13 KEROSENE MEROX PROCEDURE Latest

BYCO PETROLEUM PAKISTAN LIMITED
STANDARD OPERATING PROCEDURE

KEROSENE MEROX STARTUP
Document No: BPPL-OPS-SOP-13 Page No: 1 of 7
Issue Date: 24-Jun-2011 Revision No: 01
DOCUMENT CHANGE RECORD
REV. NO DESCRIPTION OF CHANGE EFECTIVE DATE
00 Initial Release 30-03-10

1. Company’s logo changed
01 27-06-11
2. Equipment Tagging Revised
PREPARED BY: Manager Operation REVIEWED BY: M.R IMS APPROVED BY: GM-ORC-I & II
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1.0 PURPOSE
The purpose of this procedure is to produce JP8 from Kerosene Merox unit.
2.0 SCOPE
This procedure applies for startup of Kerosene Merox unit.
3.0 DEFINITIIONS, ABBREVIATIONS AND CONCEPTS
3.1 ABBREVIATIONS
 ORC-I Oil Refining Complex-I.

 BPPL Byco Petroleum Pakistan Limited.
 CDU Crude Distillation Unit.
 EHS Environment Health Safety.
 PCV Pressure Control Valve.
 LCV Level Control Valve.
 TCV Temperature Control valve.
 FCV Flow Control Valve.
 LPG Liquefy Petroleum Gas.
 L/N Light Naphtha.
 H/N Heavy Naphtha.
 Kero Kerosene.
 LEL Lower explosive limit.
 OPS Operation
 Merox Mercaptan Oxidation Unit.
 Be Baume
 FB Reagent L/N, H/N & Kerosene Merox UOP catalyst
 NH3 Ammonia
 NaOH Sodium Hydroxide
 RSH Mercaptan
 LG Level gauge glass.

4.0 RESPONSIBILITIES AND AUTHORITIES
 GM-ORC-I & II
 Sr. Manager Operations
 Manager Operations
 Shift Incharge
5.0 PROCEDURE
The following procedure is employed for Kerosene treatment through Merox unit.
5.1. STEP-1
5.1.1. Check the entire unit line up for kerosene commissioning.

5.1.2. Make sure that all instruments are ready for operation.
5.1.3. Check availability of instrument and plant air with designed/required pressure.
5.1.4. Close all vents, drains and sample points.
5.1.5. Make sure that all valves are open of level glasses and pressure gauges.
5.1.6. Check level of salt in salt filter.
5.1.7. Make sure level of caustic pre-washer level at about 75% of upper LG.
5.1.8. Check the pre-washer Baume by laboratory & ensure it is 5 to 7 Be.
5.2. STEP-2
5.2.1. Fill the Water wash PAI-17C-7 with clean cool water up to 70% of upper LG.
5.3. STEP-3
5.3.1. Pump 20ºBe caustic to the reactor PAI-17C-4 to initially alkaline the catalyst bed
before introduction of hydrocarbon.
5.3.2. Caustic Circulate at about 1 hour in the reactor PAI-17C-4.
5.3.3. Fill the caustic pre wash PAI-13C-1A with 5to 7Be to the level of 75%.

5.4. STEP-4
5.4.1. Start kerosene filling into the unit first in to pre wash.
5.4.2. The reactor top vent line can be used to observe when filling is completed.
5.5. STEP-5
5.5.1. When the system is full of hydrocarbon, slowly increase reactor pressure up 60 psig
with the back pressure controller located on run down line.
5.5.2. Pressure to be maintained 55-60 psig.
5.6. STEP-6
5.6.1. Slowly increase hydrocarbon flow to required flow rate.
5.7. STEP-7
5.7.1. Start air injection at about 1.3 STD m3/kg RSH sulfur (21 SCF/lb RSH sulfur) or feed flow
rate according to UOP air flow chart.
5.8. KEROSENE MEROX OPERATING GUIDELINES
Pre wash Caustic 5.0 to 7.0 be

Total Alkalinity 1.9 wt%
Kerosene feed temperature 38-50ºC (55 Max)
System pressure 60psig.
5.9. SAMPLES TO BE CHECKED
5.9.1. Feed to reactor distillation

5.9.2. Acid No
5.9.3. H2S and RSH
5.9.4. Doctor Test
5.9.5. Color ASTM
5.9.6. Caustic Be and Strength
5.9.7. Cu. Corrosion
5.9.8. PH of wash water

5.10. REQUIREMENT OF ENVIRONMENT, HEALTH & SAFETY
5.10.1. ENVIRONMENT
1. Draining of H:C in to API should be kept control and should not be kept
unattended.
5.10.2. HEALTH
1. Dust mask, Ear plugs/Ear muffs, Hand gloves, safety shoes and safety helmet
must be used while working in the area.
2. Spent caustic is to be considered as dangerous as fresh caustic. Hydrogen sulfide
is a color less gas causing irritation in the eye respiratory tract. Exposure to 10
ppm for twenty minutes may prove fatal. Inhalation of low concentration of H2S
(3- 5 ppm) for short period may render the sense of smell in-effective, giving a
false indication of the absence of H2S. It has a characteristic odor of rotten eggs.
3. Mercaptans have an offensive odor and cause nausea and headache. High
concentration can cause un-consciousness and blue skin coloring, cold hand &
feet and rapid pulse.
4. Merox catalyst will stain skin & clothing; cause moderate skin and eye irritation.
5.10.3. SAFETY
1. Area should be cleaned and free from all foreign materials such as wooden/steel
planks, nut bolts, cotton waste, drums etc.
2. All safety equipments are in place and operable.
3. API sewers are working freely without any plugging.
4. Eye washers are in good working condition.
5. Maintain good communication system.
6. Personnel, who become sprayed or splashed with caustic, must wash the
affected part immediately with plenty of water.
7. Personnel, whose eyes are contaminated with caustic shall hold the eye open
and flush the eyes for fifteen minutes with water before taking the further pre-
cautions. If showering is required, the eyes shall be closed initially on showering
to prevent re-contamination of eyes tissues. After thoroughly flushing the eyes
with water consult the Doctor immediately.
8. When handling Merox catalyst uses rubber gloves and goggles.

6.0 RECORDS
Record No. Record Name Maintained by Retention Period

BPPL-OPS-LB-01 Shift Engineer log Book Shift Engineer 01 Year
BPPL-OPS-LB-02 Shift Incharge log Book Shift Incharge 01 Year
BPPL-OPS-LS-01 CDU DCS LOG SHEET DCS OPERATOR 01 Year
7.0 REFERENCE
 UOP Manual.

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BYCO PETROLEUM PAKISTAN LIMITED

STANDARD OPERATING PROCEDURE

DOCUMENT CHANGE RECORD

REV. NO DESCRIPTION OF CHANGE EFECTIVE DATE

00 Initial Release 30-03-10

CONTROLLED: COPY RIGHT © Please don`t copy without authorization

DOCUMENT DISTRIBUTION RECORD

DEPARTMENTS/HODS/OTHERS COPY NUMBER SIGNATURE

Document Control Room 2

CONTROLLED: COPY RIGHT © Please don`t copy without authorization

This procedure applies for startup of Kerosene Merox unit.

3.0 DEFINITIIONS, ABBREVIATIONS AND CONCEPTS

 ORC-I Oil Refining Complex-I.

CONTROLLED: COPY RIGHT © Please don`t copy without authorization

4.0 RESPONSIBILITIES AND AUTHORITIES

5.1.1. Check the entire unit line up for kerosene commissioning.

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5.6.1. Slowly increase hydrocarbon flow to required flow rate.

5.8. KEROSENE MEROX OPERATING GUIDELINES

Pre wash Caustic 5.0 to 7.0 be

5.9. SAMPLES TO BE CHECKED

5.9.1. Feed to reactor distillation

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5.10. REQUIREMENT OF ENVIRONMENT, HEALTH & SAFETY

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Record No. Record Name Maintained by Retention Period

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