combustion Products:
None May produce toxic gases

Hazardous Polymerisation: None

Combustible: It burns readily once involved in a fire and highly

combustible.
Explosive Material:
Explosive hazard when exposed to heat, flame.

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Corrosive Material: None

Flammable Material: It can be ignited by sparks, a small flame and

when heated..

Pyrophoric Material: No Organic Peroxide: N/Appl.

4. REACTIVITY DATA
Chemical Normally stable
Stability:

Incompatibility Readily ignited by contact with oxidising chemicals.

with other
Materials:

Reactivity: None

5. HEALTH HAZARD DATA

Routes of Entry: oral

Effects of Exposure/Symptoms: Moderately toxic.

Emergency Treatment: Medical advice should be immediately sought.

TLV (ACGIH) N/A STEL N/A

Permissible Exposure N/A Odour: N/A ppm mg/m3

Limit orl-rat LD 50 Threshold LD 50
.
NFPA Hazard
Signal Health: 1 Flammability: 3 Reactivity: 0
Special:

6. PREVENTIVE MEASURES
Personnel Protective Wear protective gloves for general containment
Equipment:

Handling and Storage Store in a cool, dry, well ventilated location. Inside storage
Precautions: should be in a standard flammable liquids storage warehouse,
room, or cabinet. Separate from oxidising materials. Storage
tank should be stainless or mild steel, High Density Polyethylene,

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Jamnagar

glass (small quantities).

7. EMERGENCY AND FIRST AID MEASURE

EMERGENCY HANDLING
OF:
Media: Dry chemical, foam, carbon dioxide, or water spray

Special Procedures: Flame proofing equipment are needed

FIRE:

Unusual Hazards: None

First Aid Measures: Seek medical help
EXPOSURE:
Antidotes/Dosages: Seek medical help

Steps to be Eliminate all ignition sources. Stop or control

taken: the leak, use water spray to cool and disperse
SPILLS
vapours.

Waste Disposal Absorb in a noncombustible material for

Method: proper disposal.

8. ADDITIONAL INFORMATION/REFERENCES
1. SAX-Dangerous Properties of Industrial Materials.-(8th Edition)
2. Fire Protection Guide on Hazardous Materials. NFPA (1985 Edition) NFPA-325.

ACGIH = American Conference of Governmental Industrial Hygienists

orl = Oral route
STEL = Short Term Exposure Limit
TLV = Threshold Limit Value

9 MANUFACTURER/SUPPLIER DATA
Name of firm: RELIANCE INDUSTRIES LIMITED. Fire Department, RIL
Village Padana/Meghpur, Taluka Lalpur, Jamnagar
Pin 361 280 Dist. Jamnagar, (Gujarat), INDIA
Phone:( 0288)291191
Telephone: (0288) 292929

Page No:
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Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

10 DISCLAIMER

Reasonable care has been taken in the preparation of the information contained in
this Material Safety Data Sheet and is given in good faith. However, Reliance
Industries Limited, Jamnagar. assumes no responsibility as to the accuracy or
suitability of such information and no warranty, expressed or implied, is made.

Reliance Industries Limited

Jamnagar
Material Safety Data Sheet

Kerosene
1. CHEMICAL IDENTITY
Chemical Name: Chemical Classification: Hydrocarbon
Kerosene

Synonyms: Kerosene Trade Name: Kerosene

Formula: Mixture of alkane C.A.S. No: 8008206 U.N. No: 1223

series, having 10-16 carbon
atoms per molecule

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Jamnagar

Shipping Name:
Codes/Label: Flammable or Combustible Liquid
Hazchem No : 3 Y
Regulated Identification
Hazardous Waste: Acrid smoke & irritating fumes

Hazardous Ingredients: N/Appl. C.A.S. Hazardous Ingredients: N/Appl. C.A.S.

No: No:

1 None 3 None

2 None 4 None

2. PHYSICAL AND CHEMICAL DATA

Boiling Range/Point: 80 - Physical State: Appearance: Pale yellow to
162 C Liquid water - white oily liquid.

Melting/Freezing Point: -40 Vapour Pressure: N/Av. Odour: Strongly

to -60 C characteristics, but some special
grades are virtually Odourless

Vapour Density: 4.5 Solubility: Insoluble in water

(Air = 1)

Specific Gravity: 0.8 to 1.0 pH: N/Av.

(Water = 1)

3. FIRE AND EXPLOSION HAZARD DATA

Flammability: Yes LEL 0.7 % Flash Point: 65 - 85 Autoignition
C Temperature: 210 C
UEL 6%
Explosion Sensitivity to Impact: Hazardous Combustion Products:
None Acrid smoke & irritating fumes

Hazardous Polymerisation: None

Combustible: When exposed to heat, flame, or oxidisers.

Explosive Material: Moderately explosive in the form of vapour when
exposed to heat or flame.
Corrosive Material:
It reacts with oxidising materials

Flammable Material It can be ignited by sparks, hot elements and

flames when heated slightly above normal room
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temperature.

Pyrophoric Material: No Organic Peroxide: N/Appl.

4. REACTIVITY DATA
Chemical Normally stable
Stability:

Incompatibility Oxidisers
with other
Materials:

Reactivity: It can react with oxidising materials.

5. HEALTH HAZARD DATA

Routes of Entry: Oral, inhalation routes.

Effects of Exposure/Symptoms: Moderately toxic. Human systemic effects are

somnolence, hallucinations and distorted perceptions,
coughing, nausea or vomiting, and fever.

Emergency Treatment: No antidote to be given, medical advice to be

immediately sought.

TLV (ACGIH) N/A STEL N/Av.

Permissible 28 g/kg Odour: N/Av. ppm mg/m3

Exposure Limit orl- Threshold LD 50
rat LD 50
Health: 0 Flammability: 2 Reactivity: 0 Special: N/A.
NFPA Hazard
Flam
Signal
mabili
Healt Reacti
h -vity
Speci
al

6. PREVENTIVE MEASURES
Personnel Protective Wear full protective clothing.
Equipment:

Handling and Storage Store in a cool, dry, well ventilated location. Inside storage
Precautions: should be in a standard flammable liquids storage warehouse,

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Jamnagar

room, or cabinet.

7. EMERGENCY AND FIRST AID MEASURE

EMERGENCY HANDLING
OF:
Media: Dry powder, foam, carbon dioxide, or halons

Special Procedures: Flame proofing equipment are needed

FIRE:

Unusual Hazards: None

First Aid Measures: Induce vomiting. Seek medical help
EXPOSURE:
Antidotes/Dosages: Seek medical help

Steps to be Eliminate all ignition sources. Large fires should

taken: be tackled by the fire brigade.
SPILLS

Waste Disposal Spillages can be absorbed with non-

Method: combustible absorbents..

8. ADDITIONAL INFORMATION/REFERENCES

1) SAX-Dangerous Properties of Industrial Materials.-(8th Edition)

2) Fire Protection Guide on Hazardous Materials. NFPA (1985 Edition) NFPA-325.

ACGIH = American Conference of Governmental Industrial Hygienists

orl-rat = Oral route on rat
STEL = Short Term Exposure Limit
TLV = Threshold Limit Value

9 MANUFACTURER/SUPPLIER DATA
Name of firm: RELIANCE INDUSTRIES LIMITED. Fire Department,
RIL
Village Padana/Meghpur, Taluka Lalpur, Jamnagar
Pin 361 280 Dist. Jamnagar, (Gujarat), INDIA
Phone:( 0288)291191
Telephone: (0288) 292929
Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

10 DISCLAIMER

Reasonable care has been taken in the preparation of the information contained
in this Material Safety Data Sheet and is given in good faith. However, Reliance
Industries Limited, Jamnagar assumes no responsibility as to the accuracy or
suitability of such information and no warranty, expressed or implied, is made.

Reliance Industries Limited

Jamnagar
Material Safety Data Sheet

Diesel

1. CHEMICAL IDENTITY
Chemical Name: Chemical Classification: Hydrocarbon
Diesel Oil, Fuel Oil no. 2, Derv

Synonyms: None Trade Name: Diesel

Formula: C 9 - C 25 C.A.S. No: N/A U.N. No: 1202

Shipping Name:
Codes/Label: Flammable or Combustible Liquid
Hazchem No : 3Z

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Regulated Identification
Hazardous Waste: Acrid smoke & irritating fumes

Hazardous Ingredients: N/Appl. C.A.S. Hazardous Ingredients: N/Appl. C.A.S.

No: No:

1 None 3 None

2 None 4 None

2. PHYSICAL AND CHEMICAL DATA

Boiling Range/Point: About Physical State: Appearance: Pale yellow,
350 C Liquid slightly viscous liquid
Vapour Pressure:
Melting/Freezing Point: <9 Odour: fuel oil type odour
0.14203 kg/m2 at 55
C
C

Vapour Density: N/A Solubility: Insoluble in water

(Air = 1)

Specific Gravity: <1 pH: N/A

(Water = 1)

3. FIRE AND EXPLOSION HAZARD DATA

Flammability: Yes LEL N/A Flash Point: 52 Autoignition
(min) C Temperature: 257
UEL N/A
C
Explosion Sensitivity to Impact: Hazardous Combustion Products:
None Acrid smoke & irritating fumes

Hazardous Polymerisation: None

Combustible: Flammable when exposed to heat

Explosive Material: Its vapour may explode if compressed

Corrosive Material:
It reacts with oxidising materials

Flammable Material It does not ignite readily.

Pyrophoric Material: N/A Organic Peroxide: N/A

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

4. REACTIVITY DATA
Chemical Stable
Stability:

Incompatibility Oxidisers
with other
Materials:

Reactivity: It can with oxidising agents

5. HEALTH HAZARD DATA

Routes of Entry: Ingestion

Effects of Exposure/Symptoms: Mildly toxic by ingestion

Emergency Treatment: No antidote to be given, medical advice to be

immediately sought.

TLV (ACGIH) N/A STEL N/A N/A

Permissible N/A Odour: N/A ppm mg/m3

Exposure Limit orl- Threshold LD 50
rat LD 50

.Health: 0 Flammability: 2 Reactivity: 0 Special: N/A

NFPA Hazard
Flam
Signal
mabili
Healt Reacti
h -vity
Speci
al

6. PREVENTIVE MEASURES
Personnel Protective Wear full protective clothing.
Equipment:

Handling and Storage Store in a cool, dry, well ventilated location. Inside storage
Precautions: should be in a standard flammable liquids storage warehouse,
room, or cabinet.

7. EMERGENCY AND FIRST AID MEASURE

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

EMERGENCY HANDLING
OF:
Media: Dry powder, foam, carbon dioxide.

Special Procedures: Flame proofing equipment are needed

FIRE:

Unusual Hazards: None

First Aid Measures: Do not Induce vomiting. Seek medical help
EXPOSURE:
Antidotes/Dosages: Seek medical help

Steps to be Eliminate all ignition sources. Large fires should

taken: be tackled by the fire brigade.
SPILLS

Waste Disposal Spillage can be absorbed with non-

Method: combustible absorbents..

8. ADDITIONAL INFORMATION/REFERENCES

1) SAX-Dangerous Properties of Industrial Materials.-(8th Edition)

2) Fire Protection Guide on Hazardous Materials. NFPA (1985 Edition) NFPA-325.

ACGIH = American Conference of Governmental Industrial Hygienists

orl-rat = Oral route on rat
STEL = Short Term Exposure Limit
TLV = Threshold Limit Value

9 MANUFACTURER/SUPPLIER DATA
In case of emergency contact
Name of firm: RELIANCE INDUSTRIES LIMITED.
Fire Department, RIL Village Padana/Meghpur,
Taluka Lalpur, Jamnagar Pin 361 280 Dist.
Jamnagar, (Gujarat), INDIA Phone:( 0288)291191
Telephone: (0288) 292929

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

10 DISCLAIMER

Reasonable care has been taken in the preparation of the information contained
in this Material Safety Data Sheet and is given in good faith. However, Reliance
Industries Limited, Jamnagar. assumes no responsibility as to the accuracy or
suitability of such information and no warranty, expressed or implied, is made.

Reliance Industries Limited

Jamnagar
Material Safety Data Sheet
Vacuum Residue

1. CHEMICAL IDENTITY
Chemical Name: Chemical Classification: Heavy Hydrocarbon Mixture of
Vacuum Residue Paraffinic and Bitumastic Materials

Synonyms: None Trade Name: None

Formula: Mixture of mainly C.A.S. No: N/A U.N. No: N/A

C24+
Shipping Name: N/A
Codes/Label: Flammable Liquid Hazchem No : N/A
Regulated Identification
Hazardous Waste: Acrid smoke and irritating fumes

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Hazardous Ingredients: C.A.S. No: Hazardous Ingredients: . C.A.S. No: N/A

N/A

1 None 3 None

2 None 4 None

2. PHYSICAL AND CHEMICAL DATA

Boiling Range/Point N/A Physical State: Liquid Appearance: dark brownish
thick liqueur

Melting/Freezing Point: N/A Vapour Pressure Odour: diesel like

@ 260 C 0.03586 kg/cm2 a

Vapour Density: Solubility: Insoluble in water

(Air = 1)

Specific Gravity: <1 pH: N/A

(Water = 1)

3. FIRE AND EXPLOSION HAZARD DATA

Flammability: Yes LEL N/A Flash Point: > 65 C Autoignition
Temperature: >257
UEL N/A
C
Explosion Sensitivity to Impact: Hazardous Combustion Products:
None May produce toxic gases

Hazardous Polymerisation: None

Combustible: It burns readily once involved in a fire and highly

combustible.
Explosive Material:
Explosive hazard when exposed to heat, flame.
Corrosive Material:
None

Flammable Material: It can be ignited by sparks, a small flame and

when heated..

Pyrophoric Material: No Organic Peroxide: N/Appl.

4. REACTIVITY DATA
Chemical Normally stable
Stability:

Page No:
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Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Incompatibility Readily ignited by contact with oxidising chemicals.

with other
Materials:

Reactivity: None

5. HEALTH HAZARD DATA

Routes of Entry: oral

Effects of Exposure/Symptoms: Moderately toxic.

Emergency Treatment: Medical advice should be immediately sought.

TLV (ACGIH) N/A STEL N/A

Permissible Exposure N/A Odour: N/A ppm mg/m3

Limit orl-rat LD 50 Threshold LD 50
.
NFPA Hazard
Signal Health: 1 Flammability: 3 Reactivity: 0
Special:

6. PREVENTIVE MEASURES
Personnel Protective Wear protective gloves for general containment
Equipment:

Handling and Storage Store in a cool, dry, well ventilated location. Inside storage
Precautions: should be in a standard flammable liquids storage warehouse,
room, or cabinet. Separate from oxidising materials. Storage
tank should be stainless or mild steel, High Density Polyethylene,
glass (small quantities).

7. EMERGENCY AND FIRST AID MEASURE

EMERGENCY HANDLING
OF:
Media: Dry chemical, foam, carbon dioxide, or water spray

Special Procedures: Flame proofing equipment are needed

FIRE:

Unusual Hazards: None

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

First Aid Measures: Seek medical help

EXPOSURE:
Antidotes/Dosages: Seek medical help

Steps to be Eliminate all ignition sources. Stop or control

taken: the leak, use foam to extinguish vapour and
SPILLS
disperse vapours.

Waste Disposal Absorb in a noncombustible material for

Method: proper disposal.

8. ADDITIONAL INFORMATION/REFERENCES
1. SAX-Dangerous Properties of Industrial Materials.-(8th Edition)
2. Fire Protection Guide on Hazardous Materials. NFPA (1985 Edition) NFPA-325.

ACGIH = American Conference of Governmental Industrial Hygienists

orl = Oral route
STEL = Short Term Exposure Limit
TLV = Threshold Limit Value

9 MANUFACTURER/SUPPLIER DATA
Name of firm: RELIANCE INDUSTRIES LIMITED
Fire Department, RIL Village Padana/Meghpur,
Taluka Lalpur,Jamnagar Pin 361 280 Dist. Jamnagar, (Gujarat), INDIA
Phone:( 0288)291191
Telephone: (0288) 292929

10 DISCLAIMER

Reasonable care has been taken in the preparation of the information contained in
this Material Safety Data Sheet and is given in good faith. However, Reliance
Industries Limited, Jamnagar. assumes no responsibility as to the accuracy or
suitability of such information and no warranty, expressed or implied, is made.

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Reliance Industries Limited

Jamnagar
Material Safety Data Sheet
Fuel Oil
1. CHEMICAL IDENTITY
Chemical Name: Chemical Classification: Hydrocarbon
Imported Fuel oil

Synonyms: Imported Fuel oil, Trade Name: Imported Fuel oil

refinery fuel oil

Formula: Mixture of mainly C.A.S. No: N/A U.N. No: N/A

C5/C6
Shipping Name: N/A
Codes/Label: Flammable Liquid Hazchem No : N/A
Regulated Identification
Hazardous Waste: Acrid smoke and irritating fumes

Hazardous Ingredients: C.A.S. No: Hazardous Ingredients: . C.A.S. No: N/A

N/A

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

1 None 3 None

2 None 4 None

2. PHYSICAL AND CHEMICAL DATA

Boiling Range/Point N/A Physical State: Liquid Appearance: Colourless liquid

Melting/Freezing Point: N/A Vapour Pressure Odour: diesel like

0.077 kg/cm2 a

Vapour Density: Solubility: Insoluble in water

(Air = 1)

Specific Gravity: <1 pH: N/A

(Water = 1)

3. FIRE AND EXPLOSION HAZARD DATA

Flammability: Yes LEL N/A Flash Point: 65 C Autoignition
Temperature: 257 C
UEL N/A
Explosion Sensitivity to Impact: Hazardous Combustion Products:
None May produce toxic gases

Hazardous Polymerisation: None

Combustible: It burns readily once involved in a fire and highly

combustible.
Explosive Material:
Explosive hazard when exposed to heat, flame.
Corrosive Material:
None

Flammable Material: It can be ignited by sparks, a small flame and

when heated..

Pyrophoric Material: No Organic Peroxide: N/Appl.

4. REACTIVITY DATA
Chemical Normally stable
Stability:

Incompatibility Readily ignited by contact with oxidising chemicals.

with other
Materials:

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Reactivity: None

5. HEALTH HAZARD DATA

Routes of Entry: oral

Effects of Exposure/Symptoms: Moderately toxic.

Emergency Treatment: Medical advice should be immediately sought.

TLV (ACGIH) N/A STEL N/A

Permissible Exposure N/A Odour: N/A ppm mg/m3

Limit orl-rat LD 50 Threshold LD 50
.
NFPA Hazard
Signal Health: 1 Flammability: 3 Reactivity: 0
Special:

6. PREVENTIVE MEASURES
Personnel Protective Wear protective gloves for general containment
Equipment:

Handling and Storage Store in a cool, dry, well ventilated location. Inside storage
Precautions: should be in a standard flammable liquids storage warehouse,
room, or cabinet. Separate from oxidising materials. Storage
tank should be stainless or mild steel, High Density Polyethylene,
glass (small quantities).

7. EMERGENCY AND FIRST AID MEASURE

EMERGENCY HANDLING
OF:
Media: Dry chemical, foam, carbon dioxide, or water spray

Special Procedures: Flame proofing equipment are needed

FIRE:

Unusual Hazards: None

First Aid Measures: Seek medical help
EXPOSURE:

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

Antidotes/Dosages: Seek medical help

Steps to be Eliminate all ignition sources. Stop or control

taken: the leak, use water spray to cool and disperse
SPILLS
vapours.

Waste Disposal Absorb in a noncombustible material for

Method: proper disposal.

8. ADDITIONAL INFORMATION/REFERENCES
1. SAX-Dangerous Properties of Industrial Materials.-(8th Edition)
2. Fire Protection Guide on Hazardous Materials. NFPA (1985 Edition) NFPA-325.

ACGIH = American Conference of Governmental Industrial Hygienists

orl = Oral route
STEL = Short Term Exposure Limit
TLV = Threshold Limit Value

9 MANUFACTURER/SUPPLIER DATA
Name of firm: RELIANCE INDUSTRIES LIMITED.
Fire Department, RIL Village Padana/Meghpur,
Taluka Lalpur, Jamnagar Pin 361 280 Dist. Jamnagar, (Gujarat), INDIA
Phone:( 0288)291191
Telephone: (0288) 292929

10 DISCLAIMER

Reasonable care has been taken in the preparation of the information contained in
this Material Safety Data Sheet and is given in good faith. However, Reliance
Industries Limited, Jamnagar. assumes no responsibility as to the accuracy or
suitability of such information and no warranty, expressed or implied, is made.

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

CAUSTIC SODA
(A) IMPORTANT SAFETY DATA

caustic soda is odurless and corrosive in nature.

TLV (C) : 2 mg/m3

(B) HEALTH HAZARD

INHALATION: cause small burns to upper respiratory tract & lungs

and mild noese irritation.
INGESTION: cause severe damage to mucous membrane.
EYES: cause severe burns.

(C) FIRE HAZARD

NIL

(D) FIRST AID MEASURES

EYE CONTACT: flush with plenty of water fro 15 minutes.

SKIN CONTACT: remove contaminated clothes and shoes.
wash the affected area with plenty of water.
INHALATION: remove the victim to fresh area.
support respiration.
seek medical aid immediately
(E) PREVENTIVE MEASURES

avoid contact with solid or liquid.

use side covered safety goggles, face shield, dust type respirator, rubber
shoes and rubber hand gloves.

IN CASE OF EMERGENCY CONTACT

SECURITY: 100 FIRE: 101 MEDICAL: 111

(F) NFPA HAZARD SYMBOL

Health: 3 Flammability : 0 Reactivity: 1

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

AMMONIA
(NH 3 )
A. Important Safety Data
 Ammonia is colourless non-flammable gas.
 Odour: Strong pungent odour.

B. Health Hazard
 Toxic.
 Causes irritation if comes in contact eyes.
 Contact of liquid with skin freezes the tissues and the caustic burns.

C. Fire / Explosion Hazard

 Non-Flammable.
 TLV : 25 ppm STEL : 35 ppm

D Emergency / First aid measures

 Stop the flow of gas. Dilute the vapours with plenty of water.
 Remove the victim to fresh air area and give artificial respiration if required.
 Skin: Remove the contaminated clothes and wash the affected area with
plenty of water and soap.
 Eyes: flush with plenty of water for 15 mins.
 Get medical help immediately.

E In case of emergency contact

 Security : 100 Fire : 101 Medical : 111

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC
 Reliance Industries Limited
Crude Complex Refinery Division Crude Distillers
Jamnagar

CHAPTER # 19

APPENDIX

Page No:
Reviewed By MAB Rev : 02
Operating Manual Issue : 02
Approved By PKJ Date : 19 July 2004
Author : VS/JKC