Phenolics-Cumene Doc. No.

: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 1 of 14

Start-up
Lining out the Overall Process
In Cumene Plant

Name Date Signature

Developed By Jinil K.C.

Process Trainer Hartono Susanto

SK Operation Specialist Abdul Rashid Bin Razali

Process Engineer Haridasan

Final Approval:-
Phenolics Operations Department Manager:-
Mr. Khater-Al, Ali Abdullah

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

 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 2 of 14

Record of revision:

Reason of revision : revise SOP template and content

Name : Jinil K.C

 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 3 of 14

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
 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 4 of 14

References:

P & ID NO’S : All P&IDs in Cumene Plant

PFD NO’S : All PFDs in Cumene Plant

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

 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 5 of 14

1. Purpose:
To provide Standard Operating Procedures for normal start up of Lining out Overall Process in Cumene Plant
in safe and logical sequence.

2. Important system components/ equipment:

All equipments in Cumene Plant

3. Potential consequences by failure system:

In case of failure of Lining out Overall Process in Cumene Plant , the Plant rate will be low and loss of energy
and utility consumption. Cumene product quality will be up set.
4. Precautions and Limitations:
4.1. Safety Precautions: All personnel are required to wear standard personal protective equipment
(PPE).
4.2. Flammable Properties: The Cumene Column, benzene column, PIPB Column, Alkylation Reactor,
Transalkylation Reactor and associated equipment receive large volumes of liquid hydrocarbon
material. Operations should take care when handling all equipment to prevent any spills and
releases.
4.3. Carcinogenic: Benzene is Carcinogenic material, Precautions are necessary to avoid direct contact
with the material and vapor releases to the atmosphere.
4.4. Flammability: Benzene, Cumene, Propylene, PIPB vapors are flammable. Avoid the presence of open
flames or sparks. Suppress vapors with firewater. Monitor firewater run-off closely.
4.5. Material Safety Data Sheets (MSDS): All personnel working in the Cumene unit must be familiar
with the MSDS’S associated with the chemicals in use in their assigned work area.
4.6. The level of protection and types of controls necessary will vary depending upon potential exposure
condition.
4.7. Be well aware of emergency fire alarm pull station & emergency contact numbers.

5. Special Tools/Equipment:

5.1. Portable gas detector.

5.2. Proper Chemical Suit
5.3. Proper chemical Gloves
5.4. Face shield
 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 6 of 14

6. Prerequisites:

Prerequisite Resp. Date Time Init

1. The plant is operating at about 50% capacity with the reactor and column
temperature profiles close to PFD values. The final step is to increase capacity C.O
to 100% of PFD value and to fine tune the reactors and columns to the most
efficient operating point.

7. Process Description:
Cumene Plant is to produce 325,000 MTPA of Cumene from benzene and propylene raw materials.
The Plant has three main sections such as Reaction, Feed Treated and Distillation Column.
Benzene and propylene prior to feeding to the reactor is purified in Feed Treated to remove basic and polar
nitrogen and sulfur compound.
In Alkylation Reactor , benzene and propylene is reacted to form cumene with small amount of DIPB and TIPB.
DIPB and PIPB are converted to additional cumene in Transalkylation Reactor.
Distillation columns are aim to purge product impurities, recycle excess benzene to reactors, isolation
cumene as product and recover DIPB and TIPB for transalkylation.

8. Operating Tasks:

8.1. Start up of the system to get 100% Plant capacity

8.2. Taking samples

9. Chemical and physical Properties (MSDS):

9.1. Chemistry
C6H6 ( Benzene )
C2CHCH3 ( Propylene )
C6H4(C3H7)2 ( DIPB )
C6H3(C3H7)3 ( TIPB )
C6H5CH(CH3)2 ( Cumene )

9.2. Physical properties : refer to SOP No. SK-Phenolics-SU-510001/07/13

9.3. Process Technology :

DIPB and TIPB as result of secondary reaction in Alkylation reactor are transalkylated with benzene to
form cumene in Transalkylation reactor.
 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 7 of 14

10. Control system and strategy :

The plant is operating at about 50% capacity with the reactor and column temperature profiles close to PFD
values. The final step is to increase capacity to 100% of PFD value and to fine tune the reactors and columns
to the most efficient operating point.

List of controllers refer to SOP No. SK-Phenolics-SU-510002 ~ 510013.

11. Interlocks:
List of Interlocks refer to SOP no. SK- Phenolics-SU-510002 ~ 510013.

12. Critical safety systems:

Refer to SOP No. SK-Phenolics-SU-510002~510013.

13. Safety and Health:

Refer to SOP No. SK-Phenolics-SU-510001~510013.

14. Environmental:
Refer to SOP No. SK-Phenolics-SU-510001~510013.

15. Quality :
Refer to SOP No. SK-Phenolics-SU-510001~510013.

16. Start up Procedure:

1. Lining Out Benzene Column.

Note:
The plant is operating at about 50% capacity with the reactor and column temperature
profiles close to PFD values. The final step is to increase capacity to100% of PFD value and
to fine tune the reactors and columns to the most efficient operating point.

Procedure step Resp. Date Time Init

1.1. Sample and analyze of Benzene Column bottom(C-51021).

1.1.1. Open inlet and outlet valves of 510-SC-0030. F.O

1.1.2 Take sample of Benzene Column bottom from 510-SC-0030 in

F.O
P&ID 510-25F-2013, as per procedure.
 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 8 of 14

Procedure step Resp. Date Time Init

1.1.3 Check toluene content in Benzene Column bottom is at< 2
F.O
ppm wt.
1.2. Adjust the temperature set point on 510-TIC-074 to controls the steam
flow to the reboiler through 510-FV-087 until the toluene content is C.O
within the required specification at< 2 ppm wt.
1.3. Sample and analyze of recycle benzene stream.

1.3.1. Open inlet and outlet valves of 510-SC-0005. F.O

1.3.2 Take sample of recycle benzene from 510-SC-0005 in P&ID

F.O
510-25F-2008, as per procedure.

1.3.3 Check Cumene content in recycle benzene is at 0.5 wt%. F.O

1.4 Adjust the side draw reflux flow through 510-FV-064 until the Cumene
C.O
content is within the required specification at 0.5 wt%
1.5 Put non-aromatics overhead purge valve 510- FV-071 in service.

1.5.1 Open upstream and downstream valves of 510-FV-071. F.O

1.5.2 Set the flow of 510-FV-071 at the PFD value of 100 kg/h ready
C.O
for full capacity operation.

1.6 Put Benzene Purge valve 510-FV-068 from Benzene Recycle Surge Drum
in service.

1.6.1 Open upstream and downstream valves of 510- FV-068. F.O

1.6.2 Set the flow of 510-FV-068 from the side draw depending
C.O
on the composition of the benzene feed.

Note:
Column is now being in automatic control mode so that can be increase the capacity
by increasing the propylene flow to the Alkylator R-51001.

2. Lining Out Cumene Column.

Procedure step Resp Date Time Init

2.1. Sample and analyze the Cumene column bottom stream. F.O

2.1.1. Open inlet and outlet valves of 510-SC-007, which is located in the
F.O
discharge feed line of P-51032A\B to the PIPB column
 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 9 of 14

Procedure step Resp Date Time Init

2.1.2. Take sample of Cumene Column bottom from 510-SC-007 in P&ID 510-
F.O
25F-2017, as per procedure.

2.1.3. Check Cumene content in Cumene Column bottom is at 0.5 wt%. (Lab
F.O
test)
2.2. Adjust the temperature set point on 510-TIC-083 to control the steam flow to
the reboiler through 510-FV-078 until the Cumene content is within the C.O
required specification at 0.5 wt%.
2.3. Sample and analyze of overhead distillate stream
F.O
2.3.1. Open inlet and outlet valves of 510-SC-008B, which is located in the
F.O
common discharge line of P-51031A or B.
2.3.2. Take sample of overhead distillate from 510-SC-008B, as per procedure.
F.O
2.3.3. Check Cymene content in overhead distillate is at <30ppm wt
F.O
2.4. Adjust the reflux flow valve 510-FV-075 until the cymene content is within the
C.O
required specification at < 30 ppm wt.
2.5. Sample and analyze the side draw product stream.
F.O
2.5.1. Open inlet and outlet valves of 510-SC-008A, which is located in the
F.O
common discharge line of P-51033A\B.
2.5.2. Take sample of side draw product stream from 510-SC-008A as per
F.O
procedure.
2.5.3. Check Cymene content in side draw product stream is at <30ppm wt
F.O
2.6. Adjust the reflux flow valve 510 FV-075 until the cymene content is within the
C.O
required specification at < 30 ppm wt.
2.7. Put Cumene Product Cooler (E-51033) in line.
F.O
2.7.1. Close the CWR valve and open the vent valve upstream CWR valve and
gradually open the cooling water supply valve (25%) until its stop F.O
venting and only water comes out. Close the vent. Mount the blind.
2.7.2. Open the CWR valve gradually and open the CWS valve 100%. If
necessary the outlet temperature can be regulated with the CWR valve. F.O
Check for leaks.
2.8. Line up Cumene to Cumene Product/Makeup Benzene Exchanger E-51034A\B.
(Benzene is already passing through the E-51034).
2.8.1. Open the block valves of 510-FV-080. In the common discharge line of
F.O
P-51033A\B to E-51034.
2.8.2. Open 510-FV-080 gradually until the required flow 39,425 kg/hr is
C.O
reached
 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 10 of 14

Procedure step Resp Date Time Init

2.8.3. Open inlet valve of E-51034 A and B.
F.O
2.8.4. Open the block valves of 510-TV-093 the temperature bypass of E-
F.O
51034A\B.
2.8.5. Open 510-TV-093 and put 510-TIC-093 on auto (set on 122oC)
C.O
2.9. Start feeding to off-spec storage tank.

2.9.1. Open the valves in Cumene line from E-51033 to off-spec storage tank
TK-51901: the NC valve, the valve upstream 519-ESV-001 and the inlet F.O
of the tank.
2.9.2. Open 510-ESV-101 in Cumene line from E-51033 to off-spec storage
C.O
tank TK-51901
2.10. Start feeding to on-spec storage tank, after get clearance for the on spec
material.
2.10.1. Close the NC valve upstream E-51033 to off-spec tank TK-51901.
F.O
2.10.2. Open 519-ESV-003 or 519-ESV-005, the upstream valves and the inlet
valves of the tanks TK-51902 A and B Cumene day storage tank C.O
respectively.
2.10.3. Close the inlet valves of the off spec tank.
F.O
2.10.4. If the plant is running in stable conditions reprocessing the contents of
C.O
the off-spec tank to the benzene column can be started

Note:
Cumene Column is now operation in automatic control mode so that the capacity can
be increased by increasing the propylene flow to the Alkylator R-51001.

3. Lining Out PIPB Column.

Procedure step Resp Date Time Init

3.1 Sample and analyze the PIPB column bottom stream.

3.1.1 Open inlet and outlet valves of 510-SC-0020 in the discharge line of P-
F.O
51042A\B to E-51044. (P&ID 510-25F-2018).

3.1.2 Take sample of PIPB Column bottom from 510-SC-0020 . F.O

3.1.3 Check TIPB content in PIPB Column bottom is at 10 wt%.
F.O
 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 11 of 14

Procedure step Resp Date Time Init

3.2 Adjust flow valve 510-FV-084 in discharge line of P-51042A\B to E-51044 to
maintain approximately 2310C at the bottom of the column. (check it in 510- C.O
TE-108 in out let of PIPB Column Reboiler E-51042)
3.3 Sample and analyze the PIPB recycle stream.

3.3.1. Open inlet and outlet valves of 510-SC-0021 in the discharge line of P-
F.O
51043A\B to E-51002 (P&ID 510-25F-2018).

3.3.2 Take sample of PIPB recycle stream from 510-SC-0021 . F.O

3.3.3 Check Heavies (Diphenylpropane) content in Transalkylation Reactor

F.O
feed is at <100 ppm.

3.4. Adjust the following valves until the heavies (diphenylpropane etc)
content is within the required specification at < 100 ppm in PIPB recycle
stream.
3.4.1 The overhead reflux valve 510-FV-085 in the discharge line of P-
C.O
51041A\B to C-51041.
3.4.2 The side draw reflux valve 510-FV-081 in the discharge line of P-
C.O
51043A\B to C-51041

3.5 Sample and analyze the overhead reflux stream.

3.5.1 Open inlet and outlet valves of 510-SC-0010 in the discharge line of P-
F.O
51041A\B to E-51044. (P&ID 510-25F-2019)

3.5.2 Take the sample of overhead reflux stream from 510-SC-0010. F.O

3.5.3 Check Cymene content in aromatics purge ,it should be 60%wt of

F.O
cymene coming to the PIPB column.

3.6 Adjust the Aromatic purge valve 510-FV-086 until the 60%wt of cymene
CO
coming to the PIPB column is removed.

Note:
PIPB Column is now being in automatic control mode so that can be increase the
capacity by increasing the propylene flow to the Alkylator R-51001.)
 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 12 of 14

4. Lining Out of Alkylation Reactor, R-51001.

Procedure step Resp Date Time Init

4.1 Slowly increase the propylene feed valves, 510-FV-001 into the 3 lower
beds of Alkylation Reactor R-51001 and 510-FV-015 into the top feed of R- C.O
51001 in 10% increments until the PFD rate is reached.

4.2 Adjust the following temperature controllers

4.2.1 510-TIC-002 in Alkylation Reactor R-51001 top feed line.
C.O
4.2.2 510-TIC-003 in Alkylation Effluent Recycle to lower 3 beds of
Alkylation Reactor R-51001

4.3 Adjust the following flow controllers

4.3.1 510-FIC-005 in P-51001discharge line to Alkylation Reactor R-
51001 top feed line.
4.3.2 510-FIC-002 in Alkylation Effluent Recycle to 2nd bed of Alkylation
Reactor R-51001. C.O
4.3.3 510-FIC-003 in Alkylation Effluent Recycle to 3rd bed of Alkylation
Reactor R-51001.
4.3.4 510-FIC-004 in Alkylation Effluent Recycle to 4th bed of Alkylation
Reactor R-51001.

4.4. Maintain the benzene to propylene weight ratio at 3.71 : 1 by

C.O
adjusting the following valves.

4.4.1 510-FV-008 in Benzene Recycle from R-51052A\B to R-51001. C.O

4.4.2 510-FV-001 in propylene feed to the 3 lower beds of the R-

C.O
51001.

4.4.3 510-FV-015 in propylene feed to the top of the R-51001. C.O

4.5. Increase the flow to Benzene Column, Cumene Column and PIPB
Column after each propylene feed increment before ramping to the C.O
next level.
 Phenolics-Cumene Doc. No.: SK-Phenolics-SU- 510014

Rev. No.: 1
Plant Start-Up
System: Cumene
Date: March 31 ,2010
Subsystem: All
Page 13 of 14

5. Lining Out of Transalakylation Reactor R-51002.

Note:
As the propylene flow increases, the PIPB production in the Alkylation Reactor R-51001 will
increase.(Propylene flow already increased in Alkylation Reactor Lining Out up to PFD rate of
2755Kg/hr in top feed and 11,634 Kg/hr in lower 3 beds of Alkylation Reactor Lining Out)

Res
Procedure step Date Time Init
p.
5.1. Increase the PIPB feed valve 510-FV-082 in PIPB Recycle pump P-51043A\B
C.O
discharge line to E-51002 up to PFD rate.
5.2. Maintain the PIPB to propylene weight ratio at 1:1 by adjusting the
following valves.
5.2.1 510-FV-082 in PIPB Recycle pumps P-51043A\B discharge line to
C.O
E-51002.
5.2.2 510-FV-051 in Benzene Recycle from R-51052A\B to E-51002.
C.O
 Phenolics- Cumene Doc. No.: SK-Phenolics-SU-510014

Rev. No.: 1
Plant Start-Up
System : Cumene
Rev. Date: March 31, 2010
Subsystem: All
Page 14 of 14

17. Table of Critical Operating Limits:

Refer to Doc No. SK-Phenolics-NO-51002 ~ 51006

18. Check list :

18.1. Safety Devices Checklist: N/A

18.2. PSV Checklist: N/A
18.3. Car Sealed Valve Checklist: N/A
18.4. Instrumentation Checklist : N/A
18.5. Blind Checklist: N/A
18.6. Vents and Drains Checklist: N/A
18.7. Electrical Checklist: N/A
18.8. System Line Up Check List: N/A