Professional Documents
Culture Documents
61
A. Plant inspection
Plant is carefully checked to ensure it is constructed according to governing plans, drawings, and
specifications. Checkout against P&IDs is done for piping, equipment and instrumentation. A punch list
of missing, incomplete, or incorrect items is prepared for correction.
This check is carried out before end of construction work to check that unit is satisfactory from an
operational standpoint.
Typically, this check (called preliminary conformity to PIDs check) is useful once construction progress
is 70% and above.
Vessels
GENERAL INSPECTION
A general inspection of vessels is made against design drawings soon after erection. This check includes:
Verification of temperature/pressure and vacuum rating on nameplate
Verification of lining condition (if applicable)
Nozzles location, size, flanges face
Thermowell location and length of immersion
Cleanliness
Inspection:
Check there is no foreign matter lodged in elongated slots. Any object firmly wedged between slot
and bolt can prevent sliding
Check that all bolts in slots are loose and located at correct ambient position. Even if bolt is at
correct end of slot, there should be some allowance for thermal contraction caused by atmospheric
conditions different from those on day of inspection
Get approximate thermal growth (approximate thermal expansion mm/m of metals versus
temperature °C) and establish that sliding plate can travel at least this distance and that slotted holes
are large enough to permit growth
Check that sliding plate is free to slide and will not be obstructed in its travel
Check that sliding plate and base plate are not bonded by rust or other
INTERNAL INSPECTION
Drums and vessels are inspected internally by observation with light source.
Bottom manhole is left open in case tools or other materials are accidentally dropped.
Vessels and tower internals are inspected carefully and checked against design documents to ensure
installation was properly carried out. This check includes:
Trays: number, location, type, spacing, levelness, weir height, downcomers, valve number and
operation, support bolting (tightness testing is usual for chimneys trays)
Check that all valves on valve type tray are clean and free to move
Check that weep holes, where provided, are not plugged
Distributors: location, alignment, size and number of openings
Vortex breakers: type, size and orientation
Demisters : size, material, support
Check that baffles at bottom of columns are correctly fitted, type, orientation and levelness
Check that instrument nozzles are clear. Those which are accessible from inside vessel can be
checked by turning on aeration air
Reactors
Inlet distributors, quench distributors: metallurgy, type, size, opening sizes, freedom to expand
Vapor/liquid collection and distribution trays: tightness, vertical positioning, liquid tightness of
bubble caps and risers, metallurgy, dimensions, packing, supports, welding, levelness, cleanliness
Catalyst support grids: metallurgy, grid type and dimensions, screen type and size, supports,
welding
Catalyst unloading nozzles: metallurgy, orientation, length
Thermowells: orientation, length, and metallurgy
Check that sufficient quantities of bolts, washers and hold downs of proper size and metallurgy are
available to reassemble any disassembled portions of reactor internals
CLEANING
All vessels, columns, drums, tanks, etc are inspected and cleaned if required, before final closure and
boxing-up.
Note:
Storage tanks must be clean of any corrosion scales or rust flakes and dust. Depending on initial
condition of tanks, cleaning by means of sandblasting may be required. Afterwards these tanks are put
under nitrogen atmosphere to prevent corrosion (or dry air if nitrogen is unavailable).
Note:
For equipment on which internals must be installed during precommissioning, final inspection is done
after internals installation.
FINAL INSPECTION
After hydrotest (on a system/test-pack basis), cleaning and dryout as required, final vessel inspection is
conducted. When vessels have been shop-tested, they are not further tested in field but may be included
as part of a piping system test.
Carefully inspect for cleanliness. After final inspection, immediately close after mutual agreement on
final closure/boxing-up document.
A vessel may be required, after inspection for conformity with design and drawings, to be closed
temporarily by precommissioning group until final inspection.
Caution:
UNATTENDED VESSELS MUST NEVER BE ENTERED.
Pumps
INITIAL CHECKING
Most critical period in life of a pump is during its initial start and several minutes immediately
thereafter. Proper installation and startup is essential for trouble-free performance. Before equipment is
first started it is checked as follows:
Review carefully manufacturer operating instructions
Check that overall installation is complete
Verify that pump and driver are properly aligned
Verify that cooling water piping is connected and in service when required
Check gland or seal oil piping. When a pump is furnished with mechanical seals, verify that all
components of flushing system such as strainers, separators, restriction orifices and coolers have
been correctly installed and are clean. It is important that flush system be clean as loss or dirty flush
can cause loss of seal
Verify that bearings shafts are clean and properly lubricated
Temporary strainers are provided for intake of each pump to be installed on pump side of intake
block valves. These strainers are installed after intake lines are flushed
Pumps are not field hydrostatically tested
RUNNING TESTS
Bear in mind that media other than design fluid are not always allowable. Typical example is LPG
pumps where use of water leads to adverse effects that may damage mechanical seals and introduce
water in system where drastic drying is being conducted before startup.
Due to differences in specific gravity between water and design fluid, care is taken not to overload
motors on motor driven pumps.
Centrifugal pumps
Following steps are followed when test-running a centrifugal pump:
Operating personnel should be familiar with literature furnished by pump and driver manufacturers
and follow any special instructions therein
Open up intake valve from source
Check that seal does not leak (if packed seal, check that packing nuts are not too slack) and that
seal flushing and cooling water connections are correctly made
Rotate centrifugal pump shaft by hand to test for free rotation but never if starter switch is not
locked
Confirm that alignment check is made on pump shaft, driver shaft and coupling
Check that coupling guard is secured over shaft
Check that grounding clip and wire is secured from motor to grounding point
Check that discharge pressure gage is installed and functioning
Check that electrician has tacked pump power supply in substation
Check that if pump is on closed recirculation loop from a vessel, vessel is vented to atmosphere to
prevent possibility of damage by pulling vacuum
When a run with water has been planned, loop system is carefully isolated
Check arrangements to vent pump for priming, if pump is not self-venting. Verify that special
connections such as bleeds and drains are properly installed
Strainers are installed before aligning pumps
Note: To prevent equipment damage, multistage centrifugal pumps in light product service (specific
gravity less than about 0.8) are not run with water
All valves in loop are opened except for control valves (manually closed from control room) and
discharge valve of pumps
If possible do not start motor on a centrifugal pump with discharge valve open as this throws an
excessive load on motor (except if specified to start with fully open valve as auto start cases)
When a hot pump is being kept hot by circulation of a stream through it from an adjacent pump,
shaft of motor may be turning slowly in direction opposite to normal rotation. If a pump is running
in this manner and is started up, excessive load is thrown on motor
Discharge valve is then opened gradually so as not to lose suction. From then, operation is
controlled from control room
Ensure pump is full of liquid after proper casing venting
Field operator checks for leaks in system, overall pump performance, and pump overload
Bearings of pumps and drivers are checked for signs of heating
Pump is run for approximately 1 hr, then shut off to make any adjustments necessary and to check
parts for tightness
Electrical motors
When a motor has been started by pressing starter button, NEVER (except in emergency) push stop
button until motor has attained full speed and amperage has fallen back to normal running value.
Manufacturer recommendations are consulted for more thorough discussion of any items mentioned
here.
Confirm that electrical specialist has test-run motors uncoupled prior to asking for operational
acceptance. Then make following checks:
Check electrical report for motor amperage
Check protection grease is removed and replaced by correct grease
Check belts are all on pulley
Check all debris has been removed from air cooler area
Check there is no loose or live electrical wiring
Check all air fan platform grating is in place and secured
Check all stop and start switches are fully installed
Check correct motor oil is in and storage protection (light) oil removed if any
Check fan motor for proper rotation and grounding (never when motor is energized)
Set fan blade pitch as per manufacturer spec. Once fan is in operation, if motor amperage is too
high or too low, pitch readjustment may be required
Set vibration shutdown switches to give permitted safe vibration level
If fan is belt-driven, adjust drive belts for proper tension and check belt condition
Confirm that fan safety shields are in place
Remove protection plywood which may have been laid over tubes
Check operation of louvers (if any)
When all above checks have been made, proceed to a four hour test run (unless otherwise agreed) and
check following:
Check amperage of motors is in normal range
Check for any noise from bearings or other
Check for any screeching or abnormal noises from pulleys (belts may be too tight, which affects
bearings)
Check all belts remain on pulleys (belts that constantly come off could indicate offset pulley)
Check air fan blades are not making abnormal noise
Check air fans on same cell are all turning at approximately same speed
Stop air fans one by one and stand underneath to observe and check following:
Check no abnormal noise occurs on rundown
Check air fans slowly come to a stop in smooth manner
Check by hand that motor has not overheated (inform electrical specialist if it has)
Complete run-in before using air cooler condenser for heat transfer duty.
Fired heaters
Inspection and checking of following main points is carried out before refractory drying.
INSTRUMENTATION
Controllers, regulators, recorders for flows, pressures and temperatures: correct zero adjustment or
designed values, normal position, connections
Thermocouples : length, location, correct connection of cables
Connections for controls (pressures, temperatures) and sampling
When not in use, connections are closed off with threaded plugs or blind flanges.
Carry out tests on all instruments which are part of safety control system. Ensure necessary
checking of burners control system has been performed
Ensure minimum stop positions are set up on fuel gas and combustion air systems (if any)
STACK DAMPER
Full-open and minimum opening position of damper is checked visually. Movement of damper must be
free and unobstructed.
TUBULAR COILS
All tubes must be clear and unobstructed. Water remaining in tubes after hydrostatic tests or other
foreign matter that may have accumulated, is removed.
Shipping braces are removed and provisions for expansion of tubular coils checked.
BURNER PIPING
Burner piping must be free of stress on burners. After dismantling piping at burners, blow piping clear
of all debris.
BURNERS
Check each burner for:
Relative orientation of ignitor, pilot burner and main burner per installation dwgs
Position of burner in combustion chamber and burner position relative to refractory
Free operation of burner air registers
Remove all debris from burner throat
REFRACTORY
Visual refractory examination is carried out and compared with conditions after refractory dryout.
MISCELLANEOUS
Check:
Operation and closure, as well as tightness of all access, observation and explosion doors,
peepholes and tube crossings
Control positions and displacement of tube supports and guides
Manual valves, especially on snuffing steam lines
Piping inspection
Long straight runs of piping should be checked for bowing when up to temperature. Bowing causes pipe
overstressing and can result in pipe failure. Rule of thumb is that if one visually notices bowing, then it
is excessive.
Spring supports
Inspection before hydrostatic testing
Check that spring stops are installed. Pipe normally transporting water is not affected as spring is
designed for weight of water; but rather than make them an exception it is simpler to state that all spring
supports have their stops installed.
During actual processing phase, following functional tests for electrical systems are performed:
For motors where they have more than one control and automatic operation, first check manual
operation, then automatic. Test each control operation to be sure control is operating in accordance
with process requirements
Interlocked control circuits for permissive start and automatic shutdown are checked to ensure
correct relay and control valve action from each alarm function. This is closely linked with
instrumentation loop testing
Check emergency power supply if installed for correct operation on power failure
Close lighting transformer primary circuit breaker
Close lighting distribution panels feeders circuit breaker and emergency lighting
Check seal fittings to ensure they are filled with sealing compound
Check all explosion-proof, vapor-tight, dust-tight and weather-tight enclosures to be sure enclosures
are secured and closed properly
Check all nameplates and lighting panel directories to be sure each circuit breaker controls proper
circuit
Electric motors
Electric motors are used primarily as drivers of moving equipment like pumps, air coolers, etc.
Therefore it is essential that, before attempting to start any electrically driven equipment, both driver
(motor) and pump are ready for operation.
Before switching on any electrical equipment, agreement from an electrical engineer is needed.
Instrumentation commissioning
Commissioning of instruments is carried out as plant comes on stream. Most attention is directed
towards liquid flow measurements. Controllers are tuned; interface level transmitters are zero checked;
scale, weld slag and trash are removed from sticking control valves; other malfunctions are corrected.
Inspection and commissioning of analyzers includes attention to sample line lengths, analyzer
enclosures, auxiliary equipment, such as carrier gas for chromatography and other items indicated in
analyzer instruction manual for.
Functional testing of instrument loops is done prior to startup to ensure correct operation of safety
devices, ESD system interlocks, and local/remote action.
Verify conformity of installation with dwgs, specs, safety rules, supplier instructions
Verify free rotation of fans and motors
Verify correct installation of anti-vibration mountings and sealing compound of any fire dampers
Verify leakage and blades of dampers run freely
Verify damper actuators are in good working order
Verify air flow direction in preheater is correct
Perform ductwork leak tests
Start unit test sequences, interlocks, vibrations
Start air flow and make balancing test (air distribution adjustment)
Telecommunications
Inspection of all telecommunication equipments is performed to ensure compliance with specifications,
drawings, codes of practice, regulations and manufacturer requirements.
General
Line and equipment cleaning is performed to eliminate weld rods and slag, abrasive dust, oxides and in
general other substances which can impede normal unit operation or damage equipment (valves, pumps,
compressors, turbines, etc).
Cleaning is usually carried out by hand on large equipment and lines having diameter greater than (or
equal to) 24", by water flushing, air blowing, chemical cleaning or other cleaning method described
hereafter.
This is not always possible, as some lines between exchangers cannot be disconnected without complete
removal of line.
As an example and for reference, following table gives flowrates (m3/h) corresponding to velocity
versus various pipe diameters.
VELOCITY
1 m/s 2 m/s 3 m/s 5 m/s
LINE SIZE
2" 7 15 22 37
3" 16 33 50 82
4" 29 58 88 150
6" 66 131 200 330
8" 117 235 350 585
10" 182 365 550 910
20" 730 1460 2200 3650
Cleaning of lines and associated equipment, which constitute various systems to be mechanically
completed then ready for startup, will be treated during construction and precommissioning phases in
two steps:
1. During construction phase, preliminary checking is implemented to prevent pipe from retaining
construction materials until actual cleaning takes place later, when feasibly and applicable with
required efficiency
2. To reach readiness for startup, cleaning is implemented for each system/subsystem. This cleaning
uses efficient methods which can be implemented only after part of plant is available
Water flushing
Water flushing, when applicable, is performed using clean water. When possible, main and spare pumps
are also run at same time and used to circulate water to remove dirt and scale via pump intake strainers.
Air blowing
Cleaning of circuits is carried out by air blowing for lines and pieces of equipment which must be kept
free from water and for some big piping (reasons: unacceptable weight, or excess quantity of water
required, or water flushing not efficient).
Air blowing is carried out with compressed air. Air blowing of a circuit is performed by using
temporary connection with compressed air network, in continuous manner for small lines or by using
vessels (drum, column, etc) as holdup/buffer capacity to get quick air release.
In some very large systems, it is sometimes not possible to use valves to blow lines. In this case, a
bursting disc (cardboard or aluminium sheet) can be used to proceed to sudden depressurization (ensure
no equipment will be damaged).
Steam blowing
Cleaning by steam blowing is carried out essentially on steam circuits.
When headers are warm, drain valves are opened and blown vigorously for a few seconds before
reclosing. Temporary movable silencer may be used to avoid exceeding noise level limitations during
steam blowing operation, if necessary.
Blowing of this piping system is considered complete and cleaned when on two consecutive targets,
collected after blowing carried out as above described, are present less than two pits per square cm with
a maximum diameter of 0.3 mm.
Targets made from aluminium sheet are inserted, on temporary vent only after that three-four blowings
(depending on experience on site) are carried out and steam appears clean.
Other steam piping and steam piping to turbine (less than 4")
Piping system blowing is considered completed when steam at exit of vent point appears clean (steam
not to be orange dust color).
Chemical cleaning
Some piping must be cleaned by chemicals when either product can react with oil left inside piping, or
in case it can lead to adverse effect to leave even very small parts of debris inside piping.
Detergent cleaning includes removal of oil, grease, soil, drawing compounds, and foreign matter other
than rust and scale. Detergent solution is circulated through pipe at temperature, concentration, and
flow rate recommended by detergent manufacturer.
When detergent flow rate is not recommended by manufacturer, flow rate is 1.5 meter/second.
Acid cleaning
All rust, scale and oxides are removed (to leave bare metal) by citric acid cleaning as follows:
Citric acid solution is circulated at temperature, concentration and flow rate recommended by
manufacturer.
Solution temperature is maintained between 80°C and 95°C throughout system during operation by
injecting steam into acid solution.
Concentration of citric acid in cleaning solution is monitored and replenished in accordance with
manufacturer instructions.
When chemical tests indicate constant ferric and ferrous ion concentration, used citric acid solution is
displaced by rinse water containing 0.05 percent to 0.10 percent citric acid solution to ensure all traces
of soluble ion are removed. This method of displacing spent cleaning solution with rinse water is used in
lieu of draining spent acid solution and refilling with rinse water. Circulation of rinse water is
maintained at least 10 minutes.
Immediately following rinse water circulation, 1.0 percent soda ash solution is circulated at 80°C for at
least 10 minutes to neutralize cleaned surfaces. pH of used soda ash solution is at least 9.5, in order to
stop circulation.
After surfaces are clean and dry, pipe is filled with nitrogen and sealed. Nitrogen pressure is 0.1 to 0.2
barg.
Pipe is not marked with paint or ink, in lieu of metal tagging, unless pipe is finish painted or insulated.
Piping is preferably installed immediately, but if this is impracticable then immediate steps must be
taken to prevent rusting.
Unless piping is going to be installed immediately, suitable closures are placed on ends and all openings
to prevent entrance of moisture or dirt.
Before installation, check that no dirt or foreign matter has entered piping and that rusting has not
occurred. If in good condition, pull through a swab saturated with carbon tetrachloride. Piping is not
bolted up until inspected for cleanliness.
Safety
All chemical cleaning activities are supervised by qualified staff in order to assure attainment of
required pickling effect and to prevent damage to materials and/or to health.
Acids are always stirred carefully in a thin stream of water, never the reverse.
Chemical cleaning
Factory-installed oil lines are flushed and sealed before shipment; they do not require additional
chemical cleaning before final oil flushing.
Two typical chemical cleaning procedures for site-prefabricated oil circuits are given below.
PICKLING PROCEDURE
Pickling procedure is not required for stainless steel piping.
Remove piping from acid bath, drain and immediately wash with cold water to remove all traces of acid.
Neutralizing procedure
Without allowing piping to dry, immerse in hot neutral solution of 0.75 to 1.5 % wt of soda ash in water
maintained at a pH value of 9 or above. Temperature of bath is about 70/80 °C.
pH paper may be used to check wet surface of piping to determine that an acidic condition does not
exist. If check shows acidity, then neutralizing treatment is repeated.
Rinse piping with cold water, drain thoroughly and blow out with service air until dry.
Blinds list
A blinds list of permanent spectacle blinds and temporary blinds on pipework and/or equipment is
always current during precommissioning and commissioning.
A marked-up set of P&IDs clearly identifies blinds position when initially commissioning units.
Until unit to be started up is inerted, following lines remain positively isolated from rest of plant:
Flare lines at battery limit are blinded and internal headers open to atmosphere, until nitrogen
introduction for inerting to prevent header overpressure
Closed drain system and fuel gas are blinded at battery limits
All process lines in and out are blinded at battery limits
C. Tightness testing
General procedure
After hydrostatic pressure testing and flushing, tightness test is conducted to check all flanges and
fittings for leaks, especially those opened during hydrostatic tests and flushing.
Unit are isolated with blinds from every part containing hydrocarbons, nitrogen or steam.
Pressure test
Tightness test for process units is carried out with air (or nitrogen when applicable and when air is
prohibited) at maximum allowable pressure which does not exceed design pressure of equipment (check
design data). Soap solution is prepared for tightness checking and all flanged connections checked with
soap. Bubbling indicates tightening is required.
This pressure followup gives an indication of tightness of system. It does not substitute leak test on each
flange with soap.
Use soap solution check for any sign of soap bubbles being formed
Pressure system with air (or nitrogen) at highest possible pressure compatible with IA/PA supply,
without exceeding normal operating pressure
Check pressure over length of time. If test is not satisfactory, every flange and connection is
inspected with soap solution. After leak repair, test is repeated until satisfactory
Leak repair/tightening
In most cases, leaks are eliminated by tightening flanges in correct manner to ensure that compression
on flange gasket is uniform. If this is not sufficient, equipment is isolated, depressurized, and gasket
replaced.
Note: Control valve packings are not tightened when dry until actual product is passing through.
Vacuum test
Drawbacks
Difficult to locate small leaks. Results not always conclusive.
Benefits
No structural stresses (eg weight) when test is carried out on equipment designed for it.
Vacuum test is usually carried out at 0.2 bar abs. Test is deemed satisfactory when pressure increase
does not exceed 25 mm Hg per hour. Otherwise, test is repeated after leak repair.
In new furnaces, drying out can be started two days after refractory lining has finished.
During dry-out operation steam is circulated through heater coils as cooling medium. Decoking facilities
are used for this purpose.
Take care for adequate ventilation and pay special care to prevent evaporated water condensing in
cooler areas of furnace
During dryout operation, make intermittent checks on damper to ensure it operates properly in hot
condition
500
450°C for 24 h
450
400
350 15°C/h
300
250°C for 36h
250
20°C/h
200
15°C/h
150
120°C for 36 h
100
50 10°C/h
WARM UP
Prestartup checklist
Following steps are completed before charging oil to unit:
1. Unnecessary blinds are removed (blinds list to be compiled on site by commmissioning team)
2. Relief valves are tested and installed
3. Flare header is purged and in service
4. Sewers are in service
5. Instruments and control systems are ready for service
6. Utilities are in service
7. Control valves and bypasses are blocked in
8. Compressors are blocked in
9. Heat tracing is in service
10. Heater dryed out and ready for firing
11. Fire fighting facilities ready for service
12. All safety equipment available
13. Entire unit purged, free of oxygen
Cold circulation
Next step is to clear vacuum column and all equipment and lines, of any free water standing in it.
Reason is that when vacuum column is up to full temperature and at normal vacuum, if only a small
amount of free water standing in a dead line is pumped into vacuum column, it flashes into a large
volume of steam and can damage column trays. Procedure adopted introduces a source of oil for
purpose of clearing water.
Light diesel previously charged in flushing oil tank 51 TK 18, is used to commission flushing oil
network providing oil to free vacuum column circuit of water and to satisfy need of flushing oil for
pump mechanical seal cooling during first startup.
During normal operation, flushing oil tank makeup is carried out using light diesel product from
atmospheric column.
With diesel oil is pumped on vacuum column through upper PA return line, a level accumulates on
LVGO chimney tray. Top side-cut pumps P-53 A/B can be started and all lines flushed out to storage
(slops) and back to column.
As LVGO chimney tray is allowed to overflow, a level will appear on HVGO chimney tray at which
time middle side-cut pumps P-54 A/B can be started and lined up as follows:
T 51 P 54 A/B E 17 E 10 A through D E 08 A through D T 51
As HVGO chimney tray overflows, a level will develop on wash oil chimney tray. P-55 A/B should then
be started and recirculate to T-51.
Quantity of injected water directly affects salt dilution in crude oil and thus salt content at unit outlet.
Below 2.5%, population of droplets becomes more tenuous and distance from one to another becomes
too great for a good coalescence.
Total wash water flow rate at each stage measured in % of crude flow rate is:
2.5% min
6% norm
12% max
Residence time of water in treating vessel is approximately five times to one of crude oil.
Mixing pressure drop is increased by increments of 0.2 bar starting from mixing valve wide open;
enough time is given (about 2 hours) to system prior to withdrawing a sample. Average value for mixing
pressure drop is 0.8 bar.
Too low delta P increases salts as contact is not sufficient; too high delta P may give:
Dirty effluent water
High electric current consumption
High BS&W carryover.
Exact position of crude/water interface is not really critical for process. It must be only maintained
within gap where too high interface will short-circuit electrode while too low interface will cause dirty
effluent water bleed. Purpose of tri-cocks sample lines is to visually check height and consistency of
emulsion cushion at interface. Compact crude at upper line and fairly clear water on lower line are
indicators of optimum operating conditions.
B. Heaters
Check flame condition of burner frequently
Totally avoid flame impingement on tubes
Check frequently condition of burner tips and burner tiles; burners are adjusted so that no flame
impingement on tubes is observed at any time
Operate heater with 20% excess air
At low excess air levels pay attention to possibility of carbon monoxide formation
Generally, low excess air operation is recommended only if heat load on unit is very constant
For optimum flame patterns and efficiency, it is important that air enters heater through burner.
Consequently, devices such as sight doors and access doors are properly closed during normal
operation.
If combustion air flow is insufficient to a point where carbon monoxide is present in flue gas, a radical
decrease in furnace outlet temperature is noticed. Under automatic control, burners then fire harder,
generating even more carbon monoxide for a given quantity of combustion air.
Under these circumstances, immediate steps are taken to rectify situation. Recommended sequence is:
Place fuel controller on manual operation
Cut back fuel firing rate (very slowly) under manual control
Raise combustion air flow (very slowly) to proper level
Gradually increase firing rate to attain proper outlet temperature again
Heater is designed to have a slight negative pressure (-2.5 mm WC) at arch when operating under all
conditions.
Material balance
CASE CASE
TAG N° UNIT A B
INLET STREAM
CRUDE FROM STORAGE 01-FI-004 m3/hr 667 667,0
WILD NAPHTHA FROM UNIT 07 07-FIC-016 m3/hr 11 12,7
OUTLET STREAM
LIGHT DIESEL 01-FIC-001 m3/hr 138 126
KEROSENE 01-FIC-002 m3/hr 69 62
HEAVY DIESEL 01-FIC-049 m3/hr NNF NNF
Atmospheric section
CASE CASE
TAG N° UNIT A B
Vacuum section
CASE CASE
TAG N° UNIT A B
Debutanizer section
CASE CASE
TAG N° UNIT A B
This lends itself to night operation since glow of tube or presence of hot spots can be observed more
easily during coke burning operation.
Time required for completion of decoking operation varies from 12 hours to 3 days, depending on
thickness of coke deposits and detailed procedure to be followed.
Steam-air decoking should not be used where tube deposits contain large proportions of salt or lime.
Steam (10 bar) and air (3 bar) are manifolded to permit simultaneous and/or alternate injection into hot
tubes.
Steam and air are used to accelerate coke spalling and burning.
Each pass of furnace is steam-air decoked separately while steam is admitted through remaining passes
to prevent overheating of tubes.
Pressure drop increased through tubes during operation up to allowable pressure drop in fouled
condition is a general indication that decoking may be required.
Sequential operations
1. Piping connections for steam, air and decoking off gas are connected to passes of tubes
2. Feed to heaters is shut off and isolated by blinds. Burners are extinguished
3. Steam is introduced to tubes to purge lines of residual oil and oil vapors. Steam purge is a
precautionary measure to prevent ignition of an explosive mixture of air and oil vapors
4. Steam is introduced into all tubes (even tubes not being decoked) to prevent overheating
5. Every other burner is ignited to provide even distribution of heat
6. Increase flue gas temperatures leaving radiant section at rate of 150°C/h until it reaches 730°C
Hold this flue gas temperature through spalling period or until air is introduced
7. Furnace temperature is increased at rate of 150°C/h per hour with close check on tube metal
temperature
Metal temperature not to exceed 650°C
Steam injection is used to regulate metal temperatures of tubes during controlled heating period in
heater
Skin thermocouples on tubes and flue gas outlet thermocouples are used to verify and control tube
and gas temperature during decoking operations
Excessive use of steam causes severe erosion in tubes and fittings during spalling since coke is very
abrasive
Steam velocity is as low as possible while still removing coke from tubes
8. When flue gas outlet radiant temperature reaches 550°C, increase steam injection to 5900 kg/hr
9. Quench water is sampled for indications of spalled coke, and if after 5 to 10 minutes spalling has
not started, following methods are used to start spalling:
a) Alternately reduce and increase steam flow rate through tubes
b) Lower flue gas temperature 50°C to 100°C
c) Add small quantity of air to steam for few minutes, then shut off air
10. Sample connection are observed constantly for evidence and extent to spalling
Degree of spalling is indicated by colour of water flowing from sample connection to sewer and
number of coke particles settled in standard sample container
Colour and condition of effluent streams vary during various stages as follows:
a) Discharge is milky with a slight grey colour before and after decoking has started and has been
completed
b) A light gray colour is seen in effluent to sewer when fine soot has been removed
c) As spalling increases, large particles of coke are removed. This condition is indicated by dark
grey to black colour in effluent to sewer
d) Discharge of burned coke appears as rust or a reddish brown in colour
11. When heavy spalling starts, steam flow is reduced to prevent erosion. There is no strict measure to
amount of steam required, and operator must depend on pressure control and visual observation of
discharge at bleeder
Maintain pressure and flow at lowest point but maintain spalling
This reduces abrasive action of coke particles being removed
12. When sampler outlet shows fine coke dust, reduce inlet pressure for minimum 10 minutes to see if
any grainy coke appears
If fine coke dust continues, reduce pressure further to be sure dust is not produced by high velocities
13. After all spalling has stopped and cannot be restored by method indicated at Point 9, reduce flue gas
to 700°C and set steam flow to approx 3000 kg/hr
Gradually add air to approximately 1/10 of steam quantities (kg/kg)
14. It is important that operator is in position to observe, through observation port, coke burning in tube
Coke burning indicated by slight glow on tube surface, approximately 1 foot in length, starts at inlet
end of tubes and progresses at rate of 1 to 1½ feet per minute
Metal surfaces should not be permitted to glow cherry red since this indicates temperature in excess
of 650°C allowable
If metal does glow cherry red, reduce air input or shut off air altogether
15. Air-steam mixture requires adjustment increasing air or reducing steam quantities, if there are
indications (tube glow) that burning has stopped or is slowing down
As an added means for restarting burning, flue gas outlet temperature can be increased 50°C
16. Should burning proceed at too rapid a rate, causing excessive heating of tubes, air quantity should
be reduced or steam increased
Should adjustment of air-steam mixture fail to slow-down burning rate, flue gas temperature should
be lowered in steps of 50°C until desired burning rate has been achieved
17. Completion of coke burning can be checked by colour of effluent as outlined at point 10 and should
be confirmed by results obtained in a gas analysis
This gas analysis should indicate about 1% CO2 when burning has been completed
Increase in air without a similar increase in CO2 confirms that burning has been completed
18. Upon completion of decoking operation, air injection into tubes has to be stopped and steam flow
rate increased for removal of residual ash giving effluent a milky white colour
LPG
LPG is normally sent to LPG recovery unit (Unit 12). Off-spec LPG is diverted to off gas from
debutanizer overhead accumulator V-05 or to flare.
Stabilized naphtha
Stabilized naphtha is normally sent to storage 51 TK 09 or to HDT unit (Unit 02). Off-spec naphtha is
diverted to light slops tank 51 TK 06.
Connection to light slop is provided as follows:
Downstream LV 032 B (s. naphtha to storage).
Kerosene
Kerosene is normally sent to kerosene Merox unit (Unit 06). Off-spec kerosene is diverted to light slops
tank 51 TK 06. Connection to light slop is provided downstream of FV 002.
Light diesel
Light diesel is normally sent to storage 51 TK 10 or to DHT unit (Unit 07). Off-spec light diesel is
diverted to light slops tank 51 TK 06. Connection to light slop is:
Downstream FV 001 (l. diesel to storage)
Heavy diesel
Heavy diesel is normally sent to storage in HDT feed tank or hydrocracker feed tank 51 TK 11/40. Off-
spec heavy diesel is diverted to light slops tank 51 TK 06. Connection to light slop is provided
downstream of FV 049.
Vacuum residue
Vacuum residue is normally sent to storage 51 TK 05/39 or to delayed coker unit (Unit 11). Off-spec
vacuum residue is diverted to heavy slops tank 51 TK 07. Connection to heavy slop is provided
downstream of LV 038 A (v. residue to storage).
Purpose is to identify quickly correct or incorrect operation of whole unit, by just selecting key
parameters in each section of unit.
Material balance
DESIGN VALUE FOR CASE A
TAG N° UNIT 100% 60%
INLET STREAM
CRUDE FROM STORAGE 01-FI-004 m3/hr 667 400
WILD NAPHTHA FROM UNIT 07 07-FIC-016 m3/hr 11 6,6
OUTLET STREAM
LIGHT DIESEL 01-FIC-001 m3/hr 138 82,8
KEROSENE 01-FIC-002 m3/hr 69 41,4
HEAVY DIESEL 01-FIC-049 m3/hr NNF NNF
Atmospheric section
Vacuum section
Debutanizer section
Material balance
Date Date
TAG N° UNIT
INLET STREAM
OUTLET STREAM
Date Date
TAG N° UNIT
ATMOSPHERIC SECTION
H-01 OUTLET TEMPERATURE 01-TIC-067 °C
T-01 FLASH ZONE TEMPERATURE 01-TI-087 °C
LIGHT DIESEL TEMPERATURE 01-TI-084 °C
KEROSENE TEMPERATURE 01-TI-083 °C
T-01 OVERHEAD TEMPERATURE 01-TI-081 °C
T-01 OVERHEAD PRESSURE 01-PI-017 barg
STRIPPING STEAM TO T-01 01-FIC-040 Kg/hr
STRIPPING STEAM TO T-03 01-FIC-052 Kg/hr
T-01 FLASH ZONE PRESSURE 01-PI-018 barg
Date Date
TAG N° UNIT
VACUUM SECTION
H-51 OUTLET TEMPERATURE 01-TIC-136 °C
T-51 FLASH ZONE TEMPERATURE 01-TI-145 °C
T-51 BOTTOM TEMPERATURE 01-TIC-146 °C
T-51 MID SIDE CUT TEMPERATURE 01-TI-149 °C
T-51 TOP SIDE CUT TEMPERATURE 01-TI-154 °C
T-51 OVERHEAD TEMPERATURE 01-TI-142 °C
T-51 PRESSURE 01-PIC-070 mmHg
STRIPPING STEAM TO T-51 01-FIC-100 Kg/hr
T-51 FLASH ZONE PRESSURE 01-PI-059 mmHg
Date Date
TAG N° UNIT
DEBUTANIZER SECTION
T-05 BOTTOM TEMPERATURE 01-TI-020 °C
T-05 OVERHEAD TEMPERATURE 01-TI-030 °C
T-05 PRESSURE 01-PIC-097 barg
T-05 TRAY 7 TEMPERATURE 01-TIC-108 °C
Loss of feed
Feed failure may occur due to failure of pumps, delay in switching storage tanks, failure of
instrumentation, etc.
Feed rate below minimum flow rate required for heater operation is detected by FT-026÷033 for crude
heater and FT-080 through 082 for vacuum heater activating logic for heater shutdown.
Accelerate heater cool down operating at maximum combustion air and flue gas dampers
Close side stripper feed control valves
Continue pumparound circulation
Preventing cracking activity made possible by residual heat still available in radiant section of heaters
must be immediately faced.
In case process flow cannot be quickly resumed, medium pressure steam must be injected through
heater coils to displace material.
B. Utility failure
Cooling water circulation to users goes on because steam turbine driven pumps automatically start;
cooling tower fans shut down and cooling of circulating cooling water is by natural draft only.
If cooling water unit normal operation is not immediately restored, proceed to CDU/VDU unit shut-
down as follows:
Shut down crude and vacuum heaters and operate at maximum combustion air and flue gas
dampers to accelerate heater cool down
Continue feed flow through unit to allow circulation through heater coils
Divert vacuum residue to slop
Increase as much as possible cooling of atmospheric column T 01 by atmospheric tower reflux
pump P 02 A/B
Increase as much as possible cooling of vacuum column T 51 by vacuum column mid side cut
pump P 54 A/B; close FV 103 to divert all material on HVGO chimney tray
Stop stripping steam to columns and strippers and divert superheated steam to steam vent Z 02
Steam failure
In a steam failure following occurs:
No steam to vacuum system ejectors causes pressure increase in vacuum column and off spec
products
Interruption of steam supply to vacuum heater causes reduced mass velocity in coils and coke
formation by cracking activity
Interruption of stripping steam causes contamination of product by lighter material
Failure of steam turbine driven pumps
Failure of atomizing steam
Following pumps only continue to operate as they are steam turbine driven:
P 01 A Crude charge pump
P 02 B Atmospheric tower reflux pump
P 10 B Atmospheric reduced crude pump
P 15 B BFW circulation pump
P 54 A Vacuum column mid side cut pump
P 56 B Vacuum residue pump
Availability of above equipment allows a safety shutdown of unit thus preventing cracking activity made
possible by residual heat still available in radiant section of heaters and relief valves actuating under
excessive pressure.
Shut down crude and vacuum heaters and operate at maximum combustion air and flue gas
dampers to accelerate heater cooldown
Continue feed flow through unit to allow circulation through heater coils
Divert vacuum residue to slop
Increase as much as possible cooling of atmospheric column T 01 by atmospheric tower reflux
pump P 02 B
Increase as much as possible cooling of vacuum column T 51 by vacuum column mid side cut
pump P 54 A; close FV 103 to divert all material on HVGO chimney tray
Increase steam flow through vacuum heater coils
Stop stripping steam to columns and strippers, and divert superheated steam to steam vent Z 02
C. Major upsets
Before making adjustments in plant, check that operating conditions are in conformity with required
specifications.