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Procedure Development/Review Record

Next Review Date:


Review Date :
Review Number (to be circled) : 1st 2nd 3rd 4th 5th 6th
SOP Development/Review Teams:
# Name ID No Designation Signature
1.
2.
3.
4.

Review Note:

Approved by :
Name :
Date :

Note:
 The Development and Review Team shall at least consist of the operation lead operator, SSV and Process Engineer. Other parties within
the same department or from other departments can be invited, if deemed necessary. Should the original developer and/or the reviewer
of this document is no longer in existence, the approver shall appoint a nominee to him and/or them.
 By default, the review interval shall be minimum once every 3 years starting from the issuance date, unless specifically advised otherwise.
The procedure developer is responsible to indicate the Next Review Date during the first establishment of this procedure on this page.
 This review exercise shall be approved by the original approver of this document, or any authorized higher level from the same
department (or division, should the Operation Manager approval required).
 The old procedure review information page shall be superseded by a new one using the same format, and to be kept as obsolete record.
TABLE OF CONTENT

Section Description Page No.

1.0 Purpose

2.0 Scope

3.0 Definitions / Abbreviations

4.0 Process Description

5.0 Health Safety & Environmental Control

6.0 Process Operation

7.0 Control Loop Description

8.0 Alarm & Interlocks

9.0 Temporary Operation

10.0 Trouble Shooting

11.0 Relief Device/Fire Protection System

12.0 Record (Check list or Log Sheet)

13.0 Process Limits

14.0 Quality Control

15.0 Document Revision History

16.0 Attachments
1.0 PURPOSE
To provide operation staff with the necessary background and information to understand how the
process works, how to prepare the unit for start-up, how to operate it and how to do prepare for
hand over a burner for maintenance and to take over after the maintenance in safe and logical
sequence.

2.0 SCOPE
This procedure is applicable to all Petrorabigh’s Direct Hire employees and Long Term Manpower
attached to Aromatic Complex Unit (R420) of Monomer II Operation Department. This procedure
applies for the activities as specified.

3.0 Definition / Abbreviations

Commissioning : The period when the dynamic verification of the functioning equipment, the
simulation of control loops and safety systems, and the operational tests are carried out.
Commissioning includes also a variety of activities such as cleaning and drying-out of piping systems,
tightness tests, running-in of pumps with inert fluid (water, nitrogen).

SSV: Shift Supervisor in charge while the activity was perform.

CO: Console Operator on duty while the activity was perform.

FO: Field Operator on duty while the activity was perform.

In service: means the system is operational main header and user’s feeder lined up. Each individual
user only is isolated either by block valves, if available, or blinds.

4.0 Process Description

The purpose of this specification is to define the requirement and configuration of a safety
system that ensures safe handover and take over the fired heater burners
The heaters in R420 unit are as below,
1. R420-FR-2130 Xylene Rerun Column Reboiler Heater

2. R420-FR-2330 Toluene Column Reboiler

3. R420-FR-2340 Heavy Aromatic Reboiler

4. R420-FR-2351Transplus Reactor Feed Heater

5. R420-FR-2520 Deheptanizer Column Reboiler

6. R420 Unit Fired Heaters Heater

Fired process heaters require properly designed burners to deliver reliable flames at given
specific conditions of Heat Release Heater Draft and Excess Air by The use of several
conditions of fuels. C-SRX burners are designed and tested to meet there requirements and
additionally to develop a flame that produces Low NOx emissions and negligible CO traces to
establish very high combustion efficiency. Emission reduction is obtained by fuel stage
mechanism and partly by internal flue gas circulation induced by the burner jet entrainment
on the flame surroundings.
Both system work to lower the peak flame temperature which is major responsible for NOX
formation. Fuel staging delays stoichiometric combustion while recirculated gas mix with the
products of combustion. Heat release is regulated by fuel pressure that is also dependent on
the type of fuel in case of very different fuel molecular weight and calorific value, different
gas tips drilling are suggested to optimize jet velocities and therefore multiple separate fuel
manifolds are provided. Combustion air capacity is a result of heater draft and ambient
conditions and can be adjusted by a manual damper in order to maintain proper excess air at
different heat releases.
The pilot burner ignites the main burner central flame which is then providing proper ignition
condition for the secondary external tips. A central battle is used
To stabilize the central baffle is used to stabilize the central flame.
The burner is made by four parts
- Refractory muffle block
- Air body [wind box] with manual air register and silencer
- Fuel central tips and risers
- Pilot burners

5.0 Health Safety & Environmental Control


5.1 The burner lance may be hot while removal, so proper gloves to be used.
5.2 Removal of the lance may require two person to hold the weight, hence care should be taken.
5.3 Wrong furnace operating conditions may cause formation of CO and Oxygen poor
environment. In case draft is not sufficient, these gas could exit from the burner air inlet
causing poisoning or explosion, a sudden opening of the air dampers may lead to an
explosion Operator hence while opening the air resister the activity should be slow and step
by step.
5.4 Following care of fuel gas/ hydrogen C5 vapors leakage should be taken while handover of
the burner to maintenance.
A. Before removal of the burner lance confirm that the fuel valves to the same burners are
closed properly.
B. DO NOT OPERATE tag is installed.
C. The pressure in the fuel line of the burner is zero.

6.0 PROCES OPERATION

S No Work Description Action by Date

6.1 Task : Isolation of main burner [ FG/Hydrogen/ C5 Vapors] for handover


S No Work Description Action by Date

a Inform to CO once you are ready to isolate the burner FO/CO


b After confirmation from CO, slowly close the gate valve for the burner [ FO
I. e. 1st manual isolation valve].
c Check the pressure in the downstream pressure gauge, When it is zero FO
and flame is off for the main burner close the downstream globe valve.
d Close The air resister to 30 %. FO
e Inform CO that the burner is isolated FO
f Install the DO NOT OPERATE tag on both the valves. FO
g Handover to maintenance team FO
h During removal of lance confirm there is no FG/Hydrogen /C5 vapors leakage by FO
gas detector.
i If the valves are passing, install end blinds for the fuel connection. FO
j Confirm the lance should be removed only after allowing to cool the tip of FO
burner for sufficient time.
6.2 Task : Isolation of pilot for handover
A Confirm the main burner for the pilot to be isolated is isolated. FO

B If not, first check with CO and isolate the main burner for the pilot to be FO
isolated, using procedure 6.1
C Close the air resister to 0 %

D Inform to CO once you are ready to isolate the pilot burner FO

d After confirmation from CO, slowly close the gate valve for the pilot
burner [i. e. 1st manual isolation valve].
e Check the pressure in the downstream pressure gauge, When it is zero FO
and flame is off for the main burner close the downstream globe valve.
c Close the air resistor to 0%. FO
d Inform CO that the burner is isolated FO
e Install the DO NOT OPERATE tag on both the valves. FO
f Confirm The pilot lamp is off in LCP/DCS FO/CO
g Handover to maintenance team FO
h During removal of lance confirm there is no FG/Hydrogen /C5 vapors leakage by FO
gas detector.
i If the valves are passing, install end blinds for the fuel connection. FO
6.3 Task : Takeover of main burner [FG/Hydrogen/C5 Vapors]
A Confirm that the lance is installed properly [i.e. bolts, gasket FO
properly secured and aligned].
b Before lighting the main burner ensure FO
S No Work Description Action by Date

1. The permit for maintenance is closed


2. The pilot for the same burner is burning properly
c If it is C5 vapors burner insure steam tracing is in service FO
d Remove the tag of DO NOT OPERATE at the valves FO
e Confirm the air resister is initially 30% open and air resistor
operation is smooth, once burner is it up air resister shall be open
as per flame pattern and O2 analyzer requirement.
f During lighting of burner check for leakage. Confirm leakage at FO
flanges by gas detector
g If leakage or not igniting , uneven flame pattern is there inform FO
CO and isolate the burner as 6.1
6.4 Task : Takeover of pilot burner
A Confirm that the lance is installed properly [i.e. bolts, gasket FO
properly secured and aligned].
b Before lighting the burner ensure the permit for maintenance is FO
Closed
C Confirm the air resistor is 30 % open. FO
c Remove the tag of DO NOT OPERATE at the valves FO
d During lighting of burner confirm no leakage at flanges by gas FO
Detector
e If There is leakage is there inform CO and isolate the burner as 6.2 FO

Status of loop
Not Applicable
Preparation for Line up
Not Applicable
Process Line up
Not Applicable

7.0 CONTROL LOOP DESCRIPTION

Not applicable

8.0 ALARM & INTERLOCK


Not applicable

9.0 Temporary Operation

Not applicable

10.0 Trouble Shooting

Not applicable

11.0 Relief Device/Fire protection System

Not applicable

12.0 Blind Record (Check List or Log sheets)

Sr. No. Blind No. Burner No. Installed By Removed By Remark

13.0 Process Limit

Not Applicable.

14.0 Quality Control


Not Applicable.
15.0 Document Revision History
Revision : 00

16.0 ATTACHMENTS
16.1 P&ID
16.2 Document: Burner Operating and Maintenance Manual