SK-Phenolics-SU - 510013 Establishing PIPB Feed To The Tranalkylation Reactor

Phenolics-Cumene Doc. No.
: SK-Phenolics-SU- 510013
Rev. No.: 1
Plant Start-Up
System: Alkylation and Transalkylation
Date: March 27 ,2010
Subsystem: Transalkylation Reactor
Page 1 of 39
Start-up
Establishing PIPB Feed to
Transalkylation Reactor(R-51002)
Name Date Signature
Developed By J.B. Mahadik
Process Trainer Hartono Susanto
SK Operation Specialist Cherian P Ninan
Process Engineer Haridasan
Final Approval:-
Phenolics Operations Department Manager:-
Mr. Khater-Al, Ali Abdullah
Sign. …………………………………………. Date ……………………………….

Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510013
Rev. No.: 1
Plant Start-Up
Page 2 of 39
Record of revision:
Reason of revision : revise SOP template and content
Name : J.B. Mahadik

Rev. No.: 1
Plant Start-Up
Page 3 of 39
Content :
1. Purpose:
2. Important system components/ equipment:
3. Potential consequences by failure system:
4. Precautions and Limitations:
5. Special Tools/Equipment:
6. Prerequisites:
7. Process Description:
8. Operating Tasks:
9. Chemical and physical Properties (MSDS):
10. Control system and strategy :
11. Interlocks:
12. Critical safety systems:
13. Safety and Health:
14. Environmental:
15. Quality:
16. Start up Procedure:
17. Table of Critical Operating Limits:
18. Checklist: All
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Plant Start-Up
Page 4 of 39
References:
P & ID NO’S:
510-25F-2006: Transalkylation Reactor & Feed Heater.
510-25F-2009: Benzene Column.
510-25F-2013: Cumene Column.
510-25F-2014: Cumene col. Condenser, Bottom pumps & Product pumps.
510-25F-2017: PIPB Column.
510-25F-2018: PIPB Col. Rec. pumps, Bottom pump and Residue and Aromatic cooler.
510-25F-2021: Secondary Benzene Treaters.
PFD NO:
510-25F-1001: Cumene Area Reaction Section.
510-25F-1003: Cumene/PIPB Column.
MSDS Nos. Ref. e-SK share folder MSDS plant wise

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Plant Start-Up
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1. Purpose:
To provide Operating Procedures for normal start up of establishing PIPB Feed to the Transalkylation Reactor
in safe and logical sequence.
2. Important system components/ equipment:

2.1. Transalkylation Reactor R-51002
2.2. Reactor Start Up Heater E-51002
2.3. Cumene Column C-51031
2.4. PIPB Column C-51041
2.5. PIPB Column Vacuum System PK-51041
2.6. Residue and Aromatic Cooler E-51044
2.7. Benzene Recycle Pump P-51023 A/B
2.8. Benzene Contaminated Oily Water Drum V-51055
3. Potential consequences by failure system:
In case of failure of PIPB feeding to Transalkylation Reactor, Cumene plant has to take shut down.
While the critical operation parameters are not maintained , trip system will active ( as per point No. 11 &
12 ) and catalyst tend to be damage.
4. Precautions and Limitations:
4.1. All personnel are required to wear standard personal protective equipment (PPE).
4.2. Material Safety Data Sheets (MSDS) – All personnel working in the Cumene area must become familiar
with the associated Benzene, Cumene MSDS in his assigned work area.
4.3. Ensure all electrical equipment properly grounded.
4.4. Keep all Motor & coupling guards in its place.
4.5. All fire detector & fire protection system, gas leak detector system are in line & ready for use.
4.6. Establish good communication between Field & Control room persons.
4.7. Safety shower system is operational .
5. Special Tools/Equipment:
5.1. Portable gas detector.

5.2. Proper Chemical Suit
5.3. Proper chemical Gloves
5.4. Face shield
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6. Prerequisites:
Prerequisite Resp. Date Time Init
6.1. Ensure that the Product storage flushing and hydrocarbon make up is
C.O.
carried out as per procedure.
6.2. Ensure that all Cumene plant battery limit equipments ready for start-
F.O.
up.
6.3. Ensure that Vent collection system and flare systems are operational. C.O.
6.4. Ensure that all utilities and OSBL facilities are operational. F.O.
F.O.
6.4.1. Nitrogen for inerting
F.O.
6.4.2. Steam systems -all levels.
F.O.
6.4.3. Steam condensate system all levels.
F.O.
6.4.4. Cooling water circulation for coolers and condensers.
F.O.
6.4.5. Potable water for safety showers.
F.O.
6.4.6. Fire water system.
F.O.
6.4.7. UPS and Auxiliary Power system.
6.5. All spectacle blinds are in their normal operating positions as per P&ID.
L.O.
Refer checklist for Blinds # 17.6
6.6. Ensure that the Line-up system as per system line-up check list # 17.9 L.O.
6.7. Ensure that the nitrogen blanketing system is in working condition and
Cumene storage tank has been properly nitrogen blanketed. L.O.
6.8. Verify that all control valves have been stroke checked and close in C.O.
manual with 0% output and all control valve bypasses are close.
6.9. Ensure that the WF, CF and BZW system has been commissioned and is
L.O.
in operational condition.
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Prerequisite Resp. Date Time Init
6.10. Ensure that fire & Gas detection system in service.

L.O.
Refer checklist for safety devices # 17.2
6.11. All Safety valves have been lined up as per PSV list.
L.O.
Refer checklist for PSVs # 17.3
6.12. All Car Seal Open/Close valves have been lined up as per checklist.
L.O.
Refer to car seals Checklist # 17.4
6.13. All instrumentation are installed and ready for service.

L.O.
Refer checklist for Instruments # 17.5
6.14. All vents (pressure –vacuum safety valve and emergency relief hatch)
are commissioned and drains on lines and equipment are closed. L.O.
Refer checklist for Vents & Drains # 17.7
6.15. Ensure that the all sample collection valves are closed L.O.
6.16. Ensure all related motors are energized. Refer checklist for Electrical #
L.O.
17.8
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7. Process Description:
DIPB and TIPB, collectively called as PIPB, which is recovered in the PIPB column and recycle benzene are
combined and reacted over the zeolite catalyst ( EM-5510) to form cumene, to increase the overall cumene
production.
The transalkylation of PIPB with benzene back to cumene is nearly isothermal with only a slight
temperature rise across the single bed catalyst.
The recycle benzene and recycle PIPB is combined in a 1 : 1 ratio and is heated to about 183 oC in the
Transalkylation Feed Heater , before being fed to Transalkylation Reactor.
The reaction is controlled at back pressure of 20 barG.
8. Operating Tasks:
8.1. Start up of the system

8.2. Taking samples
9. Chemical and physical Properties (MSDS):
9.1. Chemistry
C6H6 ( Benzene )
C6H5CH(CH3)2 ( Cumene )
9.2. Physical properties

Benzene is liquid material, colorless, sweet odor which is extremely hazardous.
As a liquid, vapor, or mist is readily absorbed through the skin, mucous membranes, gastrointestinal and
respiratory tracts, and can cause cancer .
DIPB is liquid material , colorless.
Combustible liquid and vapor.
Cumene is colorless to pale yellow liquid, with a sharp irritating odor. Soluble in alcohol, acetone, esters,
hydrocarbons, chlorinated hydrocarbons.
As a liquid , vapor, or mist is readily absorbed through the skin,mucos membranes, gastrointestinal and
respiratory tracts.
9.3. Process Technology :
To ensure all material inside the Transalkylation Reactor in liquid phase, the effluent is controlled at back
pressure of 20 barG.
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10. Control system and strategy :
The Transalkylation Reactor (R-51002) is online with 50% of the normal flow of benzene flowing through flow
control valve 510-FV-051 into the catalyst bed.
The start up Cumene material from PIPB Column (C-51041) during inventory is sent back to Benzene Column
(C-51021).
Once the PIPB column temperature and concentration profile is within specification, divert PIPB to
transalkylator.
510-FIC-051 flow indication control of Recycle Benzene to R-51002
510-TIC-050 temperature indication feed inlet to R-51002, cascade to steam flow to feed heater
510-TI-051/052/053/054/055 temperature indication of reactor catalyst bed from top to bottom

respectively
510-PIC-060 pressure indication control of Transalkylator effluent
Controllers of Benzene, Cumene and PIPB Column refer to SOP No. SK-Phenolics-SU-510002 / 510010/
510011 respectively.
11. Interlocks:
No. Interlock No. Causes Effects
High high R-51002 feed temperature Close FV-082, FV-050,ESV-117 and

1. 510-S-002 ESD-116
Low low Recycle Benzene flow
2. 510-I-002 R-51002 ESD Close 510-FV-082 and FV-050
Interlocks for PIPB Column refer to SOP no. SK- Phenolics-SU-510011
12. Critical safety systems:

12.1. High high R-51002 feed temperature. The value is 230 oC
12.2. Low low Recycle Benzene flow. The value is 8,000 kg/hr
13. Safety and Health:
13.1. Normal present Hazardous chemical

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Benzene Ref. e-SK share folder MSDS plant wise
Flammable, toxic – cancer hazard ( TLV 2.5 ppm), causes skin irritation.
Concentrations in system 99.71 wt %
Cumene Highly flammable and toxicity (TLV 50 ppm)
13.2. Potential presence of Hazardous chemical
Benzene : Harmful or fatal if swallowed. Flammable liquid and vapor. Harmful if inhaled or absorbed
through skin. Causes irritation to skin, eyes and respiratory tract. Affect central nervous system.
Cumene : Harmful or fatal if swallowed. Flammable liquid and vapor. Harmful if inhaled or absorbed
through skin. Causes irritation to skin, eyes and respiratory tract. Affect central nervous system.
13.3. Potential other Dangers

Cumene flammability is classified as 3, for material flash point below 38oC
14. Environmental:
14.1. Benzene
Air :
It will usually either break down or decompose over a few days, with the products eventually ending
up in the air. It can be washed out of the air by rain, but will evaporate and continue to contaminate the
air. It can attach to rain or snow and be carried back down to the ground.
Waste water and Soil :
Benzene in soil or water will decompose with the presence of oxygen. It does not build up in plant or
animal tissues. Benzene has a high acute toxic effect on aquatic life. Long-term effects on marine life
can mean shortened lifespan, reproductive problems, lower fertility and changes in appearance or
behavior. Benzene can cause death in plants and roots and damage to the leaves of many agricultural
crops.
14.2. Cumene
Air :
When released into the air, this material is expected to be readily degraded by reaction with photo
chemically produced hydroxyl radicals.
Waste water :
When released into water, this material is expected to readily biodegrade. When released into water,
this material may evaporate to a moderate extent.
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Soil and general :

When released into the soil, this material is expected to readily biodegrade. When released into the soil,
this material is not expected to leach into groundwater. When released into the soil, this material may
evaporate to a moderate extent.
15. Quality:
15.1. Back ground

Benzene is coming from Olefin Plant. Benzene is treated in the Clay Treated and Secondary Benzene
Treater to remove poisonous material to Transalkylator zeolite catalyst.
15.2. Quality Specification

Benzene specification as per Cumene Plant Operating Manual
Cumene specification as per Cumene Plant Operating Manual

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16. Start up Procedure:
Note:
The Transalkylation Reactor (R-51002) is online with 50% of the normal flow of benzene flowing
through flow control valve 510-FV-051 into the catalyst bed.
Procedure Steps Resp. Date Time Init
1. Line Up Vacuum to PIPB Column (C-51041)
F.O
1.1. Start the PIPB Column Vacuum Pump (PK-51041) as per
procedure or by vendor’s procedure.
C.O
1.2. Gradually reduce the set point of 510-PIC-096A to 0.85 barg.
2. Line up Concentrated PIPB from the Cumene Column (C-51031) bottom

to the PIPB Column (C-51041).
F.O
2.1. Open the upstream and downstream isolation valve in the feed
line from P-51032 A/B of 510-FV-079.
C.O
2.2. Open manually the feed to C-51041, 510-FV-079, and adjust the
flow.
C.O
2.3. Cascade the feed control valve 510-FV-079 with Cumene column
level controller 510-LIC-027.
3. Line up the start up Cumene material from PIPB Column (C-51041) back
to Benzene Column (C-51021).
F.O
3.1. Close the block valve of PIPB recycle line in the common
discharge of P-51043 A/B to E-51002.
F.O
3.2. Open the cross-over line (510-P-0045) between the transalk
ylator effluent and PIPB recycle line from P-51043 A/B, by
opening the two block valves.
C.O
3.3. Manually open flow control valve 510-FV-082 and divert start up
Cumene material to C-51021.
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Note:
Now Benzene is circulating through transalkylator and mixed Cumene /Benzene stream through
510-PV-060 to C-51021.
4. Decrease tray #30 level to 50 %.

C.O
4.1. Open the upstream and downstream block valves of 510-FV-081
on P-51043 A or B discharge to tray #29 of the column.
C.O
4.2. Open 510-FV-081 and increase the level on tray #30 to 50%.
Avoid cavitation of P-51043A or B.
C.O
4.3. Put the 510-LIC-035 (level of tray#30) in cascade with side draw
reflux flow 510-FV-081.
C.O
4.4. Gradually increase steam to reboiler (E-51042) by opening 510-FV
- 083 through 510-FIC-083 to achieve the desired profile and
desired concentration of the column.
Note:
If the PIPB column temperature and concentration profile is within specification, divert PIPB to transalkylator.
5. Line Up Recycle PIPB from (C-51041) to Transalkylator (R-51002).

F.O
5.1. Open the block valve on P-51043A or B discharge line 510-P-
0114 upstream of the junction with line 510-P-0041 i.e. Benzene
Recycle line
F.O
5.2. Manually reduce the flow through 510-FV-082 to 10% of the
normal flow rate of recycle PIPB to transalkylator.
F.O
5.3. Close the double block valves in the cross-over line 510-P-0045
to transalkylator effluent to C-51021.
Note:
Now mixed stream of Recycle PIPB & Recycle Benzene is flowing through E-51002 to Transalkylator R-51002.
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C.O
6. Set the Recycle Benzene flow controller 510-FIC-051 at about 8,500
kg/hr to transalkylator R-51002.
C.O
7. Set temperature controller 510-TIC-050, the feed temperature to the
transalkylator at 183oC.
C.O
8. Gradually increase the flow of PIPB to the transalkylator while
monitoring the level on the chimney tray #30 in the PIPB Column.
9. Line Up cooling water to E-51044.

F.O
9.1. Open the vent valve on upstream of the cooling water return
line block valve.
F.O
9.2. Keep cooling water return block valve closed.
F.O
9.3. Gradually open the cooling water supply block valve up to 25-
50%
F.O
9.4. Close the vent valve when air is removed and only cooling water
comes out. Install blind on the vent valve.
F.O
9.5. Open the cooling water return block valve gradually.
F.O
9.6. Open cooling water supply totally. Check for any leakage
10. Commission the flow controller 510-FIC-086 of Aromatics purge.

F.O
10.1. Open the upstream and downstream block valve of flow
controller 510-FV-086 to E-51044
C.O
10.2. Set the flow of Aromatics purge at 50% of normal flow by
opening flow control valve 510-FV-086 manually to residue
purge to offsite incinerator.
11. Commission the flow controller 510-FIC-084 of PIPB bottom Residue.

F.O
11.1. Open the upstream and downstream block valve of flow
controller 510-FV-084 to E-51044.
C.O
11.2. Set the flow of bottom residue at 50% of normal flow by opening
flow control valve 510-FV-084 manually to Residue purge to
offsite incinerator.
Phenolics- Cumene Doc. No.: SK-Phenolics-SU-510013
Rev. No.: 1
Plant Start-Up
System : Alkylation and Transalkylation
Rev. Date: March 27, 2010
Page 15 of 39
17.1. Table of Critical Operating Limits:

Process Consequences of
Operating Safe Safe Consequences
Variable deviating outside Safety Systems or
Range Alarms Required Actions Upper Lower of deviating Outside of
(Variable and of normal Required Actions
(Units) Limit Limit Safe Operating Limits
Tag Number) operating range
183°C 207oC PIPB to Cumene Maintain reactor 207°C 178°C PIPB to Cumene Maintain reactor temp.
510-TIC-050 conversion will be temp. 510-TIC-050 conversion will be less 510-TIC-050
less
C-51021 will be operated

C-51021 will be
Maintain 510-PIC-060 at higher pressure
510-PIC-060 20.0 bar g 21 bar operated at higher 20.0 bar g - Maintain 510-PIC-060
pressure resulting in benzene
g pressure. pressure
going to flare.
510-FIC-051 /
1.0 by _ PIPB to Cumene Maintain Recycle PIPB to Cumene Maintain Recycle
510-FIC-082
weight conversion will be Benzene to Recycle - - conversion will be less Benzene to Recycle
ratio
less PIPB ratio PIPB ratio
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17.2. Safety Devices Checklist:
Item No. Device Resp Date Time Init.
1. Deluge system in service. Refer to P&ID No. 105-45F-2114/2115/2155 L.O
2. Fire Extinguisher in position with valid date. L.O
3. Gas Detectors are in service. Refer to P&ID No. 105-45P-0601-01 L.O
4. Fire Water system in service. Refer to P&ID No. 105-45F-2101 L.O
17.3. PSV Checklist:
Item No. PSV No. Set Pressure P&ID No. Line No. Required Position Resp. Date Time Init.
1. PSV015A 40.0 bar G 510-25F-2006 510-P-0160 Open both u/s & d/s F.O
valves
2. PSV015B 40.0 bar G 510-25F-2006 510-P-0160 Open both u/s & d/s F.O
valves
valves
valves
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5. PSV023 52.20 bar G 510-25F-2006 V-51002 Open both u/s & d/s F.O
valves
6. PSV024 52.0 bar G 510-25F-2009 V-51023 Open both u/s & d/s F.O
valves
valves
valves
9. PSV030C 3.50 bar G 510-25F-2013 510-P-0259 Open both u/s & d/s F.O
valves
10. PSV110 52.0 bar G 510-25F-2013 510-HS-0001 Open both u/s & d/s F.O
valves
11. PSV063 26.9 bar G 510-25F-2014 510-CWR-0013 Open both u/s & d/s F.O
valves
12. PSV-013A 3.50 bar G 510-25F-2017 510-P-0164 Open both u/s & d/s F.O
valves
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13. PSV-013B 3.50 bar G 510-25F-2017 510-P-0164 Open both u/s & d/s F.O
valves
14. PSV-027 52.0 bar G 510-25F-2017 510-HS-0002 Open both u/s & d/s F.O
valves
15. PSV-038 5.0 bar G 510-25F-2018 510-P-0394 Open both u/s & d/s F.O
valves
16. PSV-016 29.9 bar G 510-25F-2018 510-CWR-0018 Open both u/s & d/s F.O
valves
valves
valves
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17.4. Car Sealed Valve Checklist:
Item P&ID No. Line No. Car Sealed Valve Location Position Resp. Date Time Init.
No. Description
1. 510-25F-2006 510-P-0160 U/S of PSV-015A Open F.O
2. 510-25F-2006 510-WF-0005 D/S of PSV-015A Open F.O

U/S of PSV-015B
3. 510-25F-2006 510-P-0160 Close F.O
4. 510-25F-2006 510-WF-0005 D/S of PSV-015B Open F.O
7. 510-25F-2006 510-P-0161 U/S of PSV-012B Close F.O
9. 510-25F-2006 510-HS-0011 U/S of PSV-023 Open F.O
10. 510-25F-2006 510-AV-0001 D/S of PSV-023 Open F.O

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No. Description
15. 510-25F-2013 510-P-0258 U/S of PSV-030B Open F.O
17. 510-25F-2013 510-P-0259 U/S of PSV-030C Open F.O
18. 510-25F-2013 510-WF-0011 D/S of PSV-030C Open F.O

U/S of PSV-110
19. 510-25F-2013 510-HS-0001 Open F.O
Bypass of PSV-110
20. 510-25F-2013 510-HS-0001 Close F.O
D/S of PSV-110
21. 510-25F-2013 510-AV-0004 Open F.O
U/S of PSV-063
22. 510-25F-2014 510-CWR-0013 Open F.O
23. 510-25F-2017 510-P-0164- U/S of PSV-013A Open F.O
25. 510-25F-2017 510-P-0164 U/S of PSV-013B Close F.O

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No. Description
29. 510-25F-2017 510-HS-0002 By pass line of PSV-027 Close F.O
30. 510-25F-2018 510-CWR-0018 U/S of PSV-016 Open F.O
31. 510-25F-2018 510-P-0394 U/S of PSV-038 Open F.O
32. 510-25F-2018 510-WF-0104 D/S of PSV-038 Open F.O
34. 510-25F-2021 510-P-0167 D/S of PSV-053 Open F.O
36. 510-25F-2021 510-P-0168 D/S of PSV-054 Open F.O

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17.5. Instrumentation Checklist :
Item P&ID No. Line No. Tag No Service Resp. Date Time Init.
No.
1. 510-25F-2006 510-P-0043 510-TIC-050 Yes
2. 510-25F-2006 R-51002 510-TI-051 Yes
3. 510-25F-2006 R-51002 510-TI-052 Yes
4. 510-25F-2006 R-51002 510-TI-053 Yes
5. 510-25F-2006 R-51002 510-TI-054 Yes
6. 510-25F-2006 R-51002 510-TI-055 Yes
7. 510-25F-2006 510-P-0050 510-PIC-060 Yes
8. 510-25F-2006 517-HS-0010 510-FIC-050 Yes
9. 510-25F-2006 510-HSC-0011 510-LIC-003 Yes
10. 510-25F-2006 510-P-0041 510-FIC-0581 Yes
11. 510-25F-2006 510-P-0050 510-FI-054 Yes
12. 510-25F-2017 510-P-0110 510-PIC-096 Yes

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No.
13. 510-25F-2017 510-P-0092 510-FIC-079 Yes
14. 510-25F-2017 510-P-0113 510-FIC-081 Yes
15. 510-25F-2017 C-51041 tray #30 510-LIC-035 Yes
16. 510-25F-2017 C-51041 510-LIC-033 Yes
17. 510-25F-2017 C-51041 510-PI-106 Yes
18. 510-25F-2017 C-51041 510-PI-121 Yes
19. 510-25F-2017 C-51041 510-PDI-095 Yes
20. 510-25F-2017 C-51041 510-TI-098 Yes
21. 510-25F-2017 510-P-0262 510-TI-101 Yes
22. 510-25F-2017 517-HS-0014 510-FIC-083 Yes
23. 510-25F-2017 517-HS-0014 510-ESV-114 Yes
24. 510-25F-2017 510-HSC-0015 510-LIC-031 Yes
25. 510-25F-2017 510-P-0120 510-HIC-194 Yes

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No.
26. 510-25F-2017 510-P-0119 510-HIC-142 Yes
27. 510-25F-2017 510-HS-0015 510-PI-107 Yes
28. 510-25F-2018 510-P-0139 510-ESV-115 Yes
29. 510-25F-2018 510-P-0117 510-FIC-089 Yes
30. 510-25F-2018 510-P-0120 510-FI-093 Yes
31. 510-25F-2018 510-P-0113 510-FI-097 Yes
32. 510-25F-2018 510-P-0114 510-FIC-082 Yes
33. 510-25F-2018 510-P-0121 510-FIC-084 Yes

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17.6. Blind Checklist:
Item No. P&ID No. Line No. Location Description. Required Resp. Date Time Init.
Position
1. 510-25F-2006 510-P-0017 On D/S of FO-013 to R- Close F.O

51001 Top
2. 510-25F-2006 510-P-0050 On R-51001 bottom to C- Open F.O

51021
3. 510-25F-2006 510-P-0044 On R-51001 top D/S of block Close F.O

valve to WF
4. 510-25F-2006 510-N-0010 On N2 line to R-51001 Close F.O

bottom
5. 510-25F-2006 510-P-0052 R-51001 bottom to Benzene Close F.O

pump out to P-51081
6. 510-25F-2006 510-P-0051 R-51001 bottom to WF Close F.O
7. 510-25F-2006 510-P-0041 On E-51002 process inlet Open F.O

from R-51052A or B
8. 510-25F-2006 510-P-0043 On E-51002 process outlet Open F.O
9. 510-25F-2006 510-P-0043 From E-51002 to R-51002 Open F.O

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Position
10. 510-25F-2006 510-N-0012 On N2 line to R-51001 top Close F.O
11. 510-25F-2009 510-P-0050 From R-51002 to C-51021 Open F.O
12. 510-25F-2017 510-P-0128 Reflux line from P-51041A Open F.O

or B to C-51041
13. 510-25F-2017 510-P-0117 Minimum flow line from P- Open F.O

51043A or B to C-51041
14. 510-25F-2017 510-P-0140 PIPB from PK-51041 Open F.O
15. 510-25F-2017 510-P-0112 PIPB from tray #30 to P- Open F.O

51043A or B
16. 510-25F-2017 510-P-0113 PIPB from P-51043A or B to Open F.O

tray #29 of C-51041
17. 510-25F-2017 510-P-0092 PIPB from P-510321 A or B Open F.O

to C-51041
18. 510-25F-2017 510-P-0119 U/S of HV-142 on C-51041 Open F.O

bottom to P-51042A or B
Rev. No.: 1
Plant Start-Up
Page 27 of 39
Position
19. 510-25F-2018 510-P-0115 PIPB from C-51041 to pump Close F.O

out pump P-51041A or B
20. 510-25F-2018 510-P-0124 On d/s of 510-FV-084 to C- Open F.O

51031 on P-51042A or B
discharge.
21. 510-25F-2018 510-P-0125 Pump out to E-51081 from Close F.O

P-51042A or B discharge.
22. 510-25F-2018 510-P-0121 On process inlet line of E- Open F.O

51044
23. 510-25F-2018 510-P-0122 On process outlet line of E- Open F.O

51044
Rev. No.: 1
Plant Start-Up
Page 28 of 39
17.7. Vents and Drains Checklist:
Item No. P&ID No. Line No. Location Description Required Resp. Date Time Init.
Position
1. 510-25F-2006 510-P-0017 Drain On D/S of FO-013 to Closed F.O

BZW
2. 510-25F-2006 510-P-0043 Vent on R-51002 inlet from Closed & F.O

E-51002 Blinded
3. 510-25F-2006 510-P-0044 Drain on U/S of Block valve Closed & F.O

to WF Blinded
4. 510-25F-2006 510-P-0044 Drain on D/S of Block valve Closed & F.O

to WF Blinded
5. 510-25F-2006 510-P-0160 Drain valve to WF on U/S of Closed F.O

PSV-015A
6. 510-25F-2006 510-WF-0005 Drain valve to WF on D/S of Closed F.O

PSV-015A
7. 510-25F-2006 510-P-0160 Drain valve to WF on U/S of Closed F.O

PSV-015B
8. 510-25F-2006 510-WF-0005 Drain valve to WF on D/S of Closed F.O

PSV-015B
Rev. No.: 1
Plant Start-Up
Page 29 of 39
Position
9. 510-25F-2006 R-51002 Drain valve at the bottom of Closed & F.O

R-51001 Blinded
10. 510-25F-2006 510-P-0050 Drain valve to BZW on U/S Closed F.O

of block valve on R-51001
bottom to C-51021
11. 510-25F-2006 510-P-0050 Drain valve to BZW on D/S Closed F.O

of block valve on R-51001
bottom to C-51021
12. 510-25F-2006 510-P-0041 Drain valve to BZW on U/S Closed F.O

of 510-FV-051
13. 510-25F-2006 510-P-0049 Drain valve in between Closed F.O

double block valve assembly
to BZW
14. 510-25F-2006 517-HS-0010 Drain valve on D/s of 510- Closed & F.O
FV-050 Blinded
15. 510-25F-2006 517-HS-0010 Drain valve on D/S block Closed & F.O
valve on D/S of 510-FV-050 Blinded
Rev. No.: 1
Plant Start-Up
Page 30 of 39
Position
16. 510-25F-2006 V-51002 Drain valve on U/S of PSV- Closed & F.O
023 Plugged
17. 510-25F-2006 510-AV-0001 Drain valve on D/S of PSV- Closed & F.O
023 Plugged
18. 510-25F-2006 510-HSC-0021 Drain valve on LG of V- Closed & F.O

51002 Plugged
19. 510-25F-2006 510-HSC-0021 Vent valve on LG of V- Closed & F.O

51002 Plugged
20. 510-25F-2009 510-P-0050 Drain valve to BZW From R- Closed F.O

51002 to C-51021
21. 510-25F-2017 C-51041 4”Vent valve on top of Closed &

Dome. Blinded
Vent valve on u/s of PSV-
22. 510-25F-2017 510-P-0164 Closed
013A to WF.
23. 510-25F-2017 510-WF-0014 Vent valve on d/s of PSV- Closed
013A to WF
24. 510-25F-2017 510-P-0164 Vent valve on u/s of PSV- Closed

013B to WF
Rev. No.: 1
Plant Start-Up
Page 31 of 39
Position
25. 510-25F-2017 510-WF-0014 Vent valve on d/s of PSV- Closed

013B to WF
26. 510-25F-2017 510-P-0113 Drain valve on d/s of 510- Closed

FV-081to BZW

FV-079 to BZW
28. 510-25F-2017 517-HS-0014 Drain valve on u/s of ESV- Closed &

114 Blinded
29. 510-25F-2017 517-HS-0014 Drain valve on d/s of 510- Closed &

FV-083 Blinded
30. 510-25F-2017 510-HS-0002 Vent valve on u/s of PSV- Closed &

027 Plugged
31. 510-25F-2017 510-AV-0005 Vent valve on d/s of PSV- Closed &

027 Plugged
32. 510-25F-2017 510-HSC-0029 Vent valve on LG-032 Closed &

Plugged
Rev. No.: 1
Plant Start-Up
Page 32 of 39
Position
33. 510-25F-2017 510-HSC-0029 Drain valve on LG-032 Closed &

Plugged
34. 510-25F-2017 510-HSC-0015 Drain valve on u/s of 510- Closed &

LV-031 Blinded
35. 510-25F-2017 C-51041 2”Drain valve at bottom of Closed &

C-51041 Blinded
36. 510-25F-2017 510-P-0119 Drain valve on u/s of HV-142 Closed &

to BZW Blinded
37. 510-25F-2017 510-P-0251 Vent valve on LG-034 to WF Closed
38. 510-25F-2017 510-P-0251 Drain valve on LG-034 to Closed

BZW
39. 510-25F-2018 510-P-0112 Drain valve on P-51043A Closed

suction to BZW

discharge to BZW
41. 510-25F-2018 P-51043A Drain valve of P-51043A to Closed

BZW
Rev. No.: 1
Plant Start-Up
Page 33 of 39
Position
42. 510-25F-2018 510-P-0112 Drain valve on P-51043B Closed

suction to BZW

discharge to BZW
44. 510-25F-2018 P-51043A Drain valve of P-51043B to Closed

BZW

suction to BZW
46. 510-25F-2018 P-51042A Drain valve of P-51042A to Closed

BZW

suction to BZW
48. 510-25F-2018 P-51042B Drain valve of P-51042B to Closed

BZW

FV-089 to BZW
Rev. No.: 1
Plant Start-Up
Page 34 of 39
17.8. Electrical Checklist:
Item P&ID No. Equipment No Energized Resp. Date Time Init.

No.
1. 510-25F-2018 PM-51043A Yes F.O
2. 510-25F-2018 PM-51043B Yes F.O
3. 510-25F-2018 PM-51042A Yes F.O
4. 510-25F-2018 PM-51042B Yes F.O
17.9. System Line Up Check List:
Item P&ID No. Line No. Location Description Required Resp. Date Time Init.
No. Position
1. 510-25F-2006 510-P-0114 Block valve on U/S of check valve from Open F.O
P-51043A or B to E-51002
2. 510-25F-2006 510-P-0041 U/S block valve of 510-FV-051 Open F.O
3. 510-25F-2006 510-P-0041 D/S block valve of 510-FV-051 Open F.O
4. 510-25F-2006 510-P-0041 510-FV-051 Close F.O

Rev. No.: 1
Plant Start-Up
Page 35 of 39
No. Position
5. 510-25F-2006 510-P-0041 Block valve on D/S of check valve Open F.O
6. 510-25F-2006 510-P-0043 Double block valve from E-51002 to R- Open F.O

51001
7. 510-25F-2006 510-P-0050 Double block valve in U/S start up Open F.O

Bypass line
8. 510-25F-2006 510-P-0050 Block valve on D/S of startup bypass line Open F.O
9. 510-25F-2009 510-P-0050 U/S block valve of 510-PV-060 Open F.O
10. 510-25F-2009 510-P-0050 D/S block valve of 510-PV-060 Open F.O
11. 510-25F-2009 510-P-0050 510-PV-060 Close F.O
12. 510-25F-2009 510-P-0050 Bypass valve of 510-PV-060 Close F.O
15. 510-25F-2017 510-P-0113 510-FV-081 Close F.O
16. 510-25F-2017 510-P-0113 Bypass valve of 510-FV-081 Close F.O

Rev. No.: 1
Plant Start-Up
Page 36 of 39
No. Position
19. 510-25F-2017 510-P-0092 510-FV-079 Close F.O
21. 510-25F-2017 517-HS-0014 U/S block valve of 510-FV-083 Open F.O
22. 510-25F-2017 517-HS-0014 D/S block valve of 510-FV-083 Open F.O
23. 510-25F-2017 517-HS-0014 510-FV-083 Close F.O
24. 510-25F-2017 517-HS-0014 Bypass valve of 510-FV-083 Close F.O
25. 510-25F-2017 517-HS-0014 ESV-114 Open F.O
26. 510-25F-2017 517-HS-0014 Main Steam block valve on U/S of ESV- Open F.O
114
27. 510-25F-2017 517-HS-0014 Bypass of Main Steam valve on U/S of Close F.O
ESV-114
28. 510-25F-2017 510-HSC-0015 U/S block valve of 510-LV-031 Open F.O

Rev. No.: 1
Plant Start-Up
Page 37 of 39
No. Position
29. 510-25F-2017 510-HSC-0015 D/S block valve of 510-LV-031 Open F.O
30. 510-25F-2017 510-HSC-0015 510-LV-031 Close F.O
31. 510-25F-2017 510-HSC-0015 Bypass valve of 510-LV-031 Close F.O
32. 510-25F-2017 510-P-0119 HV-142 Open F.O
33. 510-25F-2018 510-P-0112 Suction block valve of P-51043A Open F.O
34. 510-25F-2018 510-P-0113 Discharge block valve of P-51032A Open F.O
35. 510-25F-2018 510-P-0113 Bypass valve of Check valve of P-51043A Close F.O
discharge
36. 510-25F-2018 510-P-0112 Suction block valve of P-51043B Open F.O
37. 510-25F-2018 510-P-0113 Discharge block valve of P-51043B Open F.O
38. 510-25F-2018 510-P-0113 Bypass valve of Check valve of P-51043B Close F.O
discharge
39. 510-25F-2018 510-P-0119 Suction block valve of P-51042A Open F.O
40. 510-25F-2018 510-P-0120 Discharge block valve of P-51042A Open F.O

Rev. No.: 1
Plant Start-Up
Page 38 of 39
No. Position
41. 510-25F-2018 510-P-0120 Bypass valve of Check valve of P-51042A Close F.O
discharge
42. 510-25F-2018 510-P-0119 Suction block valve of P-51042B Open F.O
43. 510-25F-2018 510-P-0120 Discharge block valve of P-51042B Open F.O
44. 510-25F-2018 510-P-0120 Bypass valve of Check valve of P-51042B Close F.O
discharge
47. 510-25F-2018 510-P-0117 510-FV-089 Close F.O
51. 510-25F-2018 510-P-0114 510-FV-082 Close F.O

Rev. No.: 1
Plant Start-Up
Page 39 of 39
No. Position
55. 510-25F-2018 510-P-0121 510-FV-084 Close F.O

SK-Phenolics-SU - 510013 Establishing PIPB Feed To The Tranalkylation Reactor

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SK-Phenolics-SU - 510013 Establishing PIPB Feed To The Tranalkylation Reactor

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Phenolics-Cumene Doc. No.

Name Date Signature

Developed By J.B. Mahadik

Process Trainer Hartono Susanto

SK Operation Specialist Cherian P Ninan

Process Engineer Haridasan

Sign. …………………………………………. Date ……………………………….

Reason of revision : revise SOP template and content

Name : J.B. Mahadik

MSDS Nos. Ref. e-SK share folder MSDS plant wise

2. Important system components/ equipment:

3. Potential consequences by failure system:

4. Precautions and Limitations:

5.1. Portable gas detector.

Prerequisite Resp. Date Time Init

Prerequisite Resp. Date Time Init

6.10. Ensure that fire & Gas detection system in service.

6.13. All instrumentation are installed and ready for service.

8.1. Start up of the system

9. Chemical and physical Properties (MSDS):

9.2. Physical properties

9.3. Process Technology :

10. Control system and strategy :

510-FIC-051 flow indication control of Recycle Benzene to R-51002

510-TI-051/052/053/054/055 temperature indication of reactor catalyst bed from top to bottom

510-PIC-060 pressure indication control of Transalkylator effluent

No. Interlock No. Causes Effects

High high R-51002 feed temperature Close FV-082, FV-050,ESV-117 and

2. 510-I-002 R-51002 ESD Close 510-FV-082 and FV-050

Interlocks for PIPB Column refer to SOP no. SK- Phenolics-SU-510011

12. Critical safety systems:

13. Safety and Health:

13.1. Normal present Hazardous chemical

Benzene Ref. e-SK share folder MSDS plant wise

Cumene Highly flammable and toxicity (TLV 50 ppm)

13.2. Potential presence of Hazardous chemical

13.3. Potential other Dangers

Soil and general :

15.1. Back ground

15.2. Quality Specification

Cumene specification as per Cumene Plant Operating Manual

16. Start up Procedure:

Procedure Steps Resp. Date Time Init

1. Line Up Vacuum to PIPB Column (C-51041)

2. Line up Concentrated PIPB from the Cumene Column (C-51031) bottom

Procedure Steps Resp. Date Time Init

4. Decrease tray #30 level to 50 %.

5. Line Up Recycle PIPB from (C-51041) to Transalkylator (R-51002).

Procedure Steps Resp. Date Time Init

9. Line Up cooling water to E-51044.

10. Commission the flow controller 510-FIC-086 of Aromatics purge.

11. Commission the flow controller 510-FIC-084 of PIPB bottom Residue.

17.1. Table of Critical Operating Limits:

C-51021 will be operated

17.2. Safety Devices Checklist:

Item No. Device Resp Date Time Init.

1. Deluge system in service. Refer to P&ID No. 105-45F-2114/2115/2155 L.O

2. Fire Extinguisher in position with valid date. L.O

3. Gas Detectors are in service. Refer to P&ID No. 105-45P-0601-01 L.O

4. Fire Water system in service. Refer to P&ID No. 105-45F-2101 L.O

17.3. PSV Checklist:

17.4. Car Sealed Valve Checklist: