CDU-2 Operating Manual For Updation

CDU-2 OPERATING MANUAL
OPERATING MANUAL
(CDU-2 Unit)
MANGALORE REFINERY
AND PETROCHEMICALS LTD
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PREFACE
THIS MANUAL GIVES THE OPERATING GUIDELINES FOR CRUDE DISTILLATION UNIT, VACUUM
DISTILLATION UNIT AND NAPHTHA SPLITTER UNIT OF MANGALORE REFINERY AND
PETROCHEMICALS LTD. THE GUIDE LINES AND INSTRUCTIONS CONTAINED IN THIS MANUAL IS
FOR THE PURPOSE OF FACILITATING THE START- UP & SHUTDOWN, SUBSEQUENT OPERATION
AND EMERGENCY HANDLING OF THE UNITS.
THE OPERATING PROCEDURES AND CONDITIONS ARE INDICATIVE ONLY AND MODIFICATIONS
MAY BE NECESSARY IN DUE COURSE OF TIME AS A RESULT OF EXPERIENCE GAINED IN
ACTUAL OPERATION OF THE UNITS.
SOME OF THE INFORMATION IN THE MANUAL IS CONFIDENTIAL AND THE USERS ARE
REQUESTED TO KEEP THE MANUALS UNDER THEIR PERSONAL CONTROL AND IN GOOD
CONDITION.
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INDEX:-
S No DESCRIPTION PAGE NO
1. CHAPTER-1…..INTRODUCTION 05
2 CHAPTER-2…..CRUDE OIL 12
3 CHAPTER-3…..PRECESS DESCRIPTION
14
3.1 PREHEAT-1 AND CRUDE DESALTING 14
3.2 CRUDE PREHEAT-2/ CRUDE PREFLASHING/PREHEAT-3 21
3.3 CRUDE HEATER/CRUDE COLUMN 23
3.4 NAPHTHA STABLIZER 34
3.5 KERO/NAPHTHA SPLITTER(KSU/NSU)/ CAUSTIC/WATER WASH 36
3.6 VACUUM DISTILLATION UNIT 53
3.7 TEMPERED WATER SYSTEM/ STEAM GENERATION SYSTEM 66
3.8 CHEMICAL INJECTION 69
3.9 UTILITIES/ FLUSHING OIL SYSTEM/ EFFLUENT SYSTEM 72
3.10 FLARE SYSTEM 85
4 FUEAL GAS/LPG AMINE SYSTEM 87
5 START UP PRCEDURE 91
6 NORMAL OPERATION 126
7 SHUTDOWN PROCEDURE 132
8 EMERGENCY PROCEDURES 138
9 EQUIPMENT OPERATING PROCEDURES 147
9.1 PUMP 147
9.2 HEAT EXCHANGER 150
9.3 FURNACE 151
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10 SECTION WISE STARTUP AND SHUTDOWN PROCEDURE 158
11 CDU ENVIRONMENT ASPECT RELATED OPERATING PROCEDURES 171
CHANGE HISTORY:
Issue No. Issue Date Particulars
- - Previous issues were not controlled with Issue Number.
1.0 15-07-2017 Inclusion of recent Modifications. KSU/NSU revamp changes included.
1.1 30-07-2018 Inclusion of Desalter revamp
Change record:
Sl. No. Release Date Page/ Section affected Release Change Brief Description Of Change
From To
1 15-07-2017 CDU products section - to 1.0 CDU products destinations
mentioned separately. Changes has
been included.
2 15-07-2017 KSU/NSU revamp - to 1.0 KSU/NSU revamp changes has been
changes included. MN and HN to OMPL
included.
3 15-07-2017 VDU products section - to 1.0 VDU products destinations
mentioned separately. Changes has
been included.
4 30-07-2018 Desalter Section 1.0 to 1.1 Desalter Revamp related changes
included.
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CHAPTER I
INTRODUCTION
1.1 Description
MRPL Crude distillation Unit (Phase-2) is designed to process in a single stream 6 million tons /
annum (i.e. 18000 t/day). CDU-2 name plate capacity revised to 7.20 MMTPA in year 2011. For
compactness of the refinery to achieve maximum heat recovery both crude and vacuum distillation
Units are inter-linked.
The design basis for MRPL is (I) Bombay High crude of 39.8 degree API. (ii) Arab Mix crude of 31.1
degree API, being a 50 : 50 mix by weight.
The hourly feed rate shall be based on 8000 hours of on stream time per annum.
Based on crude assay the percentage yield of products for each type of crude is as follows;
Yields of Products:
Percentage Yield:
Products Arab Mix Arab Mix Bombay Bombay High

(TPD) (% ) High (%)
(TPD)
Fuel Gas 7 0.065 17 0.15
LPG 145 1.38 190 1.75
Stabilized Naphtha 1478 13.34 2335 21.08
Kerosene 2218 20.02 2222 20.06
Light Gas Oil 754 6.80 1224 11.05
Heavy Gas Oil 859 7.75 1330 12.08
VDO 151 1.36 151 1.36
V.G.O 2508 * 22.64 3100 27.98
Vacuum Residue 2847 26.6 485 4.38
* VGO make will be 2420 tons per day if D 1160 EP in Arab case is restricted to 565°C.
1.2 Products and their Specification

The unit shall be designed to produce products having following specifications:
(I) Mixed C3 / C4 LPG
Arab Mix BH
16.8
Vapor pressure at 65°C, Kg/cm2a max 16.8
C5 (+) content, % wt 1.0 1.0
H2S (estimated 100 ppm 10 ppm
Mercaptan (estimated) 600 ppm 30 ppm
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(Corresponds to min 95 % vol. vaporization at 760 mm Hg and 2 ° Celsius)
(ii) Stabilized Naphtha

Nominal TBP cut point, C C5 - 150 C5 - 150
Specific gravity, 15/15 C 0.700 0.750
RVP, Kg/cm2a . 74max. 75max
C4 (-) content, % wt 0.8 0.8
Sulfur, ppm 190 - 250 5 - 10
ASTM D86 Distillation, C
IBP 50 50
5% 56 62
10% 59 72
30% 78 88
50% 97 102
70% 115 116
90% 135 138
95% 143 144
EP 149 149
(iii) Kerosene
Arab Mix Bombay High
Nominal TBP cut point, C 150 - 280 150 - 250
Specific Gravity, 15 / 15 C 0.802 0.813
Sulfur content, ppm wt 3500 - 5000 3 - 10
Mercaptan Sulfur, ppm wt 65 1.5
Smoke point, mm 23 17
Flash point, C 47 41
Doctor test + ve + ve in 1st Stage
IBP 140 131
5% 172 162
10% 181 169
30% 198 181
50% 261 196
70% 237 218
90% 266 241
95% 277 250
EP 293 265
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(iv) Light Gas Oil Arab Mix Bombay High

Sulfur content, %wt 1.40 0.08
Nitrogen, ppm wt N.A 150
Pour Point, C <0 <0
Cetane Index (estimated) 57 50 (DI)
IBP 198 199
5% 252 246
10% 269 256
30% 291 268
50% 301 278
70% 311 288
90% 326 304
95% 331 312
EP 348 326
(iv) Heavy Gas Oil

Sulfur content, %wt 2.00 0.30
Nitrogen, ppm wt N.A 200
Pour Point, C (+) 6 (+) 18
Cetane Index (estimated) 56 50 (DI)
IBP 242 257
5% 302 300
10% 319 313
30% 339 328
50% 351 340
70% 363 354
90% 386 377
95% 399 390
EP 425 406
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(v) Vacuum Gas Oil

Nominal TBP cut point, C 370 - 550 (1) 370 - 550
Sulfur content, %wt 2.6 - 2.8 0.3
Nitrogen, ppm wt 910 - 960 250
Pour Point, C (+) 39 (+) 54
Flash point, C 0.5 MAX 0.5 MAX
C7 insoluble, ppm wt, 500 max 500 max
Metals (Ni + V), ppm wt 1 max 1max
IBP 352 350
5% 375 375
10% 384 387
30% 421 417
50% 449 440
70% 483 466
90% 525 503
95% 541 518
EP 565 550
The original design TBP cut range has been revised to 370 - 543 C for Arab Mix casein order to obtain
ASTM D 1160 EP of 565 C with same equipment.
(vi) Vacuum Residue
Nominal TBP cut point, C 550 (+) 550(+)
Specific Gravity, 15/15 C 1.048 1.035
Sulfur content %Wt 4.86 0.77
Nitrogen, ppm wt 3500 - 4500 100 - 1500
Pour point, C (+) 42 (+) 78
Conradson Carbon, %Wt 21.9 23.7
Viscosity @ 100 CST 200 - 2500 900
@ 50 CST 180000 - 250000 30000
Metals, ppm wt vanadium 134 - 300 5 - 10
Nickel 42 - 70 18
Ash, ppm wt 1000 max 500 max.
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1.3 Battery Limit Conditions:
Feed Stock Pressure Temperature Source

Kg/cm2g °C
Crude Oil 21.0 40 Storage
VBU Fuel Oil NA 240 Visbreaker
Product Pressure Temperature Destination

Kg/cm2g °C
Fuel Gas 6.0 45 - 60 Amine absorber (in CDU)

LPG 16.0 40 Amine absorber (in CDU)
Stabilized Naphtha 9.0 90 Naphtha Splitter (in CDU)
9.0 40 Storage
Kerosene 10.0 40 Kero Merox /VBU
Light Gas Oil 10.0 270 Visbreaker
10.0 40 HCU WO Tank
Gas Oil 10.0 40 Storage/Refinery WO
VGO 11.0 138 (AM) HCU
11.0 164 (BH) HCU
10.0 65 HCU feed tank/PFCC feed tank
Short Residue 9.0 267 VBU / BBU/DCU
7.0 160 Storage
VBU fuel oil (NA) 75 Storage
1.4 Utilities and their Specifications (at unit B/L)
Minimum Normal Maximum Mech.

Design
MP Steam :
Pressure, Kg/cm2g 14.0 15.0 16.0 22.0
Temperature, °C 255 260 270 295
LP Steam :
Pressure, Kg/cm2g 3.0 3.5 4.0 10.0
Temperature ,°C 160 175 200 225
Cooling Water :
Type : Recirculating
Supply Pressure, Kg/cm2g 5.0 5.5 7.0
Return Pressure, Kg/cm 2g 2.5 3.0 7.0
Supply Temperature. °C 33 65
Return Temperature, °C 45 65
Boiler Feed Water :
Pressure, Kg/cm2g 26.5 36.0
Temperature, °C 147 155
Utility Water :
Pressure., Kg/cm2g 6.0 17.5
Temperature. C Ambient 65
Turbidity, NTU Scale 2
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M. Alkalinity Mg/l 25 to 30
Ca Hardness Mg/l 20 to 30
Total, hardness Mg/l 30 to 40
Total Silica as SiO 2 , 10 to 15
Chlorides as Cl, Mg/l 10 to 15
Sulfated as CaCO3, Mg/l 10 to 20
Total Iron as Fe, Mg/l < 0.1
TDS, Mg/l 60 to 85
pH 7.0 - 7.5
Organicmatter,KMNo4 Mg/l <5
DM Water :
Oil Oil - free
Turbidity, Mg/l Nil
Hardness as CaCO3, Mg/l Nil
Silica as SiO2 , Mg/l < 0.02
Colloidal Silica, Mg/l < 0.005
Chloride as NaCl, Mg/l Nil
Iron as Fe, Mg/l < 0.02
Copper as Cu, Mg/l Nil
Conductivity(20°C)Mho /cm 0.2 max
pH 6.3 - 6.8
Instrument Air :
Pressure, Kg/cm2g 3.5 6.5 10.5
Dew point, °C (-) 40 C at 760 mm hg
Oil content, ppm Oil free
Temperature °C 40 80
Plant Air :
Condensate :
Fuel Oil :
Specific Gravity @ 15°C 1.02- 1.05
Sulfur content, %wt 1.86- 5.50
Fixed Nitrogen, ppm wt 3500- 4500
Sodium content, ppm wt 50 - 400
Vanadium, ppm wt 70 - 300
Nickel, ppm wt 42 - 70
CCR, %wt 20 - 23
Ash content, ppm wt 100 max
Viscosity @ 100 C 2000- 2500
Vis. @ Oper. Temperature 30 - 35
Net calorific value, Kcal/kg 9500 min
Fuel Gas :
Pressure, Kg/cm2g 3.0 3.5 4.0 6.0
Temperature, Kg/cm2g 30 40 60 80
Fuel Gas Composition (%Vol.) With HCU/CDU / VBU

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H2 28.7
C1 18.2
C2 12.8
C3 20.7
iC4 6.6
nC4 8.7
C5 0.6
CO 0.2
N2 0.6
H2O 1.1
H2S 0.5
Olefins 1.2
Molecular Weight 27.0
Heating Value, Kcal/kg 10,000 min / 12,000 max
1.5 KSU/ NSU Feed Stocks Characteristics:
Cut point, °C TBP

ASTM distillation, °C
Case I Case II Case III Case IV
C5 - 150 C5 - 150 C5 - 150 C5 - 150
LV%
IBP 38 38 39 39
10 58 58 72 72
30 78 78 88 88
50 97 97 102 102
70 115 115 116 116
90 135 135 138 138
EP 149 149 149 149
Light ends analysis (%wt)
iC4 0.02 0.02 0.05 0.05

nC4 0.48 0.48 0.45 0.45
iC5 4.90 4.90 4.00 4.00
nC5 9.66 9.66 1.17 1.17
API Gravity 70.3 70.3 56.8 56.8
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CHAPTER II
INTRODUCTION
CRUDE OIL:
Oil is a homogeneous mixture of various Hydrocarbons of saturates and ring structures. The average
ultimate composition of Petroleum is mainly given in terms of constituents of Hydrocarbons. Mainly
carbon and Hydrogen as follows:
Carbon ` 84 - 86 %
Hydrogen 11 - 14 %
Composition of Crude Oil:

The bulk of Petroleum is made up of Hydrocarbons of saturated compounds like paraffins, Napthenes
and unsaturated cyclic compounds mainly aromatics.
Paraffins: - Cn H2n +2 are the general formula of paraffins. First three compounds are gases while
compounds upto C16 are liquids and beyond that they assume semisolid consistency and well beyond
C30 they assume shape of solid blocks, sometimes even crystalline forms.
Olefins: - Olefins are represented by the general formula CnH 2n. The first four are gases and upto
C15 are liquids and beyond C15 are solids. The boiling points of olefins are generally lower by few
degrees than the saturated compounds of the same carbon number. Chemically these differ very
much from paraffins. These unsaturates are mainly formed during cracking operations. They are
generally absent in crude.
Alkynes: - The general formula for this series is CnH2n-2. These are isomeric with olefins.
Acetylenes can readily be hydrogenated to give stable compounds. These are generally absent in
crude.
Napthenes: - These are saturated ring compounds bearing the general formula CnH 2n. The
prominence of ring structure starts with five carbon atoms although C3 and C4 ring structures, are in
existence, their stability is decreased because of excessive strain. Naphthenes are isomeric with
olefins but differ profoundly in properties. Napthenes exhibit both the properties of saturated paraffins
and unsaturated aromatics.
Aromatics: - The first and smallest of the aromatics is Benzene, other simple aromatics to follow
are Toluene, Xylene, Cumene etc. Even though Benzene is unsaturated, yet it follows the principle of
substitution with Halogens other than addition. The general formula for Aromatics is CnH (2n - 6).
INORGANICS:
Sulfur Compounds: - Sulfur is found in most of the crudes in variable amounts. Generally Sulfur
compounds are present in more quantity in higher boiling stocks. Usually the Sulfur content in crude
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does not exceed 5%.

Sulfur in crude occurs in different forms like free Sulfur, Hydrogen Sulfide, Mercaptans and
Thiophenes. Heavier fractions contain Sulfides. Polysulfides, Sulphonates and Sulfates.
Sulfur occupies prominent position in refining due to its ominous problems of corrosion and odor.
Oxygen and Nitrogen: - Oxygen and Nitrogen do not occur in Free State either in crudes or in
fractions. Nitrogen presence in free form is well known in natural gas only. Oxygen occurs as
oxygenated compounds like Phenols, Cresols, Naphthenic Acids, Sulphonates, Sulfates and
Sulfoxides.
Nitrogen exists in the form of indoles, pyridines, quinolines and Amines. Usually below 2% Nitrogen is
present in two forms basic and non-basic.
Other Inorganics: - The other elements present are Nickel, Vanadium, Iron, Silica, Sodium,
Magnesium and Halogens etc. The ash formation is mainly due to these metals and inorganic.
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CHAPTER III
PROCESS DESCRIPTION
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CDU/VDU/NSU is an integrated unit having no battery limit segregation.
For the operational convenience and for the sake of simplicity in description the entire unit has been
divided into a number of small subsections as described below:
Crude Distillation Unit

Naphtha Stabilizer
Naphtha Splitter Unit
Kero/ATF Splitter Unit
Vacuum Distillation Unit
Product cooling and Run down
Utilities
Crude Distillation Unit (CDU)

In CDU, crude oil is separated into various fractions in fractionation column, based on relative volatility,
boiling point and condensation temperature of the various components. These fractions have different
properties. Few of these are lighter than crude while bottom product RCO is heavier.
Basic operational steps involved in CDU is as follows
Crude feeding and preheating
Crude desalting
Crude preflashing
Crude feeding to heater
Fractionation
Product stripping/stabilization
Product cooling/routing to desired destination
Crude Feeding to Unit:
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Major equipment of this section is crude charge pump-GA41001A/B/C. Crude is pumped to our unit by
OM&S crude booster pumps GA47002C/D. From our battery limit it flows to the suction of
GA41001A/B/C. GA47002C/D takes suction from crude storage tanks FB7002A/B/C, that are located
at the upper plateau at an elevation of 65meters. Our battery limit is provided with two block valves on
the crude line and a spectacle blind is inserted between them. Crude feed to the unit is measured by
FIC 1102 that also provides input to pass balancer of atmospheric furnace. PT1103 and PAL1103 are
provided at the battery limit to indicate failure of OM&S crude charge pumps. Local PG/TG is provided
at the battery limit to indicate pressure and temperature of crude. PAL1102 is provided at the discharge
of GA4001A/B/C to indicate failure of crude charge pump. PV1201 is provided on the common
discharge line of charge pumps and it aids in controlling desalter pressure. One 4” MP steam
connection is given to the crude charge pump discharge for steam out purpose. A 2” crude slip stream
from GA41001 discharge is taken, for injecting caustic/ammonia solution, and routed to 2 nd stage
desalter outlet. A 6” slop reprocessing line, it is presently blinded, is provided to the suction of
GA410001A/B/C, downstream of FE1102. A 12” crude /slop start-up re-circulation line is given to the
suction of crude charge pumps. FV 1101 is given to control slop flow. FI1108 reads the summation of
FI1101 and FI1102. Alternatively slop can be injected in crude at OM&S in the suction of GA47002.
Provision exists for injecting caustic and demulsifier to the suction of crude charge pump.
A push button is provided in control room to trip crude charge pump from there. GA41001A/B/C
discharge goes to crude preheat train –1.
Crude Preheating:
Crude oil preheat train is provided to accomplish the following
1. To heat the crude oil and bring it to required desalting temperature.
2. To liberate lighter, flashing components by further heating the crude after desalting.
3. To recover heat from products and other circulating streams there by reducing fuel consumption in
operating unit.
There are three crude preheat trains in the unit. A total of 24 shell & tube exchangers are arranged in
these trains in series and parallel. Exchangers with split shells have been provided with common
bypasses to tackle maintenance /tube leakage problems. A TSV is provided on every exchanger outlet
to protect against pressurization due to thermal expansion of entrapped hydrocarbons on account of
prolonged blockage and heating by other liquids. PG and TI are provided on every exchanger in order
to know the temperature profile and performance across the exchanger train.,
3.1 Crude preheats train –1 & Desalting:
Crude preheat train-1 (PHT-1) is at the upstream of the desalter. There are 9 exchangers in this
section.
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The purpose of heating crude prior to desalting is to improve fluidity, reduce viscosity and thus enable
proper mixing of crude and desalting water. PHT-1 starts downstream of PV41201. Crude is heated
from ambient temperature to desalting temperature of 130°C in PHT-1.Crude upstream of PHT-1 is
split into streams. They are PHT-1A & PHT-1B.
Crude recovers heat in PHT-1A from Kero/ATF product and Kero/ATF c/r streams in exchangers
EA41013, EA41014A/B and EA41020A/B. The outlet temperature, TI1103, of PHT-1A is around
130°C.
Crude gets heat in PHT-1B from VDO c/r, Heavy Naphtha c/r, VR, LP steam, HVGO product and LGO
product streams in exchangers EA41015,EA41016A/B,EA 41063, EA41017,EA41018A/B &
EA41019.CR, The outlet temperature,TI1109, of PHT-1B is around 132°C. FT1103 and FT1104
measure crude flow to PHT-1A and PHT-1B respectively. Flow ratio controller FRC1104 regulates the
crude flow in PHT-1B. To match resistance offered by FV1104 and equalize pressure drop
HV1101/HIC1101 is provided in branch 1A. Flow split in branches 1A and1B can vary from 2:3 to 1:1.
The provision of split in branches 1A and1B has been conceived to optimize heat recovery in PHT for
various cases of operation. This flow splitting provision is typical to all preheat exchangers.
TI 1206 indicates the PHT-1 outlet temperature. A density meter is provided across FV1104 to
measure the density of crude. Crude lines up to EA41017, EA 41063 and EA41020A/B are steam
traced to avoid congealing of crude at low temperatures. A 2” BFW line is provided at the downstream
of HV1101&FV1104 for hot water wash. Crude from PHT-1 goes to desalter with the ideal temperature
of 130°C. The temperature may be adjusted to a higher/lower value by partially bypassing exchangers.
Crude Desalting
Phenomena of desalting
Crude oil brings along with it salts, particularly those of sodium, magnesium etc., metals like arsenic,
vanadium etc., and mud. Though these are in small amounts, their presence can result in serious
problems in down stream equipment like heat exchangers, heaters and columns. Hence it is essential
to remove these impurities before processing.
The presence of calcium and sodium salts can cause plugging of heat exchangers and heater tubes,
there by reducing heat transfer coefficient. At higher temperatures, magnesium chloride decomposes
and forms hydrochloric acid ,corroding trays in the top section of column and tubes of over head
condensers etc., Arsenic acts as poison to platinum catalysts that are used in down stream process
plants. Presence of these salts also promotes coke formation in heater tubes which results in
increased pressure drop as well as less heat transfer rates. The excessive coke formation results in
escalation of hot spots on heater tubes which can result in serious and disastrous consequence of
heater tubes. Caustic injection up stream of desalter in crude is done to neutralize acids present in
crude and convert them into salts. These salts are removed by desalter water in desalter. We are
injecting caustic into desalting water of first stage desalter. Caustic injection down stream of desalter is
provided to neutralize any other acid traces formed at desalter operating conditions.
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Brine is associated with crude both as a fine suspension of droplets and more permanent emulsions.
To break these light emulsions Demulsifier is added. This ensures better functioning of desalter .
Demulsifier can be injected into crude at the up stream of mixing valves DPV1201/1202 for immediate
effect.
Application of strong electric field hastens the process of coalescing and therefore settling of all
unwanted material .When the crude oil and water mixture is subjected to high potential electric field,
the tiny droplets get distributed between the electrodes and form dipoles.This makes it possible for the
tiny particles to coalesce and form bigger particles of sufficient weight to settle down. The force of
attraction between two droplets must be of sufficient magnitude to break through the oil film. At a level
below the electrodes, an interface is formed between hydrocarbon and water. This interface level is
controlled for desalter by regulating desalted water withdrawal from the vessel. Demulsifier helps in
reducing water carry over with crude and oil carry over with brine..
Desalters are upgraded from Bielectric technology to Dual frequency technology(Q4 of FY-2018) to
process lower API crudes of 22 and above.
Dual Frequency electrostatic technology utilizes a proprietary process controller, Load Responsive
Controller and three-phase Power unit (75KW) to produce a customized electrostatic field(AC & DC)
that can be readily optimized for any crude oil. The technology provides process improvements
approaching 100% over existing mainstream electrostatic technology.
Dual frequency combines 2 modes of voltage modulation i.e., Base frequency and modulation
frequency.
Base frequency operates at 800-1600Hz and used to enhance the droplet growth and limit field
decay.
Modulation frequency operates at 1Hz to 20Hz and used to coalesce the smallest water droplets and
grow these to sufficient size for rapid separation.
Desalters were upgraded for processing a blend of opportunity crudes of lower API like Soorosh,
Nooruz, Castilla & Vasconia, Which in turn will aid GRM’s.
Load Responsive Controller is a microprocessor based controller which is programmed for various
voltage cycles and adjustment of process parameters for optimal dehydration and rag layer resolution.
It also allows to set parameters like Base Frequency, Modulation Frequency, Wave Form, Skew
Factor, Minimum Voltage & Maximum Voltage for the system and interfaces with the customer’s DCS
Load Responsive Controller (LRC) which is installed in SRR-28 acts as Human-Machine interface,
displays Voltage, current & Arcs, Generates Set point data,. Recommends optimum voltage, Captures
fault messages, Communicates with DCS using TCPIP Ethernet Protocol, Also Contains User, Vessel,
& Oil Databases.
The function of the Dual Frequency Power Supply Unit is to convert the input 3 phase 415V (50Hz)
from electrical distribution lines to high frequency, high Secondary voltage signals (around 5 – 25 KV
DC). The 50 Hz input power is rectified, modulated and inverted to obtain a modulated high frequency
signal
The 75KW Power Unit is a proprietary design consisting of 3 primary components.
 Chopper module : to produce variable amplitude and variable frequency.
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 Transformer module : Steps up the input voltage to secondary level.

 Diode module : Secondary voltage is rectified into +Ve and –Ve half wave outputs and then applied
to electrodes to create benefits of both AC and DC fields.
Desalter description
An optimum temperature of 130°C at desalter inlet will help in removing the salt from crude effectively.
Two stage crude desalter comprising of two identical , horizontal vessels PA41001 & PA41002 has
been provided to reduce salt in crude oil to the level of <0.5 PTB. Two stage desalter unit arrangement
is provided to handle crude with widely varying salt content. Depending on salt content in crude both
desalters can be operated either in series or individually but not in parallel. Each of the two desalters
can be isolated and bypassed. Crude outlet from top (for normal operation) and from bottom (for pump
out operation) is connected to GA41003A/B/C suction. For draining oily water and handling wash
streams, desalter drain connections to CBD/CRWS are also provided. De-sludging arrangement has
been provided to remove the sludge from desalters.GA41021A/B discharge is associated with
distributors inside both the desalters.FI1202&FI1203 reads desludging water flow to
PA41001&PA41002 .When desludging water is injected in the desalter through the distributor, it
loosens up the muck collected at the bottom, and facilitates easy exit from outlet. Meticulous care
should be taken during this operation as sudden jerk can upset oil water interface, leading to water and
salt carry over with crude. A 2” rag header has been provided inside the desalters to remove any
emulsion/rag layer to CBD .

First Stage Desalter PA 41001
The crude enters the 1st stage desalter PA-41001 at the bottom of the vessel, and leaves at the top
and enters PA-41002, second stage desalter at the bottom and leaves at the top. Thus the two
desalters are always full of crude oil during normal operation.
In 1st stage desalter, interface level controller LIC1201 is provided to ensure smooth functioning of
unit, the selector switch is given for controller for choosing any one LT at a time.
LI1201A(capacitance), LI1201B(displacer type) or LI1201C (DP type). In addition one interface low-low
switch along with alarm LALL1203 is provided to prevent interface from getting lost and resulting in oil
carry over along with brine from desalter.
Low Low Total Level Safety Displacer type Oil Level Transmitter 03-LSLL-1202 installed in the top of
the 1st Stage Desalter vessel provides protection against drop in total level in the Desalter vessel by
initiating DF power unit 03-PU-00-XXXX Trip. Low Low Oil level tripping alarm will be generated in the
DCS from 03-LALL-1202
High High Interface Level Safety Capacitance type Oil Level Transmitter 410LAHH1201 installed in
the top of the 1st Stage Desalter vessel provides protection against high interface level in the Desalter
vessel by initiating DF power unit 03-PU-00-XXXX Trip. (410LAHH1201 to be incorporated in PLC**).
03PDV1201 soft lock has been provided at 20%.
Since desalters are liquid filled vessels, the pressure control is achieved by manipulating PV1201.
Similar instrumentation and other facilities exist for 2 nd stage desalter PA41002 also.
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Power unit is having 2 nos. (Two) internal temperature switches [One in Chopper tank and another in
Transformer tank which are wired in series to LRC-II panel]. If there is temperature rise
due to any reason in Chopper and / or Transformer tank, it would disable the power unit on secondary
side.
It also has 3 nos. (Three) internal level switches [One in each Chopper tank, Transformer tank and
Diode tank respectively which are wired in series to LRC-II panel]. If the liquid level drops below
1"(25.4 mm) from the normal liquid level of any tank (Chopper tank, Transformer tank, diode tank) , it
would disable the power unit on secondary side.
Second Stage Desalter PA 41002
LIC1204 interface level controller.

LALL1206 interface level
LALL1205 Total oil level low.
410LAHH-1202 High High interface level
03PDV1202 soft lock at 20%
LIC1204 can manipulate either LV1204 on -1 st stage desalter water pump discharge or LV1201 cold
brine out let from PA41001.The selection for this is made by SS1206/SS1204. Based on this selection
SS1205 on actuation of either LALL1203 or LALL1206, LV1201 closes by actuation of SOV1201. Local
PG/TG are provided to indicate desalter pressure and temperature. PIC1202 on desalter top is
provided for manipulation of PV1201 .Selection to operate PV1201by PIC1201 or PIC1202 is done by
SS1201. Normally PIC1202 is set at 10.4 kg/cm2g.
PSV1201 &1202 on 1st stage desalter and PSV1203 &1204 on 2nd stage desalter are provided to
protect from over pressurization due to blocked outlet .The set value of PSV is 12.74kg/cm2g.The
discharge of these safety valves is routed to the flash zone of atmospheric column. Since this is liquid
discharge ,safety valve out let line is kept free draining towards column to avoid formation of liquid
pockets. These PSV s are located close to column to reduce the discharge pipe length where two
phase flow may occur after PSV outlet.
To ensure crude and water mix thoroughly, the mixing valves DPV1201/1202 respectively are provided
at the upstream of both desalters.
Sample tricocks have been provided to check the water levels in desalters. A 2" LP steam flushing line
is given to clean the line of any crude after taking sample.
Desalter water
Water used for desalting is stripped sour water from SRU. As an alternative DM water can also be
used. Also EA41017 LP steam condensate is routed to FA41013. SSW/DM water is taken to FA41013
through LV1207. LIC1207 controls level of FA41013. The 2 nd stage desalter water pump takes suction
from FA41013 and discharge to PA41002 under flow control FIC1201. GA41021A/B discharge (after
heating in EA41046A/B) can join either up stream of crude oil mixing valve DPV1201 of desalter
PA41001 or DPV1202 of PA41002. Brine in PA41002 is pumped out by 1 st stage desalting water
pump GA41022A/B to PA41001 under PA41002 interface level control LIC1204. Brine from PA41001
is cooled in EA41046A/B and EA41057. Finally cooled brine is sent to ETP under desalter PA41001
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inter phase level control LIC1201. A ¾” caustic injection line is given at the down stream of
EA41046A/B in the water line going to PA41001 for brine pH control. A quill provision is given at the
suction OF GA41022A/B to inject chemical .

Desalter operation
There are three cases of desalter operation based on salt content in crude.
a) Both desalter stages in operation
b) Only stage I desalter in operation
c) Only stage II desalter in operation.
Both desalter stages in operation

After premixing crude with desalter water at the up stream of DPV1201, it is fed to PA41001.Desalter
water drawn from PA41002 is pumped by GA41022A/B under interface level control LIC1204 of
PA41002.Manual selection for the interface control of PA41002 on out going brine is made by
SS1206. Inter face of PA41001 is indicated by LIC1201 and it is controlled by LV1201 on out going
brine from PA41001.Linking of LIC1201 with LV1201 operation is manually done by SS1204. PA41001
interface level as indicated by LALL1203 is manually selected by SS1205 to actuate SOV1201 and
close LV1201.Crude from PA41001 over flows to PA41002 for final desalting. Water for desalting in
this unit is drawn from FA41013 by GA41021A/B under flow control FIC1201. Heated in shell side of
EA41046A/B it enters through mixing valve DPV1202.Its flow towards DPV1201 is completely closed
to receive adequate quantity of desalting water in PA41002.Brine from PA41002 bottom is diverted to
suction of GA41022A/B and again follows a complete cycle as described earlier. PIC 1202 on PA41001
is selected to maintain its pressure by manipulating PV1201 selected by SS1201.
Only stage I desalter in operation
In this case only PA41001 is in operation and PA41002 is completely isolated/bypassed from crude,
desalting water and brine systems. Water from FA41013 drawn by GA41021A/B under flow control
FIC1201 , is heated in EA41046A/B and enters through mixing valve DPV1201 along with crude and
leaves from top of PA41001 to suction of GA41003A/B/C under desalter top pressure control PIV1201
by selecting SS1201 for operating PV1201.LIC 1201 is controlled by LV1201. LALL 1203 is manually
selected by SS1205 to actuate SOV1201 and close LV1201 on brine outlet.
Only stage II desalter in operation.
In this case only PA41002 is in operation and PA41001 is completely isolated/bypassed from crude,
desalting water and brine systems. Water from FA41013 drawn by GA41021A/B under flow control
FIC1201 , is heated in EA41046A/B and enters through mixing valve DPV1202 along with crude and
leaves from top of PA41002 to suction of GA41003A/B/C under desalter top pressure control PIV1202
by selecting SS1201 for operating PV1201. LIC 1204 is controlled by LV1201. LALL 1206 is manually
selected by SS1205 to actuate SOV1201 and close LV1201 on brine outlet.
It is very important to note that actually it is out going brine of PA41002 not from PA41001.
The major parameters that are closely monitored for good desalter operation are;
 Wash water injection rate
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 Chemical injection rate

 Oil water interface level
 Mixing valve performance
 Desalter pressure
 Desalter temperature.
Comparison of Design case:-

Properties Previous Design Design Guarantee case
API 31 and above 22 and above
Density Kg/m3 871 (Arab mix) 924
Flow m3//hr 858 (Arab Mix 6 1176 (Design Case)
MMTPA)
Inlet temperature°C 125 °C to 145 °C 110 °C to 145 °C
Mixing valve DP Max up to 3.0KSc 0.2 to 1.0Ksc (Optimum
to be set during test run)
Kg/cm2g
Inlet Pressure 12 to 13Ksc 11 to 13 Ksc
Kg/cm2g
Inlet Salt Content 165ppm 165ppm
Outlet Salt Content <0.5PTB (<1.43ppm) <0.5PTB (<1.43ppm)
BS & W Vol% 0.20% 0.20%
Wash water Vol% 6.00% 4.00%
Kinematic viscosity 2.6 to 3 cst (operating 2.37 to 4.95 cst
temp) (operating temp)
Demusifier injection 3ppm 2.0ppm
***Note: During Vessel handover to maintainence or Leak checking

If inert gas is used, do not exceed the pressure of 0.35 barg in the whole process as the bushing mechanical seal (PTFE
insulators) is designed for liquid service, not vapor service and will develop leaks.
3.2 Crude preheat train-2/Preflashing@ Preheat-3:

PHT-2 is located between desalter and preflash drum. There are totally 6 exchangers in this train.
Desalted crude over flows to the suction of GA41003A/B/C. Caustic is injected in the suction line to
neutralize naphthenic acids that are formed at higher desalter temperature. TI1203 indicates crude oil
22 | P a g e
inlet temperature of PHT-2. GA41003A/B/C discharge splits into two parallel streams, termed as PHT-
2A and PHT-2B. The purpose of heating crude in PHT-2 is to recover heat from c/r's and products as
well as to reduce load on CDU heater by preflasing lighter components of crude to atm. column in the
preflash drum.
In PHT-2A desalted crude recovers heat from Kero/ATF product, LGO c/r and HVGO product in
exchangers EA41021, EA41022 and EA41025. Crude is heated to a temperature of 175°C which is
indicated by TI1321.PHT-2B consists of EA41023, EA41024A/B & EA41031. Here crude recovers heat
from HGO product, LVGO product & HGO product respectively. The out let temperature is measured
by TI1304. TI1309 indicates the exit temperature of PHT-2.
FT1301 and FT1302 measure crude flow to PHT-2A &PHT-2B respectively. Flow ratio recorder
FIC1302 takes output from both the transmitters and controls crude flow in 2B branch. Independent
crude flow indication in 2A branch is available through FI1301.To match resistance created by FV1302
and equalize pressure in 2B stream HV1301/HIC1301 is provided 2A stream. Flow split in streams
2A/2B can vary from 2:3 to1:1. Reformate connections have been given on the crude side in the inlet
of exchangers EA41021 and EA41023 for cleaning.
Crude Preflashing:
Major equipment of this section is crude preflash vessel (FA41001) & preflash crude pump
GA41002A/B/C.
Preflashing of crude is done in preflash vessel FA41001 to remove lighter components of the crude as
far as possible and obtain consistent behavior in downstream exchangers as well as in Atmospheric
Heater at elevated temperature. FA41001 is a horizontal drum with an impingement baffle at inlet
nozzle. The heated crude at 180°C is flashed in preflash vessel at 2.9-3.8 kgsc. Pressure of the vessel
is controlled by PIC1301, manipulating PV1301. Flashed vapors' line from the vessel goes to either
flash zone of DA41001 or Naphtha section of DA41001. This routing is done to take care of excessive
flashing of crude due to very light nature. Crude level in FA41001 is maintained by LIC1301, acting on
crude inlet line to vessel. One low level alarm LALL1303 is also given on the vessel to indicate very low
crude level in preflash vessel.PSV1301/1302 are provided on vessel to protect from over
pressurization. The set value of PSV1301/1302 is 6.0 kg/cm2g. Preflashed crude is treated as
stabilized crude and it is pumped to preheat train -3 by pre flash crude pump GA41002A/B/C. Actuation
of low-low level switch(LALL1303 ) shall trip GA41002.This is the feed pump to Atmospheric Heater.
Preflash vapor KOD was provided for avoid the liquid carry over along with vapor and vapor can be
routed to naphtha section without affecting the product color. After installing the preflash KOD vapor
was routed to naphtha section and found product colorization during upset. Presently preflash vapor
being routed to flash zone.
Pre heat train-III (PHT-3):

Major equipment in this section is also shell and tube heat exchanger. PHT-3 is down stream of
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Preflash drum FA41001.There is a total of 10 exchangers in this train. The purpose of heating crude in
PHT-3 after preflasing is to recover further heat from c/r's and products at higher temperatures. Crude
from GA41002A/B/C discharge is fed to PHT-3 to heat the crude from 170°C to 288°C. However the
heat gained depends on the crude processed. TI 1310 indicates PHT-3 inlet temperature.
GA41002A/B/C discharge divides into two parallel branches.
In PHT-3A Preflashed crude gets heat in exchangers EA41026A/B, EA41027A/B, EA41028A/B/C/D/E

&EA41029 from LGO product, LVGO product, VR & Vac. slop respectively. TI1414 indicates PHT-3A
outlet temperature. PHT-3B consists of EA41030A/B/C, EA41036, EA41032, EA41033A/B, and
EA41034A/B & EA41035. Here crude recovers heat from LGO CR, HVGO CR, HGO CR, HVGO CR,
HVGO product &HGO product respectively. The out let temperature is measured by TI1408. TI1415
indicates the exit temperature of PHT-3. FT1401 &FT1402 measure crude flow to PHT-3A &PHT-3B
respectively. Flow ratio recorder FRC1401 takes output from both the transmitters and controls crude
flow in 3B branch. Independent crude flow indication in 2A branch is available through FI1401.To
match resistance created by FV1401 &equalize pressure in 3B stream HV1401/HIC1401 is provided
3A stream. Flow split in streams 3A/3B can vary from 2:3 to1:1. The provision of flow split in branches
3A/3B has been conceived to optimize heat recovery for different cases of operation. PAL-1302 at
inlet of PHT-3 shall indicate tripping of GA41002A/B/C.Crude from PHT-3 goes to atmospheric heater
pass flows.
Reformate connections have been given in crude inlet line of exchangers EA41026A/B &EA41030C for
cleaning.
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3.3 Atmospheric Heater - BA41001& Atmospheric Column DA41001:

Major equipments in this section are heater, air pre-heater, ID fan, FD fans and steam air decoking pot.
The description of this section is subdivided into
Process system
Fuel system
Air preheat system
Steam - Air decoking system.
Process system:
Preheated crude from PHT-3 is fed to the convection section of atmospheric heater BA 41001. From
convection zone it goes to radiation section and from there it flows to DA41001.The heater BA41001 is
a vertical tube, box type assembly consisting of four cells having eight parallel passes on crude oil side.
Flow in each pass is regulated by individual pass flow controllers FIC1501 -FIC1508. Ratio of crude
flow in particular pass to total crude flow is maintained by a ratio controller. The crude flow in each
pass is controlled by a pass balancer in such away that the weighted average temperature at the out
let of each pass is almost the same. Crude flow of each pass is adjusted by individual pass flow
controller. Pass balancer receives software input signal from FI1401 & FIC1402 controlling crude flow
in PHT-3, current values of all crude heater pass flows and temperatures as indicated by FIC1501 to
FIC1508/TI1513 to TI1520. Pass balancing is an advanced control feature, conceived for future
implementation. Pass balancer output is utilized by atmospheric column duty controllers on circulating
refluxes also.
The distribution of crude through each pass should be adjusted in such a way that the heat duties and
hence out let temperature of all the passes is more or less same. Depending on duty variation, pass
flow through each pass to the extent of 10% can be tolerated, while operating on manual mode or pass
balancing is not working. Crude oil from radiation zone of the crude heater, which is at 370°C flows
through the transfer line and enters the Atmospheric column DA 41001 flash zone. To avoid repetitive
description, features of only pass 1 have been taken up. For other passes, identical arrangements
exist.
FIC1505 controls and indicates crude flow through pass 1 through dual transmitter FT1513 from the
same flow element. One flow low-low alarm FALL1513 has been provided to indicate very low flow
condition in pass 1. Actuation of this alarm will trip the fuel supply to all burners of the heater except
pilots.TI1415/PI1507 indicate temperature/pressure up stream of all pass flow control valves.PG1512
&TI1505 indicate pressure and temperature at radiation zone inlet.TI1516 indicates coil out let
temperature (COT) of pass 1. High temperature soft ware alarm on the COT has been given to alert
the operator against inadequate flow or harder firing in that particular pass. Soft ware signal TI1513 is
utilized by pass balancer also. Finally heated crude from radiation section enters a common manifold
called transfer line which leads to DA41001.
25 | P a g e
TIC 1512/TI1521 indicates combined, final coil out let temperature of crude .TIC1512 controls the final
crude out let temperature of transfer line by regulating fuel to furnace. Radiation out let pressure in
transfer line is indicated by PI1528. Pressure drop across pass 1 measured as the difference of
PI1524&PI1528 readings is indicated in DCS. This pressure drop is a measure of internal condition of
the tube and increase in DP indicates tube fouling due to coke formation in the tubes.
Emergency coil steam (MP steam) connections are given in each pass at downstream of pass flow
control valve to displace the crude from the coil to the column during any emergency or after normal
shut down operation. Flushing oil can be admitted at the inlet of EA41035&EA41029 exchangers, using
the flushing oil connections given, to flush out the coils of heaters and push the black material into
column. 24 Soot blowers using MP steam are provided in convection zone of the heater. The combined
flows of emergency steam, soot blower steam and decoking steam is indicated by FI1539. Snuffing
steam (box purging) connections in header box and radiation zone of the heater are provided to
extinguish fire and provide steam blanketing. FI1540 indicates LP steam flow in snuffing steam header.
Fuel system:
BA41001 is a balanced draft furnace. Both the convection and radiation sections are used to heat
crude. In the radiation section heat is primarily transferred by radiation from the flame and hot
combustion gases. The convection section located at the top of the radiation section serves to increase
the thermal efficiency of the furnace by removing further heat from flue gas. The radiation section has
four identical cells, each cell has two passes. Tubes in radiation section are in vertical where as in
convection section they are in horizontal.
BA41001 is dual fired furnace i.e. either fuel oil or fuel gas or both can be used as fuel. Off gas from
hot well &atm. column reflux drum can also be used as fuel. There are 32 low Nox type burners. There
are 8 burner assemblies per cell. Each burner is mounted vertically upward at the center of furnace
floor. Out of 8 burners every 3rd &6th burner in each cell is dedicated to FG/Atm. off gas or hotwell off
gas or both. Remaining 24 burners are for F.O or F.G firing or both.
Fuel gas system:
The FG line is steam traced to avoid condensation of heavier components inside the line & subsequent
carryover of hydrocarbon liquid droplets to the burner. To avoid carryover of foreign particles like rust
etc. a 100 mesh strainer is provided online. FG to main burners passes through a shut down valve
SDV1501 .whose open or close position is indicated in control room by XL1501A/XL1501B. FG
flow/temperature to the main FG burners is indicated by FI1525/TI1510.
FG pressure is indicated by PI1502. Low FG pressure pre-trip alarm PAL1508 and very low pressure
trip alarm PALL1509 are provided at the inlet of fuel gas to the main burners. Actuation of PSLL1509
will shut the SDV1501. Fuel gas pressure and hence flow to burners is regulated by PIC1501. It can
be cascaded with crude outlet COT controller TIC1512. Through a selector switch SS1512, COT can
26 | P a g e
be used to select either fuel oil or fuel gas. A 2” FG tapping upstream of SDV1501 is taken for pilot
burners.PI1503/FI1526 measure pressure/flow of pilot gas to heater. A low pressure alarm PAL1510
will alert the operator when pilot gas pressure falls.
Hot well off gas system:
Off gas from hot well of VDU is routed to BA41001 through hot well catch pot. After removing entrained
droplets of oil/water in catch pot, the off gas passes through strainers of 100 meshes. Pressure of off
gas to heater is controlled by PV1513 that is provided on vent line to atmosphere. PAL1514 indicates
low pressure of off gas going to heater. To avoid possibility of back fire due to external spark, flame
arrestors FG41001/002 & FG41003 are provided on off gas line to heater as well as vent line.
Atmospheric Off gas system:
Off gases from atm. column reflux drum passes through a knock out drum to remove condensate
droplets and joins downstream of fuel gas to off gas burners pressure control valve PV1517. A shut off
valve SDV1603 is provided to close on actuation of PAHH 1518 or PALL1601. PV1601C is one of the
controllers of the Atm. Column pressure and it is positioned on atm .off gas line to heater. PSLL also
trips SOV1517 and closes PV1517.
Fuel oil system:
Fuel oil is supplied to atm. heater under pressure control PIC1505.FI1528&FI1529 are flow indicators
provided in F.O supply & return line respectively. Since F.O is under closed loop circulation the net
consumption is measured by FDI1528 as the difference between the supply and return flows.
SDV1502/SDV1503 is provided on supply and return headers of F.O circuit. Open & close indications
for these valves are available in control room. A pre trip alarm PAL1511& low-low pressure trip alarm
PALL 1512 are provided in F.O supply line.PAH1515 on F.O return is given to notice high back
pressure and disturbed F.O burner performance. High back pressure may develop due to less no. of
F.O burners in operation during turn down operation or due to closure of SDV 1503. In such cases FO
firing should be manually switched over to FG firing during turn down operation.
Since FO is normally a heavy material it should always be in circulation. If left stagnant and unused in
oil burners and piping, it can get congealed despite the fact that tracing steam is on. Circulation in
heater area FO piping (called fuel oil ring) is to be maintained even when no FO burner is on. FO is
drawn by individual burners through ¾” header from main supply line and balance quantity is sent to
FO return header. This return header from cells joins a common return header before leaving heater
area. When there is no need of FO firing in heater, the circulation can be maintained outside heater
through 2” jump over called ring bypass. Purge steam connections are provided on each oil burner.
PG's are provided on FO and atomizing steam lines of each burner. FO and atomizing steam lines are
routed to each burner of the cell. FO burners should be kept steam purged when idle. A 2” FLO
connection &drain to CBD/OWS is given in FO circuit. This is given for flushing the FO line once heater
is shut down.
27 | P a g e
When FO is fired, it is atomized as fine mist for ensuring complete combustion. The atomizing of FO is
done by desuperheating MP steam to so called atomizing steam. Atomizing steam pressure is
controlled by differential pressure controller DPIC1501 that takes signal from FO supply and
simultaneously maintains the atomizing steam pressure1.0 –1.5 kg /cm2 above FO supply pressure.
Atomizing steam pressure/flow is measured by PI1504/FI1527.Local PG&TG are also given on
atomizing steam header. A 100mesh strainer has been provided to arrest foreign particles like rust etc.
When furnace is on duel firing FG operates on PIC1501 &FO on PIC1505. TIC1512 is cascaded, using
selector SS1512, to any one fuel controller for COT control.
Combustion air system:
Atmospheric heater has independent air preheating system to cater to combustion air requirement of
its burners. The air required for heater burners is supplied by two forced draft fans GB41001A/B. Pilot
burners are self inspiring type and do not consume air from FD fan discharge. The combustion air is
preheated by flue gas in two preheaters BC41002A/B &BC41006A/B. Air preheaters consist of cast
iron &glass air preheaters. APH is a shell &tube heat exchanger. Cold air from atmosphere is sucked
by FD fan and forced through tube side. The hot flue gas leaving the convection section is sucked by
an ID fan GB41002 and routed through the shell of APH. Cold flue gas from APH is discharged by ID
fan to stack. ID fan suction temperature is maintained by bypassing APH &passing through TC1517
some quantity of air.
Steam Air Decoking System (SAD):
Steam air decoking of atmospheric heater tubes is done to remove coke deposit from inside the heater
tubes with the help of steam & air mixture. Removal of coke results in clean heater tube internals &
improves heater performance by better heat transfer to process fluid. SAD also achieves low PD
across heater tubes and reduces chances of hot spot on heater tubes. Increased pressure drop and
harder firing indicates the need of SAD.
For this operation a dedicated arrangement called SAD arrangement is provided. It comprises of
decoking pot FA41006, piping for plant air, service water and MP steam. MP steam connections to
each pass flow are given to dislodge coke film deposit from inside the heater tubes. Local &DCS
mounted flow indications (FI1517 –FI1524) are provided on each steam connection. Plant air is to
ignite the remaining coke film deposit clinging inside heater tubes and achieve final cleaning of the
tubes.FI1530 indicates total flow of plant air into MP steam lines for SAD. Service water quench
provision is given on FA41006 as well as flue gas line to quench the contents before letting out to
atmosphere. To carry out SAD, pass flow inlet &outlet of the furnace BA41001 are isolated from
process network and connected by means of swing elbows with decoking network. Heater pass flow
outlets are connected to FA41006. The heater is fired and MP steam is introduced in heater coils.
Thermal shock caused by flame cracks coke scales inside the tubes and flowing steam dislodges
them. These are carried to FA41006. This operation is called spalling. When no more coke is
removable by spalling as indicated by clear effluent, air along with steam is introduced into coils to burn
28 | P a g e
the coke from inside while firing from outside. Coke is burnt by oxygen of air and thus tube cleaning is
achieved. Burning of coke is indicated by increased tube metal temperature and presence of CO/CO2
in flue gas. No. of passes selected for spalling & coke burning is dependent on limitations posed by
steam availability and piping net work. Sudden release of coke during spalling may result in choking of
piping handling effluent or in hot spots on tubes during burning. SAD of only one pass at a time should
be done if limitations in steam and SAD piping are experienced.
Atmospheric Column –DA41001

Crude from BA41001 is fed to the flash zone of DA41001 through transfer line.
The Atmospheric column consists of 56 valve trays & 6 chimney trays... The column was
manufactured by L & T Hazira and brought and installed at site as a single piece. The trays are
numbered from bottom to top. Below the flash zone is the stripping section. It has a smaller dia at the
top &bottom sections than middle
Flash zone:
The two phase flow of crude coming from BA41001 enters the flash zone of DA41001 at the
temperature of around 370°C. Flashed hydrocarbons get liberated and go to top. Non flashed liquid
moves down which are largely bottom product called RCO. For proper stabilization of RCO and
fractionation of gas oil components certain degree of over flash is required. Over flash is achieved by
setting up COT at higher value than actually required. This over flashed material is washed with gas oil
coming down from 15th tray. It strips heavier vapor components coming up which otherwise would
move up & cause de-coloration of gas oil. Tray 11 th to 14th is called wash zone section. Flow of over
flash also can be increased buy condensing more material on 11 th tray or by reducing HGO draw off
flow. However this will result in less gas oil yield and higher energy consumption .Too large flow of over
flash liquid may result in drop in bottom temperature and make lighter RCO. It results in over loading of
vac. column. Over flash flow and temperature are indicated by FI1606/TI1616. Flash zone pressure &
temperature are indicated by PI1602/TI1622. Proper elevation is provided in over flash line to get
steady flow. A 3” line is provided above 11 th tray to release uncondensed components from over
flashed liquid. MP steam is used as stripping medium at 3.5kg/cm2 & 350°C and introduced just below
tray-1. Steam stripping helps to remove lighter constituents from RCO by reducing their partial
pressure. Thus vaporization takes place without requiring additional heat. Hydrocarbon vapors
liberated by flashing, move up along with steam in the column for further mass transfer at trays in upper
section.
29 | P a g e
Steam flow to column is controlled by FIC1611.Steam flow to column is regulated based on outgoing
RCO quantity to Vac. heater. To achieve homogeneous distribution steam is introduced through two
nozzles. Steam to Atm. Column is cut off on actuation of LAHH1602, high level in column bottom.
Safety relief from desalters, preflash drum also goes to flash zone. As an alternative preflashed vapors
can also to be routed to the 43rd tray of HN section. This action is exercised to realize greater energy
saving. When CDU operation is stable and level in preflash vessel is steady, its vapors can be diverted
to tray 43. Care should be taken to ensure that there is no level surge and subsequent crude carry over
from FA41001.
Bottom section:
RCO is collected at the bottom of the column. Column bottom level is indicated and controlled by
LIC1601. This can be done either by manipulating RCO flow to vac. heater during normal operation or
by manipulating RCO flow to VR circuit.
RCO at a temperature of 315 to 345 °C is pumped out from the bottom of the column by RCO pumps
GA41014A/B/C to any of the following destinations:
 To vacuum furnace BA41101 as RCO feed, during normal operation, under column bottom level
control cascaded with vacuum heater pass flow controls. LIC1601 adjust pass flows through
vacuum furnace.
 When VDU is not on line this RCO can be routed to VR run down circuit.
Independent level indication LI1603 along with high level software alarm is provided to have
redundancy of indication. A separate high level switch LSHH1602 is provided to trip FV1611 &cut off
stripping steam to column. This is done to prevent vibration due to hammering /resonance &
consequent damage to column internals etc. A low level switch along with alarm LAL 1604 is also
given. Temperature of RCO going to GA41014A/B/C is indicated by TI1618.
Middle Section:
Middle Section of the column has Circulating Reflux (CR) & product withdrawal net work. In order to
maintain proper temperature profile across the column, four CR systems are provided
1. Hy.Naphtha CR
2. Kero/ATF CR
3. LGO CR
4. HGO CR
These CR's are drawn from respective chimney trays and are routed to preheat trains to recover heat
and returned to column. Duty controllers are provided on CR circuits to control CR flow rates to
column. These duty controllers take corrective actions based on actual CR duty and desired CR duty
for a particular type of crude and crude through put. The CR under reference will have certain duty.
This will be governed by total crude flow and specific heat of CR and is called desired CR duty. Actual
30 | P a g e
CR duty is also computed by duty controller based on real time measurement of temperature
difference between CR draw off and CR return stream, CR flow rate and specific heat of CR. Total
crude flow, CR temperature difference and CR flow are measured by various instruments. Specific
heat of CR is fixed by operator in software for computation purpose and no on line measurement for
this property is available.
Actual and desired duty is calculated in the duty controller as under

Actual CR duty = Measured CR flow * CR temp. Difference * sp. Heat of CR stream
Desired CR duty = (Desired CR duty/Desired total crude flow)* Actual crude flow
Inputs to be manually configured by operator are specific heat of CR stream and ratio (Desired CR
duty/Desired total crude flow) for different crude. Desired CR duty should be estimated on data feed
rate basis to CDU. This is typical to all such duty controllers on circulating reflux lines. Desired CR
duty is compared with actual CR & the flow of CR is varied to achieve desire CR duty.
The circulating refluxes of atm. column are described below.
Heavy Naphtha CR system:

Heavy Naphtha CR is drawn from tray no.52 by GA41006A/B/C at around 140°C and is cooled to
120°C, in the tube side of exchanger EA41016A/B by exchanging heat with crude, and returned to
atm. column to 55th tray. TI11608/T11602 indicates its draw off and returns temperatures respectively.
Heavy naphtha CR flow is read by FI1601. FIC1601 controls the flow and JIC1601 duty controller can
also control the CR flow.
Kero/ATF CR:
Kero/ATF CR is drawn from tray no.41 by GA41007A/B/C at around 170°C and it is cooled to 125°C
in exchanger EA41014A/B tube side, exchanging heat with crude, and returned to atm. column to 43rd
tray. TI11610/T11604 indicates its draw off and returns temperatures respectively. Kero/ATF CR flow
is read by FI1602. FIC1602 controls the flow & JIC1602 duty controller can also control the CR flow.
LGO CR:
LGO CR is drawn from tray no.28 by GA41008A/B/C at around 245°C and it is cooled in
EA41030A/B/C tube side &EA41022A/B shell side exchanging heat with crude and then it goes to
EA41060 for LP steam generation & finally returns at a temperature of 175°C to atm. column to 30th
tray. TI11612/T11605 indicates its draw off and returns temperatures respectively. LGO CR flow is
read by FI1603. FIC1603 controls the flow & JIC1603 duty controller can also control the CR flow.
HGO CR:
HGO CR is drawn from tray no.19 by GA41009A/B/C at around 305°C and it is cooled in EA41032
tube side and from there it goes to stabilizer reboiler EA41003 and then it goes to EA41059 for MP
steam generation. HGO CR flow to EA41059 is controlled by split range controller FIC
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2801&TIC2802.It is cooled to 235°C before returning to atm. column to 21st tray. TI11614/T11606
indicates its draw off and returns temperatures respectively. HGO CR flow is read by FI1604. FIC1604
controls the flow & JIC1604 duty controller can also control the CR flow.
Product draws off:
Heavy naphtha, Kero/ATF, LGO & HGO products flow by gravity from 44, 31, 22 &15th trays of atm.
column to the strippers DA41002/DA41003 and DA41004/DA41005 under respective level control of
strippers. Heavy naphtha, Kero/ATF & LGO products are drawn from chimney trays. HGO product is
drawn directly from valve tray. The temperature of liquid draw off line of HN, Kerosene /ATF, LGO and
HGO are indicated by temperature indicators TI1609, TI1611, TI1621 & TI1617 respectively. Vapor
return lines from HN & Kero/ATF strippers go back to the column two trays above the draw off trays
where as for LGO &HGO strippers vapor return lines from strippers join the fractionator just one tray
above the product draw off tray. Temperature indicators are provided on vapor return line for all
strippers. 4000mm of elevation difference from DA41001 column nozzle to up stream of each level
control valve ensures its smooth functioning. 1500mm elevation downstream of level control valve
ensures sufficient back pressure to prevent flashing just downstream of control valve & consequent two
phase flow in product draw off piping.
Overhead System:
The overhead vapors of DA41001 at around 120°C pass through the over head air coolers EC41001 A
to P, EC41002 A to B & crude column over head trim condenser EA41001A/B. The condensed
Naphtha & steam is received in atmospheric column over head reflux drum FA 41002. Top pressure of
DA41001 is maintained by PIC1601 by manipulating PV1601A, PV1601B &PV1601C. PV1601A
controls excess off gas going to flare. PV1601B controls FG back up to column. PV1601C controls off
gas going to CDU heater. Condensed liquid is allowed to settle in reflux drum where steam condensate
settles in vessel boot and it is pumped to Stripped sour water treatment plant (SWS) by GA41045A/B
under interface control LIC1802. FI1801 measures the flow and AI1801 indicates pH. On actuation of
boot level LOW alarm LAL1803 LV1802 shall be closed by operation of SOV1802. GA41005A/B takes
suction from FA41002 hydrocarbon section and pumps to DA41001 as top reflux. FIC1605 regulates
the top reflux flow. This FIC can be cascaded with DA41001 top temperature controller TIC1601 for
precise control of column top temperature. Excess quantity of naphtha in reflux drum is pumped by
stabilizer feed pumps GA41004A/B as stabilizer feed. Reflux drum hydrocarbon side level controller
LIC1601 can be cascaded withGA41004A/B discharge flow controller FIC 1901. FIC1802 &FIC1803
are provided for minimum flow protection for GA41005A/B &GA41004A/B pumps respectively.
DA41001 is protected by a set of PSV’s (PSV1601 to PSV1606) from over pressurization of the
column. The set value of the first two PSV's is 5.0 ksc, the next two 5.1 ksc and the last two 5.2 ksc
respectively.
FA41002 is also protected by PSV1801 from over pressurization. The set value is 5.2 ksc. NSU
overhead two fin bundle (EC41002 A/B) has been modified for CDU overhead system and it can be
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operated for NSU overhead system as per requirement. Normally EC41002 A/B is being operated for
CDU overhead system as CDU overhead pressure high during high throughput.
Product Strippers:
There are four side cut strippers: Heavy Naphtha stripper, Kero/ATF stripper, LGO stripper, HGO
stripper.
Heavy Naphtha stripper (DA41002):
HN stripper contains six valve type trays. A 2” LP steam connection is given for steam out purpose and
local PG is given to DA41002. HN to be stripped is fed to the 6 th tray of DA41002 under level control
LIC1701. HN from DA41002 bottom is reboiled in EA41011 by LGO product. HN is stripped by hot
vapors generated in reboiler. Mass transfer between down coming HN liquid from tray 6 and uprising
HN vapors takes place across each tray. Finally stripped HN is drawn by GA41010A/B and sent to
product cooling section. GA41010A/B suction temperature is indicated by TI1704. Stripped vapors
return to the 46th tray of DA41001. GA41010A/B discharge goes to EA41055A/B shell side and
exchanges heat with BFW and from there it pass through EC41005 and finally gets cooled in
EA41007 and goes to battery limit.
One duty controller JIC 1701 is provided for controlling reboiler duty. JIC 1701 manipulates a set of
split range control valves JV1701A acting on LGO out let from reboiler and JV1701B acting on LGO
line bypassing the reboiler. Actual reboiler duty is computed by a software computation block JY1701.
By measuring and multiplying actual LGO flow (FI1701), LGO inlet & out let temperature difference
(TI1703 minus TI1702) and specific heat of LGO (operator in put), actual reboiler duty is compared
with desired set duty. Set duty is fixed by operator based on through put. If actual duty is found less
than set value, JV1701B closes more and simultaneously JV1701A opens more to increase reboiler
duty. If actual duty is found exceeding set value, LGO is bypassed more and JV1701A closes more to
restrict flow of LGO through reboiler, thus reducing its duty. Higher the reboiler duty, higher will be the
flash point of product.
HNSC can be routed to the following destinations:

1. HNSC to Line-1.(03PC2702B)
2. HNSC to Line-2/HSD blender.(03PC2702A)
3. HNSC to Line-3.(03FC2702B)
4. HNSC to OMPL.(35FC2714)
5. HNSC to Kero.
6. HNSC to storage/Slop.
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Kero/ATF stripper (DA41003):
Kero/ATF stripper contains six valve type trays. A 2” LP steam connection is given for steam out of
the stripper and local PG connection is given to DA41003. Kero/ATF to be stripped is fed to the 6th
tray of DA41003 under level control LIC1702. Kero/ATF from DA41003 bottom is reboiled in
EA41012A/B by HVGO CR. Both the exchangers operate in parallel. Kero/ATF is stripped by hot
vapors generated in reboiler. Mass transfer between down coming Kero/ATF liquid and uprising
Kero/ATF vapors takes place across each tray. A 4” stripping steam line is given in addition to the
reboiler. When VDU section is down and HVGO CR stripping steam can be used to strip lighter
contents from the DA41004. Stripped Kero/ATF is sent to EA41053, MP steam generator, and 41054,
LP steam generator. From EA41054 Kero/ATF product goes to EA41021 in PHT-2 and then to
GA41011A/B suction. GA41011A/B discharge is routed to EA41020A/B &EA41013 in PHT-1 and sent
to product cooling section. EA41053 inlet temperature is indicated by TI1711. Stripped vapors return to
32nd tray of DA41001. The vapor return temperature is measured by TI1712. Outlet of EA41013 goes
to EC41006. Downstream of EA41013 one slip can be routed to DHDT feed and flow can be regulated
through 03FV5010 flow control valve. EC41006A/B and EA41008A/B and then goes to battery limit.
From the battery limit Kero/ATF can be routed to HSD pool/ Merox-1 & 2/HSD blender/DHDT feed tank
with FIC 2706 by manipulating FV2706. One slip stream is taken from the upstream of FV2706 and
used as cutter stock to make LSHS when low sulfur crude is being processed. Kero can also route to
CDU-1 battery limit. Downstream of FV2706 one stream (¾”) taken to chemical area for corrosion
inhibitor dilution.
One duty controller JIC 1702 is provided for controlling reboiler duty. JIC 1702 manipulates JV1702
provided on HVGO CR side at the outlet of the reboiler. Actual reboiler duty is computed by a software
computation block JY1702. By measuring and multiplying actual HVGO CR flow (FI1702), HVGO CR
inlet & out let temperature difference (TI1708 minus TI1726) and specific heat of HVGO CR (operator
input), actual reboiler duty is compared with desired set duty. Heat duty is fixed by the operator based
on through put. If actual duty is found less than set value, JV1702 opens more to increase reboiler
duty. If actual duty is found exceeding set value, HVGO CR flow is reduced by JV1702 to reduce heat
duty. Higher the reboiler duty, higher will be flash point of stripped stock. Stripping steam to DA41003
is adjusted by a globe valve and FI1703 shows total steam consumption of DA41003 & DA41004.
When side cut naphtha is not pulled Kero flash should be increased by increasing the reboiling.
Minimum flow protection is given for GA41011A/B. FIC1705 controls the minimum flow required for the
pump by varying FV1705.
Kerosene can be routed to the following destinations:

1. Kerosene to Merox-1 & 2.
2. Kerosene to DHDT.((03FC5010)
3. Kerosene to DHDT feed tank(03FC5007)
4. Kerosene to HSD blender.(03FC5006)
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5. Kero to HSD line-2 (FV2706B)

6. Kero to HSD line-3 (FV2706A)
7. Kerosene to MFO blender.(VBU-2 and SFO CDU-1)
8. Kerosene to SR .
9. Kerosene to Slop.
LGO Stripper (DA41004):
LGO stripper contains four valve type trays. A 2” LP steam connection is given for stripper steam out
and local PG connection is given to DA41004. LGO is fed to the 4 th tray of DA41004 under level control
LIC1703. MP steam is used as stripping medium in this stripper. Steam flow is regulated by FRIC
1703. It regulates MP steam flow to DA41004 based on unit mass of LGO product as indicated by
FIC2707. Steam to product ratio is decided by the operator and configured in software for routine
control. Stripping steam reduces partial pressure of hydrocarbon components inside the stripper and
helps them vaporize at relatively low temperature. These vapors move up in DA41004. Mass transfer
between down coming LGO liquid and uprising steam-hydrocarbon vapors takes place across each
tray. Stripped light vapors return to 23rd tray of DA41001
Stripped LGO is pumped by GA41012A/B and sent to HN reboiler (EA41011). FIC 1706 measures
total LGO drawn from DA41004 and FV1706 is provided to ensure minimum flow through LGO pump.
LGO from EA41011 goes to EA41026 & EA41019 for heat recovery in PHT. From EA41019 LGO splits
into two streams. Downstream of EA41019 one stream can be routed to DHDT feed and flow can be
regulated through 03FV5008 flow control valve. Other stream of LGO goes to EA41041 (Tempered
Water Exchanger), EC41004 & EA41009 goes to storage. Hot well slop oil pump discharge can also be
routed to LGO Stripper inlet line to avoid slopping hot well slop oil.
LGO can be routed to the following destinations:

1. LGO to DHDT (03FV5008)
2. LGO to GOHDS/VBU-2 blender.
3. LGO to flushing oil tank
4. LGO to flushing oil header
5. LGO to HSD line no-2 (03FV2707A)
6. LGO to HSD line no-3/HSD blending(03FV2707B).
7. LGO to tank 23B/Slop(03FV2707)
8. LGO to DHDT feed tank(03PV5002)
HGO Stripper (DA41005):
HGO stripper contains four valve type trays. A 2” LP steam connection is given to the stripper for
steam out purpose and local PG connection is also given. HGO is fed to the 4 th tray of DA41004 under
level control LIC1703. MP steam is used as stripping medium in this stripper. Steam flow is regulated
by FRIC 1704. It regulates MP steam flow to DA41005 based on unit mass of HGO product as
35 | P a g e
indicated by FIC2708. Steam to product ratio is decided by the operator and configured in software for
routine control. Stripping steam reduces partial pressure of hydrocarbon components inside stripper
and helps them vaporize at relatively low temperature. These vapors move up in DA41005. Mass
transfer between down coming HGO liquid and uprising steam-hydrocarbon vapors takes place across
each tray. Stripped light vapors return to 16th tray of DA41001
Stripped HGO is sent to EA41035 in PHT –3. From there it is pumped by GA41013A/B to EA41031
&EA41023 in PHT-2 and then to product cooling section. Downstream of EA41023 one stream goes to
DHDT unit with flow controlled by FV5012 and other stream flows through EA41040 (Tempered Water
Exchanger), EC41005 & EA41010 goes to storage.
HGO can be routed to the following destinations:

1. HGO to DHDT unit (03FV5012)
2. HGO to HSD LINE-2/HSD blending (03FV2708A).
3. HGO to HSD LINE-3/DHDT feed tank (03FV2708B).
4. HGO to tank 23B/Slop (03FV2708)
5. HGO to GOHDS (03FV2708C).
6. HGO to VBU-2 Blender (During unit upset)
3.4 Naphtha Stabilizer (DA41006):
Naphtha stabilizer removes LPG (C3 &C4) and fuel gas from unstabilised Naphtha. Naphtha obtained
from FA41002 contains lighter ends which vaporize at normal atmospheric conditions. This naphtha if
stored as such, in storage tanks, will release lot of hydrocarbon vapors that can lead to pressurization
of storage vessel. To avoid this, lighter components from naphtha are removed. This process is called
naphtha stabilization. It is done here in DA41006. DA41006 has 40 numbers of SS410 valve trays. The
column is provided with a set of safety valves PSV1901/1902 set at 15ksc. A 2” LP steam connection
is given for steam purging during shut down. To monitor temperature & pressure profile TI1903,
TI1910, PI1901 - at top , TI1904- at tray 32, TI1905/TI1906-at tray 3, PG1903- feed entry section and
PI1902- at bottom are provided. Unstabilised naphtha is first heated to 130°C in feed/ bottom
exchanger EA41052A/B & before entering the 21 st tray under flow control FIC1901 which is normally
cascaded with LIC1801.Unstabilised naphtha can be routed to slop header upstream of EA41052A/B
by operating HV1903 (Normally we will not slop Unstabilised naphtha as it creates problems in slop
tank.).
DA41006 overhead pressure is maintained by PIC 1901 by manipulating PV1901 which is at the outlet
of stabilizer over head condenser EA41002A/B. PIC1904/PV1904 provided on the Off gas line of reflux
drum can also control reflux drum pressure, & hence stabilizer column top pressure, independently if
PIC1901 is not in operation. One hot vapor bypass of 8” size has also been provided across
EA41002A/B. It can be used to maintain stabilizer pressure in case of rapid fall. A selector switch
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SS1901 is given to choose between HIC1902 and PIC1901.
The over head vapors condensed in EA41002A/B are received in over head reflux drum FA41003
.This is LPG. It is pumped by naphtha stabilizer reflux/ LPG product pump GA41015A/B under level
control LIC1903. Part of LPG from GA41015A/B discharge is used as reflux to DA41006 and it is
controlled by FIC1902 which can be cascaded with DA41006 top temperature controller TIC1920.
Uncondensed light hydrocarbons from FA41003 termed as fuel gas are routed to Amine absorber.
PIC1904 controls the pressure of FA41003 by manipulating PV1904. FI 1903 measures the FG flow
from FA41003. GA41015A/B is given minimum flow protection by providing FV1905. LPG run down to
amine absorber is controlled by FIC2701. A sample point provision is given at the discharge of the
pump.
Sour water collected in the boot of FA41003 is sent to sour water system or CBD under vessel
pressure. The interface level in reflux drum boot is indicated by LI1904. Water draining from boot is
done manually. On actuation of LALL1906, SDV1902 provided on sour water out let line shall close.
This prevents LPG from escaping with sour water during water draining. PSV1903 is provided on
FA41003 to protect against over pressurization. It is set at 15.0ksc. A 2 “line is connected to flare to
depressurize the column.
Stabilizer reboiler EA41003A/B is provided at the stabilizer bottom to supply necessary heat for boiling
unstabilised naphtha. Both the exchangers operate in parallel. Heating medium is HGO CR. FIC1904
provided on HGO CR supply line to EA41003 A/B controls HGO CR flow to reboiler. Tray 3
temperature controllers TIC 1905 which is maintained at around 157°C can be used to control reboiler
duty with the help of FV1904A provided on HGO CR return line or FV1904B provided on heating
medium bypass (HGO CR bypass) line. One baffle of adequate height is provided inside the column.
Height of the baffle is selected in such a way that adequate liquid head is ensured to cause gravity
flow of colder liquid through the reboiler. Difference in densities of hot &cold liquids establishes
circulation through reboiler. Unstabilised naphtha from column bottom flows to reboiler under gravity
and is reboiled in EA41003A/B. Heated and partly vaporized naphtha from reboilers enters below the
chimney tray. Lighter components from unstabilised naphtha move up in the trays in vapor form and
condense in over head condensers. Stabilized naphtha overflows to the other side of the baffle at the
column bottom. This is cooled in EA41052A/B and sent as feed to DA41007. If DA41007 is not in
operation stabilized naphtha can be sent to caustic & water wash directly. Stabilizer bottom level is
maintained by LIC1901, acting as master controller of FIC2001 (feed to DA41007). Independent high
&low level alarm switches are provided on column bottom. On actuation of low-low level alarm of
column bottom as indicated by LALL1905, SDV 1901 provided on let line shall close.
Stabilizer shall operate mainly on two conditions:

1.Total condensation of overhead vapors
2.Partial condensation of overhead vapors
Normally top pressure is maintained at 9.0 to 10.2ksc by PIC1901. If non condensables are more as in
37 | P a g e
light crude PIC 1901 set value can be increased. Partial condensation mode of operation of stabilizer
is conceived only for light crudes. In this case stabilizer top pressure is maintained at 9.0 ksc. The top
pressure is now maintained by PIC1904.
3.5Naphtha Splitting Section.(KSU/NSU)
KSU Design:-
KSU will process naphtha from either Arab Mix crude (AM / C5 - 150) or Bombay High crude
(BH / C5 - 150) to produce 70 (+/- 10) - 150°C cut Naphtha bottom product as feed to NSU .
KSU is designed to process 240 m3/hr IM Naphtha and 80 m3/hr BH Naphtha. Total 320 M3/hr (IM+BH)
Naphtha.
Kero Splitter Unit (KSU) was designed to recover heavy naphtha from Kerosene by splitting the
straight run kerosene. Later an in house modification was carried out to split stabilized naphtha C5-150
into three cuts by using DA41008 Kero splitter column, Reboiler and associated system which was not
in use right from the day one. Here KSU means stabilized naphtha FRN splitting into two cuts.
Consequently Naphtha Splitter Unit used for further splitting. KSU system can be bypassed and
stabilized naphtha (C5-150 cut) can directly feed to NSU as per requirement. KSU was used for
splitting the naphtha to produce the feed for ISOM Unit by splitting the Naphtha feed from CDU.
Later in November-2014 KSU/NSU system was revamped for maximizing the capacity utilization of
penex unit.
Totally Full Range Naphtha (FRN) will be cut into four cuts.
Light Naphtha : C5 to 70°c
ISOM feed naptha : 70 to 90°c
Middle Naphtha : 90 to 110°c
Heavy Naphtha : 110 to 150°c
Post KSU/NSU revamp configuration:-
NAME ASTM D-86 Cut Points SOURCE DESTINATION
Pentane Rich Naphtha IBP-C5 (Mainly Pentanes) KSU Top Naphtha Pool
ISOM Feed C6-90°C NSU-2 Top ISOM Plant
Middle Naphtha 90°C-110°C NSU-2 Side cut Naphtha Pool/OMPL
Heavy Naphtha 110°C-150°C NSU-2 Bottom CCR Unit
38 | P a g e
KSU/NSU REVAMP CHANGES

KSU
 GA41019 suction line replaced, line size was changed from 16” to 20 “
 GA41019 discharge to EA41051A/B inlet line replaced, line size was changed from 8” to 10”.
 EC41008A&B outlet line and header replaced, line size changed from 8” to 10” and EC41008 outlet common
header line changed from 8” to 12”.
 EA41070A/B condenser was incorporated between EC41008 outlet and FA41005.
 DA41008 pressure controller PC3302 (old flare controller) line was dismantled.
 FA41005 PSV3302 upstream spool piece was extended and 410PV3304A (new flare Control valve) upstream
tapping was taken.
 KSU feed to tray 17 isovalve downstream old spool was replaced with new spool piece for routing Phase-1
naphtha via new FC3301A after Preheating with HGO Pdt in EA41072.
 EA41050B (New R/D trim cooler) was incorporated in parallel with existing EA41050A for heat duty sharing.
 FV2704 was dismantled and new spool piece was provided.
 GA41017 outlet to EC41012 inlet line a new flow controller FC3302A was provided.
NSU
 GA410120 suction line size was changed from 18” to 24 “
 GA41020 discharge to EA41051C line changed from 6” to 8”
 EC41002 outlet line changed from 12” to 16”.
 FA41004 inlet ‘F’ type nozzle replaced.
 NSU column tray no 21 tray box given for draw nozzle and also vapour line return line of FA41070 in between
tray no 22 and 23.
 EA41051C tube side (Hy naphtha) outlet was routed to EA41044 inlet.
 EA41051C tube side was given bypass TV2001 for better NSU feed temperature.
 NSU feed to tray 16 isovalve downstream old spool was replaced with new spool piece for routing Phase-1
naphtha via new FC2209A after Preheating with HGO Pdt in EA41072.
.
KSU:-
Light naphtha C5-70°c from KSU top either directly goes to LN pool. It can also route to LN merox for
treatment (reducing RSH) or LN storage. KSU bottom goes to naphtha splitter unit where it is splitted
into C5-90°c. That is the feed to ISOM unit. It can also be routed to ISOM feed tank or LN pool. 90
-110°c (Middle naphtha) is drawn from 21st tray of NSU as side product and NSU bottom is 110-150°c
cut. Middle naphtha can go to LN pool or MS blending after LN treatment or OMPL. LN and MN can
go to storage via LNHeader-1 or LN header -2. Major equipments of Kero splitter unit (KSU) are Kero
splitter column, Kero splitter overhead condenser, Kero splitter overhead reflux drum, Reflux pumps,
and Kero splitter furnace & product coolers.
Provision is made to take CDU-1 stabilizer bottom to DA41008 as feed and also DA41008 bottoms
can be routed to CDU-1 naphtha splitter unit. This is to produce CDU-1 naphtha to split into the
above said three cuts..
Stabilized naphtha from stabilizer bottom is routed to EA41052 (Stabilizer feed/ bottom Exchanger),
39 | P a g e
EA41051A/B (KSU splitter feed/bottom exchanger) and then to Kero splitter DA41008. In splitter,
stabilized naphtha (C5-150 cut) is split in two streams viz., overhead stream or light naphtha (C5-
70°C cut) and bottom stream (70-150 °C cut). Splitting of naphtha is done by distillation. Heat
required for distillation is supplied by Kero splitter furnace BA41007.
Kero splitter column (DA41008):

Splitter DA41008 has 35 valve trays. Stabilized naphtha is fed to tray 17 of DA41008 under FIC-3301,
cascaded with stabilizer bottom level controller LIC-1901. It can be fed to tray 10 and 14 also to vary
the length of tray contact in the splitter. If heavier bottom cut is to be produced, feed shall be
introduced on tray 17 vice versa. CDU-1 naphtha can be fed after heating at EA41072
exchanger(HGO) at tray no-17 with feed control FC3301A. Since splitter operates at much lower
pressure than stabilizer, some flashing downstream of FV-3301 can be expected. A number of PSVs
with different set pressures is provided for DA41008. PSV-3301D is set at 3.2 kg/cm2g. PSV- C is
set at 3.35kg/cm2g and PSV-3301B is set at 3.5kg/cm2g and PSV-3301 A are set at 3.65kg/cm2g.
Such a staggered setting helps in the controlled release of vapors and avoids the actuation of all the
PSVs at the same time. LP steam connection is given to DA41008 for steam out purpose. This
normally remains blinded and shall be used only during s/d for hydrocarbon purging.
TI 3305 is provided on DA41008 overhead vapor outlet line. DA41008 shall be operated by controlling
tray 3 temperatures. The Heater firing can either be controlled by the tray 3 temperature or the heater
COT. Kero splitter bottom pumps GA41019 A/B/C deliver DA41008 bottom material to Kero splitter
furnace BA41007 for picking up necessary heat required for reboiling. Reboiled and partly flashed
material from BA41007 enters below tray 1 of the column. Vapors from this stream disengage and rise
to the top and liquid drops down to the bottom of the column. Since composition of reboiler outlet
stream and bottom product is same, one part of GA41019 A/B/C discharge is sent to EA41051A/B
for exchanging heat with feed and from there to the product coolers level control LIC3301.DA41008
bottom level is indicated and controlled by LIC-3301, acting as master controller of FIC -2001 when
cascaded. Independent LAH-3302/LALL-3301 is also provided to indicate high or very low levels in
DA41008 bottom. Mass transfer takes place between down coming stabilized naphtha and the flashed
vapors across each tray.
Kero splitter reflux drum (FA41005):
Uncondensed light naphtha vapors leave the column overhead under pressure control PIC-3301 to
Kero splitter overhead condensers EC41008A &B. These are air coolers having provision to isolate
individual tube bundle. High vibration trip switches are provided on every` fan motor of air cooler
system with a common alarm VAHH (Indicates tripping of any fan motor due to high vibration). Outlet
of EC41008A/B goes to EA41070A/B trim cooler. The condensed light naphtha enters the Kero splitter
overhead reflux drum FA41005. One inverted U type seal of elevation 450mm more than air cooler
40 | P a g e
bottom nozzle is provided. Liquid filling of this seal prevents vacuum formation. Few non condensable
which buildup in reflux drum will be flared intermittently by 410 PIC-3304A for maintain reflux drum
pressure. In case of low ambient temperature the condenser outlet temperature may fall sharply to
low values leading to partial vacuum conditions in reflux drum. DPIC-3301 has been provided
between column top and reflux drum to prevent such partial vacuum formation in reflux drum. The 12”
size line on which DPIC-3301 is mounted is called hot vapor bypass line. It routes hot vapors from
column top directly to reflux drum, bypassing the overhead air condensers; as and when the
differential pressure across the reflux drum and column top exceeds set value of DPIC-3301.
In case of pressure rise in the splitter column, PIC-3301 increases the control valve opening, thereby
increasing condensation. If rise in DA41008 top pressure occurs and persists due to presence of non
condensable, hot vapor bypass valve (DPIC-3301) senses higher differential pressure and opens to
increase the pressure in reflux drum. However, if equilibrium conditions in reflux drum are altered due
to increase in pressure of reflux drum (caused by opening of DPIC-3301 for a longer time period)
increase in the reflux drum temperature may also be experienced. The overhead system pressure rise
then shall be controlled by opening 410 PIC-3304A to flare. Temperature indication of common
condenser outlet and FA41005 outlet is indicated by TI-3306/ TI-3307. PSV-3302 set at 3.5kg/cm2g is
provided at FA41004 top to protect it in case of over pressurization. Sour water collected in the boot of
FA41005 is sent to either OWS or to CBD under vessel pressure. High water level in boot may result
in water carry over with reflux/light naphtha and can make it off spec. The water level in Naphtha
splitter overhead reflux drum boot is indicated by LI-3305/LG-3303. Looking at level gauge, water
draining from boot is done manually.
Overhead vapors from DA41008 are condensed in EC41008A/B and then in EA41070A/B. The
condensed liquid at 40-50°c is collected in the splitter reflux drum FA41005. This is Kero splitter
overhead stream, also called light naphtha. It is pumped out by KSU reflux/ overhead product pumps
GA41017 A/B under FA41005 level control LIC-3304. One part of stream from GA41017 A/B
discharge is used as reflux to DA41008. Its flow is controlled by FIC-3302. Other part of stream from
GA41017 A/B discharge is sent to EC41012 and then to EA41050A/B and from there to caustic wash
unit. Up stream of caustic wash LN can be sent to ISOM unit as ISOM feed ( if ovhd spltting is C5-90
Deg). If ISOM unit rejects LN or ovhd splitting is C5-65/70 Deg, it can be routed to the following
destinations after caustic wash and water wash.
1. LN to CCR blender
2. LN to ISOM storage
3. LN to naphtha pool along with middle naphtha either to LN-1 Header or LN-2 header
FIC-3303 indicates total product flow from FA41005. FV3303 is provided to ensure minimum flow
through GA41017.
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Kero (Naphtha) splitter furnace:
Major equipment of this section is naphtha splitter furnace.
Description of Kero (Naphtha) splitter furnace is divided into the following subsections:
Process system
Fuel system
Air preheating system
All these are described in the following pages:
Process system:
The DA41008 bottom stream from GA41019 A/B/C discharge is heated to desired vaporization
temperature of 135-150c in fired heater BA41007. TI-3401 indicates Naphtha temperature upstream
of all pass flow control valves. BA41007 has four passes each of 6" size. The last and penultimate
tube of each of the passes is of 8" size. Radiation section tubes are placed vertically along the heater
walls while convection section tubes are placed horizontally above radiation section tubes. Flow in
each pass is controlled by the individual pass flow controller, FIC-3402/FIC-3403/FIC-3404/FIC-3405,
provided in each pass. Individual pass flow controller controls flow in each pass through a pass
balancer. Pass balancer receives software input signals of the prevailing flow rate and COT in each
pass (indicated by FIC-3402 through FIC - 3405 and TI-3406 through TI-3409). Weighted average
temperature of each pass is calculated by software and this is utilized by the pass balancer for
regulating pass flows. The flow in each pass is controlled by the pass balancer in such a way that the
heat duty across each pass is equal to that of the other. The distribution of naphtha among the
passes should be done in such a way that the outlet temperatures of all the passes are more or less
the same. Inequality in pass flow rates to the extent of 10% can be tolerated, while operating on
manual mode or when pass balancer is not working. Effort should be made to maintain the same pass
flow and the same weighted average of COT to achieve homogeneous duty across each pass. If COT
of a particular pass is deviating too much due to unequal firing, pass flow through that pass is
automatically adjusted by pass balancer. Common COT is indicated by TI-3410. Fuel firing in the
heater is controlled by TIC-3410 which is cascaded to either FO or FG firing. Pass balancing is an
advanced control feature conceived for future implementation. Naphtha feed enters the heater
convection section and passes to the radiation section. All the four passes of BA41007 join together
at the outlet of the radiation zone and then enter the naphtha splitter column DA41008. To avoid
repetitive description, features of only pass 1 have been taken up. For other passes, identical
arrangements exist. FIC-3402 measures Naphtha flow through pass-1. Through dual transmitter FT-
3413, taken from one element, one flow low-low alarm FALL-3413 has been provided to indicate very
low flow condition in pass-1. Actuation of this alarm will trip the fuel supply to all burners of the heater,
excluding pilots. PI-3415 measures naphtha pressure at convection zone inlet. TI-3409 indicates coil
outlet temperature (COT) of naphtha at pass-1 outlet. Software signal of TI-3409 is utilized by pass
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balancer. Finally heated Naphtha enters a manifold of 26” size, called transfer line, before flowing to
DA41008. PI-3419/ TI-3410 indicate pressure and temperature in the transfer line. Increased
pressure drop across the heater coil is a measure of fouling in the tube.
Emergency coil steam connection is given to each pass, downstream of pass flow control valve, to
displace the hydrocarbons from the coil to the column during any emergency or during normal
shutdown operation.
Soot blowers, that use MP steam, are provided in the convection zone of the heater. Soot blowing will
be required when there is poor heat pick up in the convection zone coils as indicated by a slight
increase in flue gas temperature. Emergency steam and soot blower steam connections are taken
from the MP steam header and their combined flow is indicated by FI-3410.
Snuffing stem (LP Steam) connection is provided to the header boxes and the radiation zone of the
heater in order to extinguish fire and provide steam blanketing. To facilitate safe handling of emergency
steam/snuffing steam even during an emergency like fire in heater area, the isolation valves of
emergency steam and box purge steam are provided at a safe distance of at least 15mtrs from the
heater.
Fuel system:
BA41007 is a dual fired, vertical, cylindrical furnace, forced draft heater where either fuel gas or fuel oil
or both can be used as fuel. KSU furnace has 6 forced drafts; low Nox combination fuel fired burners,
arranged in a circle along the heater walls and is mounted upwards.
The fuel systems of KSU furnace are described below:
Fuel gas system:
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Fuel gas (FG) from battery limit is supplied by a 6” header. The FG line is steam traced to avoid
condensation of heavier components in it inside the line itself and hence prevent carry-over of
hydrocarbon liquid droplets to the burner. To arrest carryover of foreign particles like rust etc a 90
mesh strainer is provided on the line. FG to main burners passes through a shutdown valve SDV-
3403 whose open or close position is indicated in control room by XL-3403 A/ XL 3403 B. Fuel gas
flow / temperature to the main FG burners are indicated in DCS by FI-3407 / TI-3420. Local
temperature and pressure gauges are provided at the inlet of fuel gas to the main burners. Fuel gas
pressure indicator PI-3410, low fuel gas pressure pre-trip alarm PAL-3401 and a very low
pressure trip alarm PALL-3402 are provided at the inlet of fuel gas to the main burners. Actuation of
PALL-3402 will shut the SDV-3403 on fuel gas supply to the main burners of the furnace.
Fuel gas pressure and hence flow to burners is controlled by PIC-3410. It can be cascaded with
temperature controller TIC-3410. Through a selector switch SS-3401, this can be used to select
either fuel oil or fuel gas as the controlling fuel. A 1” tapping upstream of shutdown valve has been
taken for pilot burners. On the pilot gas line, PI-3408 / FI-3411 are provided to measure FG pressure /
flow to pilot burners. A low pressure alarm PAL-3411 will alert the operator when pilot gas pressure
falls. PG-3410 / PG 3411 indicate FG pressure in main and pilot gas lines in field.
Fuel oil system:
Fuel oil (FO) is supplied to splitter furnace by a 2” line under pressure control PIC-3403. Through a
selector switch SS-3401, temperature can be used to select either fuel oil or fuel gas pressure as the
controlling fuel. Flow indicator FI-3418 is provided on the main fuel oil supply line to heater and FI-3408
is provided on the main fuel oil return line from heater. Since this is a closed circuit through which
circulation is maintained, the net consumption of fuel oil is measured as the difference between the two
by FDI-3418. Shutdown valves SDV-3402 / SDV- 3401 are provided on supply and return header of
fuel oil. Open and close indications for these valves are available in control room. A fuel oil pressure
low - low trip alarm PALL - 3405 and a pre- trip alarm PAL - 3404 are provided on FO (supply) line.
Local PG/ TG near heater battery limit are also provided to indicate pressure/ temperature of the FO in
the field for local burner adjustments.
Since FO is normally a heavy material, it needs to be always maintained in circulation. If it is

stationary because of not being used in oil burners, it can get congealed even when tracing steam of
the FO circuit is on. Circulation in heater area FO piping (forming a closed circuit across all passes
called fuel oil ring) is maintained even when no FO burner is in use. To prevent congealing inside
piping, FO circulation past heater as well as burners should be maintained. FO is drawn by individual
burners through 3/4" header from main FO supply line and balance quantity is sent to FO return
header. This return header joins a common return header, leaving heater area.
Fuel oil circulation should be maintained in supply to return ratio of 2:1. When there is no need of FO
firing in the heater, the circulation can be maintained outside heater, through a 2" header called ring
bypass. Atomizing steam connections are provided on each oil burner. Pressure gauges are provided
44 | P a g e
on FO and atomizing steam lines of each burner. FO and atomizing steam connections are provided
to each oil burner. FO burners should be kept steam purged when idle. 2” flushing oil connection is
provided on FO (Supply) line. CBD/OWS drain is provided on FO (return) line. These provisions are
used to flush the line within battery limit after heater shutdown. When fuel oil is fired, it is atomized or
sprayed as a fine mist for realizing complete combustion. The spraying of FO is done by MP steam in
FO burners.
Atomizing steam pressure is controlled by differential pressure controller DPIC-3401, taking pressure
signals from FO supply and MP steam headers simultaneously. It maintains the atomizing steam
pressure 1.0 - 1.5kg/cm2 above fuel oil pressure. Atomizing steam pressure / flow is measured by PI-
3407 / FI-3409. Local pressure and temperature gauges are also provided on the atomizing steam
header. To arrest carryover of foreign particles like rust etc, a 90 mesh strainer is provided on the
line.
Air preheating system for BA41007 is different. On the top of convection coils there is an air preheating
coil. Combustion air from FD fan GB41003A/B discharge goes to air preheating coil Air is getting
heated to 100°C, 03TI3406 reads the temperature. For detailed operation of air preheating system &
related information, please refer operating manual prepared by HMTD.
Combustion airflow low tripping (03FSL3134) of heater brought down to 7000kg/hr from 900kg/hr for
less throughput operation. Similarly combustion airflow low setting for individual FD fans (03FSL3131
and 03FSL3141) brought down to 8000kg/hr from 10000kg/hr.
Furnace interlocks:
Following process interlocks are provided to trip the furnace.
1. Fuel oil pressure at the inlet of furnace goes very low (as sensed by PALL -3405) when the furnace
is operating on fuel oil. It closes SDV-3402/ SDV-3401 on fuel oil supply and return lines.
2. Naphtha feed flow through individual pass to furnace goes low (as sensed by any of FALL - 3413 /
FALL - 3414/ FALL-3415 / FALL-3416) It will close both fuels to heater.
3. Actuation of emergency push button shall stop fuel oil / gas to heater. However pilot burners shall
remain unaffected.
4. Fuel gas pressure at the inlet of furnace goes very low (as sensed by PALL-3402) when the
furnace is operating on fuel gas. It will close SDV-3403 on fuel gas line
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Naphtha Splitter Unit (NSU)/ NSU-2:
NSU Design:-
Naphtha Splitter Unit (NSU) is required to produce feed for the Reformer Unit by splitting the Naphtha
feed from CDU. NSU processes C5 - 150°C cut naphtha from either Arab Mix crude (AM / C5 - 150) or
Bombay High crude (BH / C5 - 150) to produce 75 (+/- 10) - 150°C cut Naphtha as bottom product.
Accordingly, NSU is designed for 253 m3/hr KSU bottom Naphtha.
Major equipments of Naphtha splitter unit (NSU) are Naphtha splitter column, overhead condenser,
Naphtha splitter overhead reflux drum, Reflux pumps, Naphtha splitter furnace and product coolers.
Naphtha from KSU bottom is routed to EA41051A/B (KSU feed/ bottom Exchanger), EA41051C
(Naphtha splitter feed/bottom exchanger) and then to naphtha splitter (DA41007). In case KSU
shutdown or bypass Stabilized naphtha from stabilizer bottom can be routed to EA41052 (Stabilizer
feed/ bottom Exchanger), EA41051C (Naphtha splitter feed/bottom exchanger) and then to naphtha
splitter DA41007. In splitter, stabilized naphtha (C5-150 cut) is split in two streams viz., overhead
stream or light naphtha (C5-105 cut/ C5-110 cut / C5-115 cut) and bottom stream or reformer feed
naphtha (105-150 cut). Splitting of naphtha is done by distillation. Heat required for distillation is
supplied by naphtha splitter furnace.
Naphtha splitter column (DA41007):
Splitter DA41007 has 30 valve trays. Stabilized naphtha is fed to tray 16 of DA41007 under FIC-2001, cascaded
with stabilizer bottom level controller LIC-1901. It can be fed to tray 13 also to vary the length of tray contact in the
splitter. If heavier bottom cut is to be produced, feed shall be introduced on tray 16 vice versa. Phase-1 naphtha can
be fed at tray 16 of NSU via FC2209A after Preheating with HGO Product in EA41072.
Since splitter operates at much lower pressure than stabilizer, some flashing downstream of FV-2001
can be expected. A number of PSVs with different set pressures is provided for DA41007. PSV-2001G
is set at 3.3 kg/cm2g. PSV-2001 F&C are set at 3.5kg/cm2g and PSV-2001 E&B are set at
3.7kg/cm2g. PSV-2001 A&D are set at 3.9kg/cm2g. Such a staggered setting helps in the controlled
release of vapors and avoids the actuation of all the PSVs at the same time. LP steam connection is
given to DA41007 for steam out purpose. This normally remains blinded and shall be used only during
shut down for hydrocarbon purging.
TI 2003 is provided on DA41007 overhead vapor outlet line. DA41007 shall be operated by controlling
tray 3 temperatures. The Heater firing can either be controlled by the tray 3 temperature or the heater
COT.
In NSU column for Middle Naphtha draw off, NSU column tray no 21 tray box given for draw nozzle and
One more box between tray no-22 and 23 also for FA41070 vapor return line.
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Middle naphtha is withdrawn from tray no-21 to FA41070 with GA41070A/B pump. From pump
discharge one MN stream goes to upstream of EC41012 (KSU top) with controller FV2002A to LN-
1/LN-2 and other MN stream goes to EA41071 (CW) and then to OMPL via 35FV2715. MN stream
one more tapping taken at upstream of 35FV2715 line to HSD blending joining at HNSC to Line-2 c/v
upstream to route MN to either to HSD blender or to HSD Line-1/2/3.
Naphtha splitter bottom pumps GA41020 A/B/C deliver DA41007 bottom material to Naphtha splitter
furnace BA41002 for picking up necessary heat required for reboiling. Reboiled and partly flashed
material from BA41002 enters below tray 1 of the column. Vapors from this stream disengage and rise
to the top and liquid drops down to the bottom of the column. Since composition of reboiler outlet
stream and bottom product is same, one part of GA41020 A/B/C discharge is sent to EA41051C for
exchanging heat with feed and from there to the product coolers level control LIC-2001. DA41007
bottom level is indicated and controlled by LIC-2001, acting as master controller of FIC -2206 A/B
when cascaded. Independent LAH-2005/LALL-2004 is also provided to indicate high or very low levels
in DA41007 bottom. Mass transfer takes place between down coming stabilized naphtha and the
flashed vapors across each tray. NSU bottom can be sent to CCR-1/CCR-2, CCR feed tank, OMPL
and HSD blender.
Naphtha splitter reflux drums (FA41004):
Uncondensed light naphtha vapors leave the column overhead under pressure control PIC-2001 to
naphtha splitter overhead condensers EC41002A to H. These are air coolers having provision to
isolate individual tube bundle. High vibration trip switches are provided on every fan motor of air cooler
system with a common alarm VAHH-2001 (Indicates tripping of any fan motor due to high vibration).
The condensed light naphtha enters the Naphtha splitter overhead reflux drum FA41004. One inverted
U type seal of elevation 450mm more than air cooler bottom nozzle is provided. Liquid filling of this
seal prevents vacuum formation. Few non condensable which buildup in reflux drum will be flared
intermittently by PIC-2002 to maintain reflux drum pressure. In case of low ambient temperature the
condenser outlet temperature may fall sharply to low values leading to partial vacuum conditions in
reflux drum. DPIC-2001 has been provided between column top and reflux drum to prevent such
partial vacuum formation in reflux drum. The 16” size line on which DPIC-2001 is mounted is called
hot vapor bypass line. It routes hot vapors from column top directly to reflux drum, bypassing the
overhead air condensers; as and when the differential pressure across the reflux drum and column top
exceeds set value of DPIC-2001.
47 | P a g e
In case of pressure rise in the splitter column, PIC-2001 increases the control valve opening, thereby
increasing condensation. If rise in DA41007 top pressure occurs and persists due to presence of non
condensable, hot vapor bypass valve (DPIC-2001) senses higher differential pressure and opens to
increase the pressure in reflux drum. However, if equilibrium conditions in reflux drum are altered due
to increase in pressure of reflux drum (caused by opening of DPIC-2001 for a longer time period)
increase in the reflux drum temperature may also be experienced. The overhead system pressure rise
then shall be controlled by opening PIC-2002 to flare. Temperature indication of common condenser
outlet and FA41004 outlet is indicated by TI-2004/ TI-2005. PSV-2005 set at 3.5kg/cm2g is provided
at FA41004 top to protect it in case of over pressurization. Sour water collected in the boot of FA41004
is sent to either OWS or to CBD under vessel pressure. High water level in boot may result in water
carry over with reflux/light naphtha and can make it off spec. The water level in Naphtha splitter
overhead reflux drum boot is indicated by LI-2003/LG-2003. Looking at level gauge, water draining
from boot is done manually.
Overhead vapors from DA41007 are condensed in EC41002A/H. The condensed liquid at 78°c is
collected in the splitter reflux drum FA41004. This is naphtha splitter overhead stream, also called
light naphtha. It is pumped out by naphtha splitter reflux/ overhead product pumps GA41016 A/B
under FA41004 level control LIC-2002. One part of stream from GA41016 A/B discharge is used as
reflux to DA41007. Its flow is controlled by FIC-2002. Other part of stream from GA41016 A/B
discharge is sent to EA41004 A/B and from there to caustic wash unit. FI2004 reads the LN product
rate to caustic wash. Uncondensed light hydrocarbons from FA41004 top, termed as off gas are
routed to flare under PIC-2002. FIC-2003 indicates total product flow from FA41004. FV2003 is
provided to ensure minimum flow through GA41016 A/B. Up stream of caustic wash LN can be sent to
ISOM unit as ISOM feed ( if ovhd spltting is C5-90 Deg). If ISOM unit rejects LN, it can be routed to
the following destinations after caustic wash and water wash:-
1. LN to CCR blender
2. LN to ISOM storage
3. LN to naphtha pool along with middle naphtha either to LN-1 Header or LN-2 header
48 | P a g e
Naphtha splitter furnace (BA41002):
Major equipment of this section is naphtha splitter furnace.

Description of Naphtha splitter furnace is divided into the following subsections:
Process system
Fuel system
All these are described in the following pages:
Process system:
The DA41007 bottom stream from GA41020 A/B/C discharge is heated to desired vaporization
temperature of 168/165°c in fired heater BA41002. TI-2101 indicates Naphtha temperature upstream
of all pass flow control valves. BA41002 has six passes each of 6" size. The last and penultimate tube
of each of the passes is of 8" size. Radiation section tubes are placed vertically along the heater walls
while convection section tubes are placed horizontally above radiation section tubes.
Flow in each pass is controlled by the individual pass flow controller, FIC-2101/FIC-2102/FIC-
2103/FIC-2104/ FIC-2105/FIC2106, provided in each pass. Individual pass flow controller controls flow
in each pass through a pass balancer. Pass balancer receives software input signals of the prevailing
flow rate and COT in each pass (indicated by FIC-2101 through FIC - 2106 and TI-2104 through TI-
2109). Weighted average temperature of each pass is calculated by software and this is utilized by the
pass balancer for regulating pass flows. The flow in each pass is controlled by the pass balancer in
such a way that the heat duty across each pass is equal to that of the other. The distribution of
naphtha among the passes should be done in such a way that the outlet temperatures of all the passes
are more or less the same. Inequality in pass flow rates to the extent of 10% can be tolerated, while
operating on manual mode or when pass balancer is not working.
Effort should be made to maintain the same pass flow and the same weighted average of COT to
achieve homogeneous duty across each pass. If COT of a particular pass is deviating too much due to
unequal firing, pass flow through that pass is automatically adjusted by pass balancer. Common COT
is indicated by TI-2110. Fuel firing in the heater is controlled by TIC-2110 which is cascaded to either
FO or FG firing. Pass balancing is an advanced control feature conceived for future implementation.
Naphtha feed enters the heater convection section and passes to the radiation section. All the six
passes of BA41002 join together at the outlet of the radiation zone and then enter the naphtha splitter
column DA41007.
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To avoid repetitive description, features of only pass 1 have been taken up. For other passes,
identical arrangements exist. FIC-2101 measures Naphtha flow through pass-1. Through dual
transmitter FT-2112, taken from one element, one flow low-low alarm FALL-2112 has been provided to
indicate very low flow condition in pass-1. Actuation of this alarm will trip the fuel supply to all burners
of the heater, excluding pilots. PI-2115 measures naphtha pressure at convection zone inlet. PG-
2122 and TI-2119 indicate pressure and temperature at radiation zone inlet. TI-2105 indicates coil
outlet temperature (COT) of naphtha at pass-1 outlet. Software signal of TI-2105 is utilized by pass
balancer. Finally heated Naphtha enters a manifold of 30” size, called transfer line, before flowing to
DA41007. PI-2121/ TI-2110 indicate pressure and temperature in the transfer line. Increased
pressure drop across the heater coil is a measure of fouling in the tube.
Emergency coil steam connection is given to each pass, downstream of pass flow control valve, to
displace the hydrocarbons from the coil to the column during any emergency or during normal
shutdown operation. Soot blowers, that use MP steam, are provided in the convection zone of the
heater. Soot blowing will be required when there is poor heat pick up in the convection zone coils as
indicated by a slight increase in flue gas temperature. Emergency steam and soot blower steam
connections are taken from the MP steam header and their combined flow is indicated by FI-
2110.Snuffing stem (LP Steam) connection is provided to the header boxes and the radiation zone of
the heater in order to extinguish fire and provide steam blanketing. To facilitate safe handling of
emergency steam/snuffing steam even during an emergency like fire in heater area, the isolation
valves of emergency steam and box purge steam are provided at a safe distance of at least 15mtrs
from the heater.
Fuel system:
BA41002 is a dual fired, vertical, cylindrical furnace, where either fuel gas or fuel oil or both can be
used as fuel. NSU furnace has 12 forced drafts; low NOx combination fuel fired burners, arranged in a
circle along the heater walls and is mounted upwards. The fuel systems of NSU furnace are described
below:
Fuel gas system:
Fuel gas (FG) from battery limit is supplied by a 6” header. The FG line is steam traced to avoid
condensation of heavier components in it inside the line itself and hence prevent carry-over of
hydrocarbon liquid droplets to the burner. To arrest carryover of foreign particles like rust etc a 90
mesh strainer is provided on the line. FG to main burners passes through a shutdown valve SDV-
2103 whose open or close position is indicated in control room by XL-2103 A/ XL 2103 B. Fuel gas
flow / temperature to the main FG burners are indicated in DCS by FI-2107 / TI-2120. Local
temperature and pressure gauges are provided at the inlet of fuel gas to the main burners. Fuel gas
pressure indicator PI-2109, low fuel gas pressure pre-trip alarm PAL-2101 and a very low
pressure trip alarm PALL-2102 are provided at the inlet of fuel gas to the main burners. Actuation of
PALL-2102 will shut the SDV-2103 on fuel gas supply to the main burners of the furnace. Fuel gas
50 | P a g e
pressure and hence flow to burners is controlled by PIC-2110. It can be cascaded with temperature
controller TIC-2110. Through a selector switch SS-2001, this can be used to select either fuel oil or
fuel gas as the controlling fuel. A 1” tapping upstream of shutdown valve has been taken for pilot
burners. On the pilot gas line, PI-2108 / FI-2111 are provided to measure FG pressure / flow to pilot
burners. A low pressure alarm PAL-2111 will alert the operator when pilot gas pressure falls. PG-
2110 / PG 2111 indicate FG pressure in main and pilot gas lines in field.
Fuel oil system:
Fuel oil (FO) is supplied to splitter furnace by a 3” line under pressure control PIC-2103. Through a
selector switch SS-2001, temperature can be used to select either fuel oil or fuel gas pressure as the
controlling fuel. Flow indicator FI-2118 is provided on the main fuel oil supply line to heater and FI-2108
is provided on the main fuel oil return line from heater. Since this is a closed circuit through which
circulation is maintained, the net consumption of fuel oil is measured as the difference between the two
by FDI-2118. Shutdown valves SDV-2102 / SDV- 2101 are provided on supply and return header of
fuel oil. Open and close indications for these valves are available in control room. A fuel oil pressure
low - low trip alarm PALL - 2105 and a pre- trip alarm PAL - 2104 are provided on FO (supply) line.
Local PG/ TG near heater battery limit are also provided to indicate pressure/ temperature of the FO in
the field for local burner adjustments.
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Since FO is normally a heavy material, it needs to be always maintained in circulation. If it is stationary

because of not being used in oil burners, it can get congealed even when tracing steam of the FO
circuit is on. Circulation in heater area FO piping (forming a closed circuit across all passes called fuel
oil ring) is maintained even when no FO burner is in use. To prevent congealing inside piping, FO
circulation past heater as well as burners should be maintained. FO is drawn by individual burners
through 3/4" header from main FO supply line and balance quantity is sent to FO return header. This
return header joins a common return header, leaving heater area. Fuel oil circulation should be
maintained in supply to return ratio of 2:1. When there is no need of FO firing in the heater, the
circulation can be maintained outside heater, through a 2" header called ring bypass. Atomizing steam
connections are provided on each oil burner. Pressure gauges are provided on FO and atomizing
steam lines of each burner. FO and atomizing steam connections are provided to each oil burner.
FO burners should be kept steam purged when idle. 2” flushing oil connection is provided on FO
(Supply) line. CBD/OWS drain is provided on FO (return) line. These provisions are used to flush the
line within battery limit after heater shutdown.
When fuel oil is fired, it is atomized or sprayed as a fine mist for realizing complete combustion. The
spraying of FO is done by MP steam in FO burners. Atomizing steam pressure is controlled by
differential pressure controller DPIC-2101, taking pressure signals from FO supply and MP steam
headers simultaneously. It maintains the atomizing steam pressure 1.0 - 1.5kg/cm2 above fuel oil
pressure. Atomizing steam pressure / flow is measured by PI-2107 / FI-2109. Local pressure and
temperature gauges are also provided on the atomizing steam header. To arrest carryover of foreign
particles like rust etc, a 90 mesh strainer is provided on the line.
Air preheating system for BA41002 is common with VDU furnace BA41101 to cater to combustion air
requirement of its burners. For detailed operation of air preheating system & related information,
please refer operating manual prepared by HMTD.
Furnace interlocks:
Following process interlocks are provided to trip the furnace.
1. Fuel oil pressure at the inlet of furnace goes very low (as sensed by PALL -2105) when the
furnace is operating on fuel oil. It closes SDV-2102/ SDV-2101 on fuel oil supply and return lines.
2. Naphtha feed flow through individual pass to furnace goes low (as sensed by any of FALL -
2112 / FALL - 2113/ FALL-2114 / FALL-2115 / FAL-2116/ FALL - 2117) It will close both fuels to
heater.
3. Actuation of emergency push button shall stop fuel oil / gas to heater. However pilot burners
shall remain unaffected.
4. Fuel gas pressure at the inlet of furnace goes very low (as sensed by PALL-2102) when the
furnace is operating on fuel gas. It will close SDV-2103 on fuel gas line.
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CAUSTIC / WATER WASH FACILITIES:

Caustic wash is generally used to remove sulfur compounds like hydrogen sulfide and / or methyl &
ethyl mercaptan. Equal volumes of hydrocarbon liquid and caustic solution are mixed / recirculated.
During this operation, caustic - hydrocarbon emulsion is formed which is allowed to settle in a vessel.
Typical retention time for caustic emulsion to separate out from hydrocarbons (naphtha to LPG) varies
from 90 minutes to 45 minutes.
Naphtha, kerosene and ATF are washed with caustic to remove CS2, CO2, H2S, phenols and
mercaptan which may be present or can be generated during processing. Caustic solutions are
hazardous wastes. Traces of caustic are removed by water washing of these streams. The caustic/
water wash systems are described below:
Light Naphtha wash system:
Light naphtha from naphtha splitter DA41007 or DA41008 reflux drum and reformer feed naphtha from
DA41007 bottom are given caustic / water wash simultaneously in two identical but separate systems.
Caustic wash:
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Light naphtha is admitted in light naphtha wash vessel FA41015 through a mixing valve HIC-2201/ HV-
2201. Caustic circulation pumps GA41024 A/B, taking suction from bottom of FA41015 and
discharging into FA41015 through mixing valve HV-2201 are provided. 25 vol % caustic solutions with
12 - 15 %w/w of caustic strength are circulated by these pumps where it is mixed with naphtha.
Caustic and Naphtha mixing in the valves, results in conversion of H2S, phenols mercaptan and other
chemicals to caustic solution. Depending on efficiency of mixing in the mixing valve, reduction of
above chemicals shall take place. Mixing of the two streams can be improved by throttling the mixing
valve with the help of HIC-2201. Reducing the port opening of the mixing valve increases stream
velocity through the valve, resulting in better energy transfer to streams mixing. However, impact of
additional pressure drop due to mixing valve throttling on rundown control valve and upstream system
should be carefully evaluated and monitored. Hydrocarbon phase separates out from caustic in
FA41015 due to adequate availability of residence time. Naphtha overflows from top of FA41015 to
water wash vessel FA41016 through another mixing valve HIC-2202 / HV-2202. Caustic solution
settled in FA41015 bottom is recirculated again under flow control FIC-2201. On repeated circulation,
strength of caustic goes down to less than 75% of its initial strength due to picking up of compounds
mentioned above. This is called spent caustic and is drained out through a 2" line connected from
GA41024 A/B suction to spent caustic drum FA41017. Spent caustic drum FA41017 is a vertical
vessel connected with flare. It receives caustic from LPG caustic wash. Hydrocarbon vapors
disengaged from caustic solution escape to flare and spent caustic is pumped out to WWTP or it can
be routed to FA41010 caustic dosing tank in CDU by spent caustic pumps GA41026 A/B. One level
indicator LI-2204 is provided on the vessel.
During caustic make up, normally caustic circulation should not be stopped and strength of spent
caustic solution should be increased by gradual draining and equivalent make up. Excessive loss of
fresh caustic solution through drain should be avoided during make up, as drain as well as make up
line both are connected from common portion of pump GA41024 A/B suction line. Quantity of caustic
make up is indicated by FI-2210. PSV-2201(S.V 17Kscg) is provided on FA41015 top to protect it from
over pressurization due to exposure of vessel in the external fire. LI-2205 & LG-2201 are provided on
the vessel to indicate level in the vessel. FA41015 always operates with full of liquid, without any
vapor space.
Water wash:
Caustic washed naphtha carries with it fine droplets of caustic solution which can make product
corrosive if stored as such. Therefore these caustic solution traces need to be removed from naphtha
before sending it to storage. For this purpose, thorough water wash is given to naphtha. Naphtha
water wash vessel FA41016 is provided for this purpose. Water circulation pump GA41025 takes
suction from FA41016 bottom and discharges water back to vessel through HV-2202. Circulating
water flow is controlled by FIC-2202. Pump GA41024 B acts as common stand -by for caustic and
water circulation duties.
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Water mixing with naphtha in HV-2202 results in its water saturation. An interface of alkaline water
and water washed naphtha is formed in FA41016. This inter-phase is indicated and controlled by LIC-
2201. Water washed naphtha floats on top of water in the vessel. Water saturated, caustic free
naphtha is routed to gasoline storage tanks or H2 plant feed storage tanks under flow controller PIC-
2205.
Water entering with naphtha settles down in lower portion of FA41016. This alkaline water is drained
from FA41016 bottom to spent caustic drum FA41017 under LIC--2201 (FA41016 interface level
controller). Water drain out connection from FA41016 is a 2" line connected from GA-025 suction to
FA41017. Quantity of water make up to FA41016 is indicated by FI-2207. One set of DM water make
up pumps GA41029 A/B is provided to boost up DM water pressure and supply make up water for
washing purposes. PI-2201 indicates DM water pressure at suction of these pumps. PSV-2202 (Set at
17Kscg) is provided on FA41016 top to protect it from over pressurization due to exposure of vessel in
the external fire. LI-2206 and LG-2202 are provided on the vessel to indicate level in the vessel.
FA41016 always operates with full of liquid, without any vapor space.
Reformer Feed Naphtha wash system:
This system is not required when heavy naphtha is coming from splitter bottom. It can be bypassed.
When naphtha splitter is under bypass condition and naphtha is directly coming from stabilizer bottom
this can be lined up. RFN is given caustic and water wash in a similar manner as described above for
light naphtha. Caustic wash vessel FA41018 and water wash vessel FA41019 are provided for the
purpose.
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RFN from DA41007 bottom enters FA41018 through mixing valve HIC-2203/ HV-2203. Caustic
circulated by GA41027 A/B under flow control FIC - 2203 is mixed with RFN in the mixing valve and
both streams enter FA41018. RFN overflows to FA41019 for water wash and spent caustic is drained
to FA41017 as per strength requirement. Make up caustic flow to GA41027 A/B suction is indicated by
FI-2208. RFN from VV-018 top enters FA41019 through mixing valve HIC-2204/ HV-2204. Water
circulated by GA41028 under flow control FIC - 2204 is mixed with RFN in the mixing valve and both
streams enter VV-019. RFN is drawn from FA41019 top and sent to CRU feed tanks or naphtha
storage tanks under flow control FIC - 2206A or FIC -2206B. RFN rundown flow can be cascaded with
DA41007 bottom level controller LIC-2001. Selector switch SS-2001 can be used for this selection.
Depending on selection, FIC-2206A/ FV-2206A or FIC-2206B / FV-2206B shall be operational for level
controller LIC 2001. FIC- 2006 an operation shall be selected for higher yield during AM case of
operation. Alkaline water from FA41019 is drained to FA41017 under FA41019 interface level controller
LIC-2202. Spent caustic is drained as per strength requirement. Make up caustic flow to GA41027
A/B suction is indicated by FI-2208. Make up water flow to GA41028 suction is indicated by FI-2209.
GA41027 B acts as common standby for caustic and water circulation duties.
PSV-2203/ PSV-2204(Set at 16Kscg) are provided on FA41018/ FA41019 top to prevent their over
pressurization due to exposure of vessels in the external fire. Level indications and level gauges are
provided on both the vessels to indicate level in the vessel. FA41018/FA41019 always operate with full
of liquid, without any vapor space. Provision exists to bypass any or all the vessels of caustic / water
wash facilities.
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3.6 Vacuum Distillation Unit:

Vacuum Distillation Unit (VDU) separates RCO into Vacuum Diesel, LVGO, HVGO, Vacuum slops and
Vacuum residue. It essentially consists of a vacuum heater; vacuum column and Product run down
cooling arrangement. All these facilities are described as under.
Vacuum Furnace (BA41101):
Major equipment of this section are vacuum heater, air preheater, ID/ FD fans and steam air decoking
pot.Description of vacuum heater is divided into following subsections:
Process system
Fuel system
Steam - Air decoking system.
All these are described in following pages:
Process system:
From radiation zone of vacuum heater, RCO enters vacuum column DA41101. Reduced crude oil (RCO)
from the bottom of the atmospheric distillation column at 315 to 345°c is mixed with vacuum slops recycle
stream and the combined stream is heated to desired vaporization temperature of 400°c to 410°c and
388°c before entering the Vacuum column DA41101 for fractionation. The purpose of maintaining slop
recycle stream (about 5% of RCO flow) is to provide necessary over flash.
The distribution of RCO among the passes should be done in such a way that the heat duties and hence
outlet temperatures of all the passes is more or less same. Depending on heat duty deviation, pass flow will
be varied. Inequalities in pass flow rates to the extent of 10% can be tolerated, when operating on manual
mode or when pass balancer is not working. All the eight passes of BA41101 join together at the outlet of
the radiation zone and then enter the vacuum column DA41101. Pressure gauges and temperature
indications are provided at all the external cross overs of pass flows from convection to radiation section.
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To avoid repetitive description, features of only pass 1 have been taken up. For other passes, identical
arrangements exist.04-FIC-2305 controls and indicates RCO flow through pass 1. Through dual
transmitter 04-FT-2313, taken from one element, one flow low-low alarm 04-FALL-2313 has been
provided to indicate very low RCO flow condition in pass.1. Actuation of this alarm will trip the fuel
supply to all burners of the heater, excluding pilots. 04-TI-2301 indicates RCO temperature upstream
of all pass flow control valves. 04-PG-2312 and 04-TI 2305 indicate RCO pressure and temperature at
radiation zone inlet.
MP steam connection is provided in the pass flow in radiation section inside heater for increasing
velocity and consequently the pressure drop through heater tubes. Turbulent two phase flow through
the radiation zone helps in reducing coke formation. Flow indicator FI 2317 indicates the flow of this
steam, called velocity steam. Injection point for this steam on the heater tube is located in such a way
that steam meets RCO stream where flashing of the stock commences. Three alternative locations for
injecting velocity steam on the tube have been provided. 04-TI-2315 indicates coil outlet temperature
(COT) of RCO of pass-1. High temperature software alarm on the COT has been provided to alert the
operator against inadequate flow or harder firing in that particular pass. Prolonged high temperature
may lead to coking up of that particular pass. Software signal of 04-TI-2315 is utilized by pass
balancer also. Finally heated RCO enters a manifold of 44" size, called transfer line, before entering
the vacuum column. 04-TIC-2312/ TI-2311 indicate combined, final coil outlet temperature of vacuum
heater. The final RCO temperature of the transfer line is controlled by this temperature indicator
controller 04-TIC-2312 which regulates the quantity of fuel to the furnace. 04-PI- 2306 / PI 2328
indicate pressure at radiation zone outlet in common transfer line. Pressure drop across the heater coil
is a measure of internal tube condition and increase in pressure drop indicates tube fouling due to coke
formation in the tubes.
Emergency coil steam connection is given in each pass, downstream of pass flow control valve to
displace the RCO from the coil to the column during an emergency or during normal shutdown
operation. Soot blowers are provided in convection zone of the heater. Soot blowing will be required
when there is poor heat pickup in convection zone as indicated by increase in flue gas temperature.
Emergency steam, soot blower steam, coil steam and decoking steam connections are taken from MP
steam header and their combined flow is indicated by 04-FI-2340. Combined coil steam flow is
indicated by 04-FI-2339.
Snuffing steam (box purging steam) connections to header boxes and radiation zone of the heater are
provided to extinguish fire and provide steam blanketing. To facilitate safe operation of emergency
steam/purge steam even during an emergency like fire in the heater area, the isolation valves of
emergency steam and box purge steam have been provided at a safe distance of at least 15 meters
from the vacuum heater.
Fuel system:
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BA41101 is a balanced draft furnace. Both the convection and radiant sections are used for heating
RCO. The combustion chamber houses the radiant section tubes. Tubes in radiation section are
arranged horizontally along side walls. In this section heat is primarily transferred by radiation from
the flame and hot combustion products.
The convection section provided at the top of the radiation section serves to increase the thermal
efficiency of the furnace by removing further heat from the flue gas. Tubes in convection section are
placed horizontally above combustion chamber. The heater is provided with total of 24 forced drafts,
combustion fuel burners of low Nox type. A low pressure alarm PAL-2304 will alert the operator when
pilot gas pressure falls. PG 2325 / PG-2326 indicate FG pressure in main and pilot gas lines in field at
heater battery limit. Twelve numbers of pilot and main FG burner tapping are provided in every cell of
the heater.
Fuel oil system:
Fuel Oil (FO) is supplied to vacuum furnace by a 2" line under pressure control PIC-2305. Through a
selector switch SS-2312, COT can be used to select either fuel oil or fuel gas pressure as the
controlling fuel. It can be cascaded with COT controller TIC-2312.Flow indicator FI 2328 is provided on
main fuel oil supply line and FI 2329 is provided on the main fuel oil return from heater. Since this is a
closed circuit through which FO circulation is maintained, the net consumption of fuel oil is measured
as the difference between the two values by FDI 2328. Shutdown valves SDV 2302 / SDV-2303 are
provided on supply and return header of fuel oil. Open and close indications for these valves are
available in control room. A fuel oil pressure low-low trip alarm PALL-2307 and a pre-trip alarm PAL-
2306 are provided on FO (Supply) line. Local PG/TG near heater battery limit is also provided to
indicate pressure/ temperature of the FO in the field for local burner adjustments. PAH - 2311 on FO
return header is provided to indicate high back pressure and/ or disturbed FO burner performance.
High back pressure may develop in FO header due to less number of FO burners during turndown
operation or due to closure of SDV 2302. Therefore FO firing should be manually switched over to FG
firing during turndown operation.
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Since FO is normally a heavy material, it needs to be always maintained in circulation. If it is left

stagnant and unused in oil burners and piping, it can get congealed in spite of tracing steam of the FO
circuit being on. Circulation in heater area FO piping (Forming a closed circuit across all passes called
fuel oil ring) is maintained even when no FO burner is in use. A ratio of 1:1 fuel oil consumption to
return is normally maintained to obtain good control on firing and prevent congealing of the IFO
system. To prevent congealing inside piping, FO circulation past heater as well as each burner should
be maintained. FO is drawn by individual burners through 3/4" header from main FO supply line and
balance quantity is sent to FO return header. This return header from cells joins a common return
header before leaving heater area. When there is no need of FO firing in the heater, the circulation
can be maintained outside heater, through a 2" header called ring bypass. Purge steam connections
are provided on each oil burner. Pressure gauges are provided on FO and atomizing steam line of
each burner. FO and atomizing steam are routed to each burner of the cell. FO burners should be
kept steam purged when idle. 2" flushing oil connection is provided on FO (Supply) line. CBD/ OWS
drain is provided on FO (Return) line. These provisions are used to flush the line within battery limit
after heater shutdown.
When fuel oil is fired, it is atomized or sprayed as a fine mist for realizing complete combustion. The
spraying of FO is done by desuperheated MP steam. MP steam is used for FO atomization in FO
burners. Atomizing steam pressure is controlled by differential pressure controller DPIC-2301, taking
pressure signals from FO supply and MP steam headers simultaneously. It maintains the atomizing
steam pressure 1.0 - 1.5 kg/ cm2 above fuel oil pressure. Atomizing steam pressure / flow is
measured by PI-2309 / FI- 2327. Local pressure and temperature gauges are also provided on the
atomizing steam header. To arrest carryover of foreign particles like rust, etc., a 100 mesh strainer is
provided on the line. When furnace operates on combination fuel, FG operates on PIC2301 and FO
operates on PIC2305. Selector switch SS2312 is used to select only one fuel for COT control by
cascading.
Combustion Air system:
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The heat carried away by the flue gas after convection section is utilized for preheating the air required
for combustion. Vacuum heater has a common air preheating system with NSU heater to cater to
combustion air requirement of their burners. The combustion air required for vacuum heater burners is
supplied by two forced draft fans, GB41101 A/B. Pilot burners are self inspiriting type and do not
consume combustion air from FD fan discharge.
The combustion air is preheated by flue gases in preheaters BC41102 & BC41106. Air preheater
consists of cast iron and glass air preheaters. It is a shell and tube type heat exchanger. Cold air from
atmosphere is sucked by FD fans and forced through tube side. The hot flue gas leaving the
convection section of furnace is sucked by an ID fan GB41102 from upstream of stack damper and
routed through shell of APH. Flue gas exchanges heat with cold air across tubes of APH. Cold flue
gas from Air preheater is discharged back above stack damper and let out to the atmosphere.
Steam - Air decoking system:
Steam air decoking (SAD) of vacuum heater tubes is done to remove coke deposit from inside heater
tubes with the help of steam and air. Removal of coke results in clean heater tube internals and
improves heater performance by better heat transfer to process fluid. SAD also achieves low
pressure drop through heater tubes and reduces chances of hot spot inside heater tube. Need for
steam air decoking of the heater tubes is indicated by increased pressure drop and harder firing.
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For this operation a dedicated arrangement called SAD arrangement is provided. It comprises of
decoking pot FA41104, Plant air, service water and MP steam piping. MP steam connections to each
pass flow are provided to dislodge coke film deposit from inside the heater tubes. Local and control
room DCS mounted flow indications (FI-2341 to FI 2348) are provided on each steam connection.
Plant air is provided to ignite the remaining coke film deposit clinging inside heater tubes and achieve
final cleaning of the tubes. FI - 2330 indicates total flow of plant air into MP steam lines for SAD.
Service water quench provision is given on FA41104 as well as flue gas line to quench the contents
before letting out to atmosphere.
To carry out SAD, pass flow inlet and outlet of the furnace BA41101 are isolated from process network
and connected by means of swing elbows with the decoking network. Heater pass flow outlets are
connected to the decoking drum FA41104. MP steam is introduced in heater passes and it is fired
from outside. Thermal shock caused by flame cracks coke scales inside the tube and flowing steam
dislodges them. These are carried to FA41104. This operation is called spalling. When no more coke
is removable by spalling as indicated by relatively clear color of effluent, air is introduced into pass flow
to burn the coke inside the tube while firing from outside. Coke is burnt by Oxygen of air and thus
tube cleaning is achieved. Burning of coke is indicated by increased tube metal temperature and
presence of CO/ CO2 in flue gas. Number of passes selected for spalling and coke burning is largely
dependent on limitations posed by steam availability and piping network. Sudden release of coke
during spalling may result in choking of the piping handling effluent or may result in hot spots on the
tube during burning.
SAD of other heaters or more passes of the same heater can also be planned subject to limitations in
steam availability and ease of monitoring.
Heater Interlocks:
Following interlocks are provided to trip the furnace:
1. Fuel Gas pressure at the inlet of furnace goes very low (as sensed by PALL-2302) when the
furnace is operating on fuel gas. It will close SDV-2301 on fuel gas line to main burners of
BA41101 only.
2. Fuel oil pressure at the inlet of furnace goes very low (as sensed by PALL-2307 when the furnace
is operating on fuel oil) It closes SDV-2302/ SDV-2303 on fuel oil supply and return lines.
3. Feed RCO flow through individual pass to the furnace goes low as sensed by any of FALL 2309
through FALL-2316. It will close both fuels to heater excluding pilot gas.
4. Actuation of emergency push button shall stop fuel oil / gas to heater. However pilot gas burners
shall remain unaffected.
Vacuum Distillation column (DA41101):
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The vacuum column DA41101 has three sections of different diameters. Top section is of 7000mm
diameter, middle section of 8900mm and bottom section of 4000mm diameter. The tower is made of
carbon steel with a lining of SS-410 on inner walls up to LVGO section and below. The included
portion of the column is provided with 3.0mm corrosion allowance. All draw off trays are made of SS-
410. The column is provided with four side cuts viz., vacuum diesel, slop, LVGO & HVGO. Vacuum
Residue (VR) is drawn as bottom product. Chimney trays are provided for all side draw off products.
The column has 5 packed sections.
Description of the vacuum column has been taken up zone wise, starting from bottom.
Vacuum Column Bottom section:
The partially vaporized RCO feed stock coming from the vacuum heater enters the column in the flash
zone below the slop draw off chimney tray. The vaporized portion rises up the tower and is
fractionated into four side stream products. The liquid portion of the feed drops to the bottom section
of the tower and is withdrawn as vacuum residue. Column bottom level is maintained by 04-LIC-2404,
cascaded on VR run down flow controller 04-FIC-2603 or 04-FIC-2605. SS-2404 is provided to
cascade 04-LIC -2404 with these flow controllers. Vacuum column bottom level is indicated by 04-LI-
2406 also. Independent low level alarm LAL-2411 is provided on column bottom to alert the operator
against low bottom level and probable malfunctioning of 04-LIC-2404. LSHH-2410 is provided which
trips stripping steam to column in case of high level in column bottom. This prevents inadvertent
vibration and resultant damage to column trays and internals. One local level indication LI - 2406 is
also provided at the column bottom to indicate the level in the field.
A circumferential baffle above feed inlet and a vapor de-entrainment baffle above stripping section are
provided to minimize entrainment of heavier hydrocarbon liquid droplets.
One 10" MP steam header supplies steam to column bottom below tray 1 for stripping purpose. Steam
flow to column is controlled by 04- FIC-2409. MP steam provided at the vacuum column bottom
serves to reduce partial pressure of hydrocarbons.
Vents of all pumps taking suction from vacuum column are connected back to vacuum column above
tray 10 through a common 3” line. With this arrangement all pumps connected with vacuum column /
strippers can be primed.
Provision is given to route all products to slop header to help stabilize the unit and route only on
specification streams to rundown storage tanks.
Vacuum Residue Draw off:
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Vacuum Residue is drawn by VR + Quench pumps.

VR pump discharge can be routed to following destinations:
1. To start up line through RCO feed line at BA41101 pass flow inlet manifold. VR pump
GA41106A/B discharge is circulated back to the vacuum column bottom below flash zone during
VDU start up circulation.
2. To the top of vacuum column above bed 1 for vacuum column starts up circulation and heating.
Normally it is not in service. It is in blinded condition.
3. To shell side of crude-VR exchanger EA41028A-E (Preheat train -3) then to
1) To DCU unit via 03FV5001
2) To VBU/BBU units and VBU blender
3) To EA41058
4. D/S of EA41058 Sr can be routed to :-
A) DCU feed Tank (03FV5002)
B) EA41019
5. D/S of EA41019 can be routed to
A) IFO blender (03FV5003)
B) Storage (FV2603) to Tank 35 or 9 series or slop.
Downstream of EA41028 A/B/C/D/E, VR splits in two parts. First part goes as VR quench to vacuum
column bottom. VR quench is required to maintain the vacuum column bottom temperature at around
350°C (after quenching) to reduce chances of polymerization reaction in column bottom. Absence of
VR quench may lead to continued cracking and polymerization reaction of vacuum residue molecules
during hold up in the tower. Higher VR temperature coupled with longer residence time promotes
these phenomena and manifests itself in coke formation in column bottom. DA41101 bottom
temperature is controlled by varying the VR quench stream flow. VR quench flow to column bottom is
regulated by 04-FIC-2403 Vacuum column bottom temperature is controlled by 04-TIC-2411,
manipulating cold VR quench flow to column bottom. Since only a small fraction of VR is required as
VR quench in vacuum column, second part of VR is diverted to VBU/BBU unit directly or to EA41063.
VR then flows through a steam generator EA41058. Downstream of EA41058 can be routed to DCU
feed tank and tempered water cooler before going to storage(Tak 35 or 9 series).
TIC-1106 maintains VR temperature at EA41058 A/B inlet with the help of two control valves TV-1106
and TV-1107 that are located across EA41063. In case of drop in VR temperature, hotter VR is
bypassed across EA41063 through increased opening of TV-1107. VR from EA41063 goes to shell
side of EA-058 A/B for steam generation. VR from EA41058 A/B is finally cooled in tempered water
cooler EA41109 A/B. At the downstream of EA41058A/B kerosene is injected as cutter stock during
LSHS make. Cooled VR finally flows to storage through FV2603. Provision also exists for routing
Vacuum slop product to VR run down downstream of FV 2603. VR flow controller FIC - 2603 can be
cascaded either to vacuum column bottom level or atmospheric column bottom level. Selection
between these two level controllers (04- LIC-2404 of vacuum column or LIC - 1601 of atmospheric
column) is made by a selector switch SS-2404, depending upon operation.
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Vacuum slop draw off:
Immediately above flash zone, a wash zone consisting of two sections is provided. Slop section is a
combination bed with a demister pad above wash zone packing. Height of packing is governed by
heat withdrawal requirement by circulating reflux. The vapors rising from the wash zone pass through
a demister pad provided above the wash section to trap entrained droplets of heavy hydrocarbons
which could otherwise adversely affect the HVGO / LVGO quality. Slop & recycle is drawn by
Slop+recycle pumps GA41104 A/B/C. It is drawn from chimney tray -4, below bed 5. In order to
minimize residence time on slop withdrawal tray, one slop quench drum FA41112 is provided. This
vessel serves basically as a surge vessel to slop pump suction. It also acts as a vapor detrainment
vessel. Level in FA41112 is regulated by 04-LIC-2407, which is cascaded to vacuum slop run down
flow controller.
GA41104 A/B/C discharge goes to the following locations:
 As recycle stream to vacuum furnace along with RCO.
 As product rundown and slop quench.
 Product run down goes to VR loop while making LSHS, MFO blender and it can be routed to
HVGO loop also. Vacuum slop can be routed to BBU/SFO.
GA41104 discharge is split in two parts:
* First part goes to vacuum furnace as slop recycle under flow control 04-FIC-2408. The slop recycle
stream is pumped back to the column through vacuum furnace along with heated RCO. The purpose
of maintaining slop recycle is to provide necessary over flash in the vacuum column. The slop recycle
from slop pump is mixed with RCO pump discharge before heating in vacuum furnace. 04-FIC-2408
sends software signal to vacuum heater balancer also.
** Second part of slop pump discharge goes to tube side of EA41029 for heat exchange with crude and
then to shell side of EA41056 A/B for steam generation. From here it goes to tempered water cooler
EA41105. Finally vacuum slop product is routed to rundown along with MFO or VR under flow control
FIC - 2606.
Slop quench stream tap off is taken from downstream of EA41105. Slop quench flow to draw off line is
provided to terminate coking reactions in slop draw off zone and pump suction by preventing
overshooting of slop draw off temperature, as indicated by 04-TI-2410. Slop quench flow is regulated
by 04-FIC-2412. Temperature controller 04-TIC-2408 (provided at slop pump suction) can be
cascaded with slop quench flow to FA41112. A sampling provision is given at the immediate
downstream of FV2606.
GA411004A suction have the facility to reprocess RCO.
Heavy vacuum gas oil (HVGO) draws off:
A large quantity of rising hydrocarbon vapors from slop zone wash section is condensed in HVGO
section by circulating reflux to yield the HVGO product. HVGO product + internal reflux (IR) +
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Circulating reflux (CR) are drawn by HVGO product + IR+ CR pumps GA41103 A/B/C from the third
chimney tray. Level in chimney tray is indicated and controlled by 04-LIC-2403. Level control on
chimney tray is essential to prevent dry run of the pump. Pressure in HVGO draw off zone is
indicated by 04-PI-2403. HVGO stream, GA41103A/B/C discharge, is split into three streams. They
are:
 Internal reflux for washing of slop section packing.
 Circulating reflux.
 Product stream.
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Bed 5, in slop zone, is washed by HVGO internal reflux stream. This stream enters the vacuum
column, without any cooling, above bed 5. HVGO IR rate is regulated by 04-FIC-2406 in such a way
that proper washing of the packing is always achieved for all throughputs. Height of packing is fixed
and is dependent on heat withdrawal requirement by slop quench stream. One distributor is provided
for proper distribution of the HVGO IR stream over entire cross sectional area of the column packing.
Basket filters FD41105 A/B are provided to arrest carryover of foreign materials back into column.
Pressure drop across the filters will be indicated by 04-DPI-2405 and its rise shall indicate need of
changeover of the filter in line.
HVGO product goes to EA41034 A/B, EA41025 and EA41018 A/B for heat exchange with crude.
Then it is sent to temper water cooler EA41103 A/B before being let down to various destinations as
described below:
 HVGO can be sent to VBU through a 3" line under VBU flow control. A 2" tapping has been
taken from this line to supply flushing oil to meet the requirements of various equipments and
instruments in CDU.
 To storage under HVGO rundown flow controller FIC-2602. This flow controller can be cascaded
with level controller of HVGO draw off chimney tray, 04-LIC-2403.
 The booster pump GA41109 A/B/C takes suction from the upstream of EA41103 A/B to supply
high temperature feed, along with LVGO, to Hydrocracker. HVGO flow to Hydrocracker is
controlled by FIC-2710 which can be cascaded with LIC-2403 using selector switch SS-2403.
 To PFCC feed Tank at d/s of EA41103 via 03FV5004
HVGO CR from GA41103 A/B/C discharge is split into two streams. One stream goes to the tube side
of EA41012A/B (kero stripper reboiler) as reboiling media. HVGO CR flow through reboiler is regulated
by JV-1702. HVGO CR downstream of kero reboiler is sent to DA41101. Second part of HVGO CR
goes to the tube side of EA41033 A/B and EA41036 for heat exchange with crude. HVGO CR at the
outlet of EA41036 A/B is then sent to vacuum column. One differential pressure indicator DPIC-1401
regulates HVGO CR flow through EA41033 and EA41036. Reduction in DPV-1401 opening occurs to
maintain pressure drop and hence flow across Kero/ ATF stripper reboiler.
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Low pressure drop across EA41033A/B and EA41036 can occur on account of higher HVGO CR flow
demand in the reboiler. In this case, DPV-1401 opening will reduce to restrict HVGO CR flow through
EA41036 to vacuum column and will instead increase the flow to Kero / ATF stripper reboiler. HVGO
CR streams from EA41036 and EA41012 A/B join together and are routed to bed 4 of the vacuum
column. Before entering the column, LVGO IR joins the HVGO CR stream. Bed 4 in HVGO zone is
washed by HVGO CR along with LVGO internal reflux stream. This combined stream enters the
vacuum column above bed 4. LVGO IR rate is regulated by 04-FIC-2405 in such a way that proper
washing of the packing is always achieved for all throughputs. Height of packing is fixed and
dependent on heat withdrawal requirement by HVGO quench stream. One distributor is provided for
proper distribution of the LVGO IR and HVGO CR streams over entire cross sectional area of the
packing. Distributor ensures uniform distribution of CR and proper wetting of packing. Basket filters
FD41104 A/B are provided to arrest carryover of foreign materials back into column. Pressure drop
across the filters will be indicated by 04-DPI-2404 and its rise shall indicate need of changeover of the
filter in line.
HVGO CR flow to the column is regulated by a duty controller. Duty controller computes actual duty of
HVGO CR and adjusts HVGO CR flow based on desired duty. Input regarding desired duty should be
computed manually based on throughput to column and fed to duty controller through software. Duty
controller works on the product of flow and temperature difference of the stream to control the flow rate
of circulating reflux based on the heat duty difference between the set value and the measured value
as computed by software computation block. Duty controller JIC-2407 has been provided on the
common HVGO CR line for this purpose. HVGO CR flow (indicated by FI 2407), HVGO draw off
temperature (indicated by TI 2406) and HVGO CR temperature (indicated by TI 2405) send input
signals to a software computation block JY-2407. A typical and representative value of specific heat of
HVGO CR stream is already configured in this software block. If specific heat of HVGO CR stream
also changes, the same should be revised to get correct duty of HVGO CR. This arrangement is typical
to all duty controllers of the column.
Light vacuum gas oil (LVGO) draw off:
The uncondensed hydrocarbon vapors of HVGO zone are condensed in LVGO section by LVGO
circulating reflux to yield the side draw product.
LVGO Product + Internal reflux (IR) + Circulating reflux (CR) is drawn by LVGO product + IR + CR
pumps GA41102 A/B from the second chimney tray. Level in chimney tray is indicated and controlled
by 04-LIC-2402. Level control on chimney tray is essential to prevent dry run of the pump. Pressure
in LVGO draw off zone is indicated by 04- PI- 2402.
LVGO is split into three streams and routed to different locations as follows:
 As internal reflux for washing of HVGO section packing. This stream joins HVGO CR.
 As LVGO product to product rundown.
 As LVGO CR to LVGO section packing of the vacuum column.
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LVGO product goes to tube side of EA41024 A/B for heat exchange with crude. From here it is sent
to temper water cooler EA41104 and EA41107 before being routed to storage. Hot LVGO from the up
stream of EA41107 goes to the suction of GA41109A/C and GA41109A/C pumps LVGO to
hydrocracker under flow control FIC-2709. FIC-2709 can be cascaded to LIC 2402 using selector
switch SS-2402. In case of HCU shutdown LVGO is routed to storage under LVGO run down flow
control FIC 2607. This flow controller can also be cascaded with level controller of LVGO draw off
tray. LVGO can be routed to MFO blender via LVGO can also be routed to PFCC feed Tank under
control FIC5005 at d/s of EA41107.
LVGO CR from discharge of GA41102 A/B is sent to shell side of crude/ LVGO CR exchanger
EA41027 A/B under duty controller JIC-2402. LVGO CR stream from EA41027 A/B is routed to the
third bed of the vacuum column. Distributor is provided on LVGO CR line inside the column and over
the bed for uniform distribution of CR and proper wetting of packing. LVGO CR flow to column is
regulated by a duty controller, similar to HVGO CR. LVGO CR flow (indicated by FI-2402), LVGO
Draw off temperature (indicated by TI-2404) & LVGO CR temperature (indicated by TI-2402) send
input signals to a software computation block JY-2402. A typical and representative value of specific
heat of LVGO CR stream is already configured in this software block. If specific heat of LVGO CR
stream also changes, the same should be revised to get correct duty of LVGO CR.
Vacuum Diesel (VDO) draw off:
The fourth side stream is vacuum diesel product + IR + CR. The rising, uncondensed hydrocarbon
vapors from LVGO zone packing are condensed in vacuum diesel section by vacuum diesel
circulating reflux to yield the side draw product.
Vacuum diesel product + Internal Reflux (IR) + circulating reflux (CR) are drawn by vacuum diesel
product + IR + CR pumps GA41101 A/B from the first chimney tray. Level in chimney tray is indicated
and controlled by 04- LIC- 2401. Level control on chimney tray is essential to prevent dry run of the
pump. Pressure in vacuum diesel draw off zone is indicated by 04- PG-2417.
Vacuum diesel is split into three streams and routed to different destinations. These are:
 As internal reflux for washing of bed 2 of vacuum column.
 As vacuum diesel product to product rundown.
 As vacuum diesel CR to packing of vacuum diesel section of vacuum column.
Bed 2 in LVGO zone is washed by vacuum diesel internal reflux stream. This stream enters the
vacuum column above bed 2 without any heat exchange. Vacuum diesel IR rate is regulated by 04-
FIC-2404 in such a way that proper washing of the packing is always achieved for all throughputs.
Height of packing is fixed and dependent on heat withdrawal requirement by LVGO CR steam. One
distributor is provided for proper distribution of the vacuum diesel IR stream over the entire cross
sectional area of the column packing. 04-FIC-2404 can be cascaded with vacuum diesel draw off tray
level controller 04-LIC 2401. Basket filters FD41102 A/B are provided to arrest carryover of foreign
materials back into column. Pressure drop across the filters will be indicated by 04-DPI-2403 and its
rise shall indicate need of changeover of the filter in line.
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Vacuum diesel product goes to shell side of tempered water cooler EA41102 A/B and then to vacuum
diesel water cooler EA41108 A/B for final cooling before being rundown to storage (HSD line – 2 & 3
and tank- 23B) under vacuum diesel rundown flow controller FIC -2609. One line of 2" size from
downstream of EA41108 A/B can supply flushing oil to CDU/VDU. Its flow is indicated by FI-2613.
Downstream of GA41101A/B one stream can be routed to DHDT unit feed and flow can be regulated
through 03FV5009 flow control valve. Downstream of EA41015 one stream routed to GOHDS for hot
feed and flow can regulated through 03FV2609D flow control valve. Slop oil from hot well can also be
routed to storage along with vacuum diesel.
Vacuum diesel CR from discharge of GA41101 A/B is split into two parts for cooling before routing back
to vacuum column. First part of diesel CR goes to air cooler EC41101 A/B. High vibration trip alarm
VAHH-2602 is provided on fan motor of this air cooler to protect the equipment from damage due to
high vibration. Second parts of diesel CR goes to the tube side of crude/ vacuum diesel CR exchanger
EA41015 and then to the shell side of tempered water cooler EA41101. Cooled diesel CR stream from
air cooler joins diesel CR stream from EA41101 and combined stream is sent to bed 1 of vacuum
column. Flow of vacuum diesel CR is controlled by 04-FIC-2401 which can be cascaded with vacuum
column top vapor outlet temperature 04-TIC-2401. EA41108 A/B outlet connected to outlet of EC41101
A/B for reduces the CR return temperature. Distributor is provided on vacuum diesel CR line inside the
column and over the bed packing for uniform distribution of CR and proper wetting of packing.
Vacuum column overhead system:
Steam and a small amount of light hydrocarbons produced as a result of cracking; pass out of the
vacuum column top through a 72” size line. The uncondensed vapors flow through a demister pad,
provided in the column top vapor space, to a set of steam ejectors. Demister pad prevents carryover of
liquid droplets to ejectors and condenser system.
Vacuum column top temperature is indicated and controlled by 04-TIC-2401. Vacuum column top
pressure is controlled by 04-PIC-2501. Compound type local pressure gauges (with pressure and
vacuum ranges) are provided at column top and on over head vapor line at inlet of ejector elements.
PSV-2401-2402(set at 3.5kscg) shall protect the vacuum column from over pressurization. These
PSV discharges are routed to flare header. Rupture discs are provided upstream of PSV's which apart
from other advantages prevent reverse flow from flare header to column in case of damage of safety
valves plug seat arrangement. PAL 2406 in flare header downstream of PSV’s is provided to indicate
such an eventuality. Vacuum is created and maintained in the column by 3 stage ejector system with
condensers. Each ejector has 3 elements and each element has 1/7, 2/7 and 4/7 fraction of ejectors
total capacity. If required each ejector element can be isolated by cutting of steam and isolating suction
inlet valves in the event of reduction in load.
Non condensable from vacuum column top are sucked by first stage ejector EE41101 A/B/C and sent
to ejector first stage inter condenser EA41111. Vapors are condensed to a limited extent in EA41111.
Condensed material from the condenser travels down into a vessel called hot well. Non condensable
from EA41111 are sucked in by second stage ejector EE41102 A/B/C. The vapors are further
condensed to some more extent in ejector second stage condenser EA41112. Condensed material
from the EA41112 travels down into hot well. Non condensable from EA41112 are sucked in by third
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stage ejector EE41103 A/B/C. The vapors are further condensed in ejector third stage condenser
EA41113. Non condensable from EA41113 vent are routed to inlet of first stage ejectors. Vacuum
column overhead pressure is maintained by 04-PIC-2501, acting on PV-2501. (Mounted on non-
condensable line from EA41113) Vacuum column can be operated by controlling overhead pressure
through 04-PIC-2501 or flash zone pressure through 04-PIC-2405. SS-2501 is provided for this
selection. Vacuum column operation through flash zone pressure indicator controller is done in case of
non representative indication of top pressure controller; the situation may arise due to excessive
pressure drop in column internals, primarily on account of either very high throughput or fouled column
internals. One fuel gas connection is provided on vacuum column top for breaking vacuum in vacuum
column during certain start up and shutdown steps.
MP steam to all ejectors is supplied in parallel by a 12" header through a pressure controller 04-PIC-
2502. Ejector steam flow is indicated by 04-FI-2501. One strainer with differential pressure indication
04-DPI-2501 is provided to arrest line scales etc from reaching into ejectors and adversely affecting
performance of overhead system. Ejector steam pressure should be maintained constant as far as
possible for smooth operation of vacuum column. Cooling water to all condensers is supplied in series.
This arrangement is critical to ensure proper condensation temperature for vapors which are
successively lean in condensable contents. Cooling water to none of the condensers can be isolated
individually. Proper air releasing provision is given to cooling water line during start up or cooling water
failure.
Hot well FA41101 is a horizontal vessel provided to separate out condensed hydrocarbons from vacuum
column overhead stream and provide effective sealing of the system operating under vacuum from
atmosphere. Hot well is provided with three compartments created by two internal baffles of different
height. The process lines, also called barometric legs carrying condensate from all ejector condensers
are kept dipped in water in middle compartment of the hot well. These lines have a water seal in the
middle compartment, equal to baffle height. The elevation difference between the ejector condenser
outlet nozzle and the tip of the barometric legs is kept more than 10 meters to allow condensed water to
flow by gravity and so that external air cannot break the dipped water seal and enter vacuum column
under any circumstances.
One goose neck type water seal is provided on overflow line connected from sour water side of hot well.
Goose neck water seal of 1500mm height on over flow line ensures isolation of hot well vapor space
from atmospheric air when column is under vacuum. This arrangement is required to prevent escaping
of hot well off gases to atmosphere under normal operation of VDU. When vacuum column is under
small positive FG pressure, this seal can prevent escaping of FG to atmosphere. However, to prevent
blowing out of this water seal due to excessive FG pressure, it is advisable to keep this seal isolated
when vacuum column is under positive pressure. One vent of 200mm height is provided on inverted U
portion of this goose neck seal. This vent ensures venting of any entrapped hydrocarbons in water seal.
It is very important to note that the drain line of this seal and hot well should be kept blinded (down
stream of drain valve), so that water seal formed by level in middle compartment of hot well is not lost
by accidental mal-operation of drain valve. Venting arrangements for letting out non condensable from
hot well at safe height or routing into atmospheric heater are provided. One catch pot FA41103 is
provided on hot well vent line to arrest the escape of hydrocarbons droplets. Non-condensable from
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FA41103 are called hot well off gases and burnt in atmospheric heater to realize greater fuel economy
and alleviate disposal problem. The condensate(s) from the middle compartment overflow to the
adjacent compartments. The water-hydrocarbon interface is formed in the middle compartment from
where the hydrocarbon overflows to its higher baffle height compartment (slop oil compartment) and
water moves to sour water compartment (lower baffle height side). The sour water from lower baffle
compartment is pumped out to sour water stripper / ETP by sour water pumps GA41107 A/B under hot
well sour water level controller 04-LIC-2501. 04-FIC-2503 acts as a minimum continuous flow protection
to this pump.
Condensed and separated hydrocarbon components (called slop oil) are collected in oil compartment of
hot well and sent to a water co-alescer FA41102 for removal of free water droplets. Slop oil from hot
well is pumped out to coalescer intermittently by Slop oil pump GA41108A/B. Slop oil pump is inter-
locked with hot well high oil level and low oil level alarms for auto starting and auto stopping. Water
coalescer FA41102 is a horizontal vessel with a boot. One coalescing element is fitted inside the
vessel. Water droplets present in slop coalesce in coalescer element and collect in boot. An interface is
formed between separated water and slop oil. It is indicated by 04-LI-2504. Level gauge and local level
indications are also provided on coalescer. Slop oil from coalescer overflows to LGO stripper or vacuum
diesel rundown or light slop tank through heavy slop header line with flow indicated by 04-FI-2502. An
NRV provision is given to avoid back up of material from the slop header. Water from coalescer boot is
manually drained to sour water line going to sour water stripper / ETP or OWS, looking at level gauge.
However, on actuation of 04-LALL-2506, SDV-2501 provided at boot outlet shall close, thus preventing
hydrocarbons from escaping with water.
3.7 Tempered water system & Steam Generators:

Tempered water system:-
For the hydrocarbon products of congealing nature at room temperature, cooling water cannot be used
for their final cooling before sending them to storage. Due to too low temperature of cooling water,
viscosity of hydrocarbon liquid may increase at or near heat exchange surface of the exchanger unit
and a film can get formed. Thus use of cooling water for cooling of congealing hydrocarbon streams
may result in poor heat transfer in the heat exchanger as well as complete choking over a prolonged
period of time. To avoid above problems, congealing hydrocarbons are never allowed to cool down
below a certain temperature. For this purpose, a closed type cooling water circuit, called tempered
water circuit is provided to cool these products to a temperature above their pour point. In tempered
water system, Boiler Feed water is circulated in a closed circuit where it picks up heat in heat
exchangers provided specifically for cooling hydrocarbon products of congealing nature. Hot water is
cooled in other heat exchangers and admitted back into tempered water vessel. Evaporation losses
are made up periodically. The tempered water cooling system has been provided for cooling of LGO,
HGO, LVGO, HVGO, Vacuum slop, vacuum diesel and VR streams.
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The tempered water system consists of a Tempered water drum FA41014, Main tempered water
pumps GA41035 A/B, Tempered water pumps GA41036 A/B and main tempered water air coolers
EC41009 A/B/C/D, tempered water air cooler EC41010A/B. TW drum is an elevated atmospheric
vessel, located above the air coolers EC41009/EC41010. Tempered water inlet line is elevated
minimum 1000mm above air coolers to provide effective elevation difference between tempered water
hold up and air cooler, thus preventing over flow problems. The vessel is provided with a local level
gauge and level indication LI-2601. A 2.0” BFW make up line is provided to make up for evaporation
losses. One overflow line of 2” size is also provided on the drum. Tempered water at 65°c is drawn by
main tempered water pumps GA41035 A/B and tempered water pumps GA41036A/B.
Main tempered water pumps GA41035 A/B supply tempered water to the following destinations:
To tube side of Vac., diesel CR exchanger EA41101, Vac., diesel product exchanger EA41102 A/B,
HVGO product exchanger EA41103 A/B, LVGO product exchanger EA41104, HGO product exchanger
EA41040, LGO product exchanger EA410041, Vacuum slop product exchanger EA41105 and naphtha
splitter bottom / tempered water exchanger EA41044 in series. On circulation in this circuit, tempered
water gets heated to approximately 121°c in these exchangers. The hot tempered water is cooled in air
coolers EA41009 A/B/C/D before entering the tempered water drum again. The outlet temperature of
tempered water air cooler is indicated and controlled by TIC -2609; acting on two control valves FV
2610A (mounted on air cooler inlet line) and TV 2601B (mounted on air cooler bypass line) TW flow in
this line are regulated by FIC 2601.
Tempered water pumps GA036 A/B supply tempered water to following destination:
Tempered water goes to tube side of LVGO Product cooler exchanger EA41107 and VR product
cooler exchanger EA41109 A/B in series. On circulation in this circuit, tempered water gets heated to
approximately 80°c in these exchangers. The hot tempered water is cooled to 65°c in tempered water
air cooler EC41010A/B before entering the tempered water drums again. The outlet temperature of
tempered water air cooler is indicated and controlled by TIC-2620, acting on two control valves TV-
2620A( mounted on air cooler outlet line ) and TV 2620B( mounted on air cooler bypass line). TW flow
in this line is regulated by FIC 2614. Finally cooled tempered water enters tempered water drum
FA41014. High vibration alarms and high vibration trip switches are provided on all fan motors of
EC41009 A/B/C/D as well as EC41010 A/B. High vent provision is given to release vapor from the
circulation circuit. Thermal relief valve is also given on each exchanger out let line.
Steam generation:
MP and LP steam is generated from BFW in the unit by recovering heat from outgoing products.
BFW from off sites is received in the unit through a 4” header for steam generation.
MP steam generation:
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For MP steam generation, BFW is first preheated in tube side of heavy naphtha / BFW exchanger
EA41055 A/B by recovering heat from outgoing product. Necessary heat for MP steam generation is
supplied by vacuum slop, HGO CR and kero / ATF product streams passing through shell side of
steam generators EA41056 A/B, EA41059 and EA41053 as described earlier. Preheated BFW enters
MP steam drum FA41023 under its level control LIC-2801 through a distributor.
Steam drum venting provision through a silencer and draining to CRWS from shell side of all steam
generators is provided. PSV-2801/ PSV-2802(set at 22kscg) are provided to protect the steam drum
from over - pressurization in the event of external fire. One demister is provided in the upper portion of
the drum to prevent water droplets carry over along with steam. Local PG/ TG and LG are typically
available on each steam drum.
Relatively cold BFW enters all the three steam generators and picks up heat from hot hydrocarbon
streams. Heated and partly vaporized BFW enters steam drum again due to difference in density.
Flashing occurs in the steam drum. MP steam is disengaged from water and leaves through top of the
drum.
Saturated steam flows to MP steam header under drum vapor space pressure control PIC-2801. MP
steam generated in this system is at 210°c while that available from off sites is at 290°c. MP steam
flow from the drum is measured by FI-2802. An NRV bypass provision is given at the steam drum outlet
which helps in steam drum warm up during start up.
LP steam generation:
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For LP steam generation, BFW is split in two parallel parts.
First part is supplied to Kero / ATF Product steam generator EA41054. Necessary heat for LP steam
generation is supplied by Kero / ATF product stream coming from MP steam generator EA41053. Hot
Kero / ATF product enters tube side of Kero / ATF product LP steam generator EA41054. BFW from
off sites enters Kero / ATF LP steam generator EA41054 under its level control LIC-2802. Steam
generator venting provision through a silencer and draining to CRWS from shell side of the generator is
provided. PSV - 2803/ PSV 2804(set at 10.0 kscg) are provided to protect the steam drum from over-
pressurization in the event of external fire. One demister is provided in the upper portion of the drum
to prevent water droplets carry over along with steam. Flashing of BFW occurs in the steam generator.
LP steam is disengaged from water and leaves through top of the generator. Saturated steam flows to
LP steam header under generator vapor space pressure control PIC-2802. LP steam flow from the
generator is measured by FI-2803. A warm up provision is given at the out let (NRV bypass) for use
during start up.
Second part of BFW is supplied to LP steam drum FA41024. BFW enters LP steam drum FA41024
under its level control LIC-2803 through a distributor. Steam drum venting provision through a silencer
and draining to CRWS from shell side of all steam generators is provided. PSV-2805/ PSV-2806 (Set
at 10.0 kscg) is provided to protect the steam drum from over pressurization in the event of external
fire. Necessary heat for LP steam generation is supplied by LGO CR and vacuum residue product
streams passing through shell side of two steam generators EA41060 & EA41058 A/B. TIC - 2810
controls LGO CR temperature by venting some of the steam to atmosphere through TV-2810. This
indirectly controls pressure in the steam drum. Relatively cold BFW enters both the steam generators
and picks up heat from hot hydrocarbon streams. Heated and partly vaporized BFW rises to steam
drum again due to difference in density. Flashing occurs in the steam drum FA41024. LP steam is
disengaged from water and leaves through top of the drum. One demister is provided in the upper
portion of the drum to prevent water droplets carry over along with steam. Saturated steam flows out
to LP steam header. LP steam generated in this system is at 151°c while that available from off sites is
at 175°c. LP steam flow from the drum is measured by FI 2804. A warm up provision is given at the
out let (NRV bypass) for use during start up.
Steam Blow down system:
In order to depressurize and blow down steam systems safely, FA41023, FA41024 & EA41054 drains
are connected with a steam blow down drum FA41025. This drum has a vent at safe height, drain
connection with water seal / vacuum breaker provision and service water quench connections. Blow
down from any of the steam generators can be quenched with service water and routed to CRWS
from this blow down drum. 500mm high water seal on drain line ensures minimum 0.5 meters depth
of water inside blow down drum.
3.8 Chemical Injection facilities:
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Hydrochloric acid from the salt in the crude and hydrogen sulfide dissolved in the crude (or formed
from the dissociation of heavy sulfur compounds present in crude) concentrates in the overhead
system. Both form acid solutions which are corrosive. Measures must be taken to overcome their
affects.
The overhead system including condensers and reflux drum is made of carbon steel. In order to
protect this section, caustic solution, ammonia solution and corrosion inhibitors are added at various
points. The purpose of injecting caustic at the outlet of desalter is to achieve better mixing of these
chemicals with crude and neutralize the acids/ acid salts, mainly HCI & H2S as soon as they are
formed (at a temp., of 120°c and above) The reaction products i.e.; sodium go along with reduced
crude. The balance acids and acid gases if any will go up to the overhead system where ammonia is
injected in the overhead vapor line for neutralization. Amount of ammonia should be controlled in such
a way that pH of reflux drum water remains at around 5.5 to 6.5.
Injection of caustic at the outlet of desalter should be maintained in such a way that the salt formation
should be low in the overhead circuit which might scale up the overhead condensers tubes. A slightly
acidic condition of the overhead system is desirable to keep ammonium salts in solution, which if
precipitates would foul and plug the condensers. Corrosion against slightly acidic condition is
minimized by adding corrosion inhibitors in the overhead vapor line. The inhibitor is also added in
reflux line. Top section of the column is also benefited from the injection of corrosion inhibitors mainly
in the reflux line. These inhibitors are high boiling compounds and can perform satisfactorily at higher
column top temperatures also.
The amount of inhibitor injected depends upon the type of inhibitor used and generally specified by the
vendor. However slight adjustment is made by operating personnel depending upon iron content in the
reflux drum water. These inhibitors are filming organic compounds which cover entire metal surface of
the system with a thin film. This prevents contact of corrosive water with metal surface.
Various points of chemical injections are listed below:
Caustic system:
Fresh Caustic solution having strength of 20° Be is received from CDU-1 through a 2” header to
FA41010. FA41010 can also receive spent caustic from FA41017. It is diluted to 6 – 8 % strength in
FA41010. Two additional tanks FA41007 A/B also are provided to store caustic solution with strength of
5 - 6 %. Each storage tank is provided with service water connection for dilution and plant air
connection for agitation purpose. Level gauges and overflow lines are also provided on each tank.
Care should be taken to ensure that tanks are not pressurized due to inadequate relieving of air
through tank vent.
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Caustic solution from battery limit can be either directly routed to or pumped by caustic make up pump
GA41037 to naphtha caustic wash system. Additional caustic pump GA41033C was installed for
maintain sour water chlorides during one pump under maintenance and high sulfur crude processing.
Dilute caustic solution from FA41010 or FA41007 A/B is pumped by caustic injection pumps GA41033
A/B/C to the following destinations:
 To suction of crude charge pumps GA41001 A/B/C.
 To stripped sour water line downstream of EA41046. Normally for brine pH control caustic is
injected here. Not at crude charge pump suction.
 To crude slip line downstream of desalter.
Ammonia injection system:
A battery of liquid ammonia cylinders is provided for meeting ammonia requirement. Ammonia gas is drawn
from ammonia cylinders at a reduced pressure into ammonia solution vessel FA41011. RO-2901 & NRV is
provided for this purpose on ammonia line. PSV 2911 is provided on this line to prevent over pressurization
of ammonia line. High and low pressure alarms are provided on this line to indicate either high ammonia
gas pressure due to blocked inlet / excess flow or exhaustion of ammonia cylinders. FI-2901 indicates
ammonia gas consumed towards solution making. DM water connection is provided on ammonia vessel for
preparing solution. Ammonia solution vessel is a vertical vessel with a water seal in its vent to prevent
ammonia from escaping while preparing solution. Water seal will blow off during excess pressure build up
in the vessel. GA42204B (Antifoam injection pump) converted as ammonia injection pump as this pump
was not in use and additional pump is useful for maintain sour water pH during one pump under
maintenance and high sulfur crude processing.
Finally, 2 - 3WT% ammonia solution is injected by Ammonia solution injection pumps GA41034 A/B
and GA42204 A to the following destinations:
1. To crude and vacuum column overhead line. For crude column the flow is indicated by FI-2902
and pressure restricted by RO - 2902. For vacuum column the flow is indicated b y FI 2904 and
pressure restricted by RO-2904.
2. To discharge circuit of GA41033 A/B for injection into desalted crude. Its flow is measured by FI-
2903. This is normally not on line.
Sour water pH is to be maintained in the range of 5.5 -6.5.
Demulsifier Injection system:
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Demulsifier chemical is received in drums and transferred to Demulsifier drum FA41009 for dissolving
in reformate or kerosene in the ratio 1:5 or dilution as per vendor specification. Presently demulsifier is
injected as a neat chemical without dilution. FA1009 is a vertical drum operating at atmospheric
pressure. Local level gauge, reformate/kero inlet line, sample point and draining arrangement to OWS
are also provided on vessel. Demulsifier chemical is unloaded into FA41009 with the help of a hand
pump or pneumatic pump. It is dissolved in FA41009 with the help of a mixer GD-002. Dissolved
demulsifier is pumped by GA41032 A/B. It is injected in crude line at the upstream of desalter -1 & 2.
To control the demulsifier consumption GA41032B is replaced with a small capacity pump (17LT/H).
Corrosion inhibitor injection system:
Corrosion inhibitor chemical is received in drums and transferred to corrosion inhibitor drum FA41008
for dissolving in reformate or kerosene in the ratio 1:9 or dilution as per vendor specification. FA41008
is a vertical drum operating at atmospheric pressure. Local level gauge, reformate/kero inlet line,
sample point and draining arrangement to OWS are also provided on vessel. Corrosion inhibitor
chemical is unloaded into FA41008 with the help of a hand pump or pneumatic pump. It is dissolved in
FA41008 with the help of a mixer GD -001. Dissolved corrosion inhibitor is pumped by GA41031 A/B
and is injected in crude and vacuum column overhead lines and GA41043A injects in the atmospheric
Column over head reflux line.
Tri Sodium Phosphate Injection system:
Tri Sodium Phosphate (TSP) chemical-Nalco 7205 is received in barrels and transferred to TSP drum
FA41032 for dissolving in DM water in the ratio 1:5. FA41032 is a vertical drum operating at
atmospheric pressure. Local level gauge, DM water inlet line, sample point and draining arrangement
to OWS are also provided on vessel.
Tri- Sodium phosphate chemical is unloaded into FA41032 with the help of a hand pump or pneumatic
pump. It is dissolved in FA41032 with the help of air driven portable agitator GD-004. Dissolved TSP is
pumped out by TSP injection pumps GA41043B and is injected in FA41024 & FA41023. TSP which is
injected in these drums controls scale formation by forming chelate with chemical compounds already
present in water. A provision is made to inject TSP in the common line to both steam drums.
3.9 Utility /Flushing Oil & Effluent System systems:-
Utilities:-
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The supply of utilities is common to CDU/VDU/NSU & ATU block. Isolation of utility headers and
measurement are also common for CDU/VDU/NSU.
The utility system consists of Instrument air (IA), Plant air (PA), Cooling water (WC), Service water
(WS), DM water, Boiler feed water, LP steam, MP steam, Fuel oil, Fuel gas and Flushing oil.
Closed blow down, flare, Contaminated Rainy water system (CRWS) and Oily water system OWS
networks are also provided within the unit.
Instrument air system:
A 3" instrument air header supplies instrument air to the unit. This header is provided with an isolation
valve and a spectacle blind at unit battery limit. PI-4202 indicates the pressure of instrument air at the
battery limit, in DCS. A local pressure gauge is also provided on this line. Instrument air consumption
rate in unit is indicated by FI - 4202 in DCS. Various instrument air tappings are taken from this
header. Instrument air is used as motive force for pneumatically operated control valves.
Instrument air phas-1/phase-2 and phase-3 interconnection modification done at CDU-2 B/L.
Plant air system:
A 4” plant air header supplies plant air to the unit. The header is provided with an isolation valve and a
spectacle blind at the unit battery limit. The pressure of the PA at the battery limit is indicated by PI-
4201. FI-4201 indicates PA flow to unit. A number of utility hose stations are provided for plant air
from this 4" header. For decoking of crude furnace and vacuum furnace separate 4" tappings are
taken from main header. 1" size plant air tappings are provided to FA41007A/B &FA41010 (caustic
tanks) for agitation.
Nitrogen:
The Nitrogen to the unit is received by a 2" header. The flow of Nitrogen to the header is indicated by
FI4203 and the pressure in the header is indicated by PI4203. Local indicators also available at battery
limit. There is a low pressure alarm PAL4203 in the Nitrogen header to alert the operator in case of low
header pressure. Nitrogen serves desalter 1 & 2 and vacuum column over head.
Cooling water system:
34" supply and return cooling water headers to the unit are tapped from underground headers running
on the side of the unit. Isolation valves with downstream spectacle blind have been provided at the
battery limit of the unit, on both the headers. The CW supply line is provided with PI-4401, FI-4401 &
TI-4401 to indicate pressure, flow & temp at battery limit. Local pressure/ temperature indicators are
provided on CW (supply & return) lines. TI-4402 is also provided on CW (return) line.
Cooling water header serves following equipments in CDU/VDU unit:
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EA41004 A/B Naphtha splitter overhead product cooler.

EA41050A/B KSU overhead product cooler
EA41070A/B KSU overhead cooler
EA41071 MN product cooler
EA41007 Heavy Naphtha product cooler
EA41008 Kero / ATF Product cooler.
EA41010 HGO product cooler
EA41009 LGO Product cooler
EA42201 Lean amine to LPG Absorber
EA42202 LPG/Lean amine cooler
EA42203 FG cooler
EA41042 Naphtha splitter bottom cooler
EA41001 A/B Atmospheric column trim cooler
EA41002 A/B Stabilizer condenser
EA41057 Brine cooler
SC-1, SC-2 Sample coolers
FA41021 CBD drum
EA41108 A/B Vacuum diesel cooler
GB41001A/B7GB41002 ID/FD fans
GB41101A/B, GB41102 ID/FD Fans
GA41015A/B,GA42201A/B ,GA42202A/B Seal Pots
EA41111 I stage ejector inter condenser
EA41112 II stage ejector inter condenser
EA41113 Ejector after condenser
The following pumps have cooling water connections for their bearing house ,casing &stuffing boxes as
per respective API plan.
GA41001A/B/C Crude charge pump.

GA41002A/B/C Preflashed crude pump
GA41003A/B/C Desalted crude pump
GA41004A/B Naphtha stabilizer feed pump
GA41006A/B/C HN CR pump
GA41007A/B/C Kero/ATF CR pump
GA41008A/B/C LGO CR pump
GA41009A/B/C HGO CR pump
GA41010A/B HN side cut product pump
GA41011A/B KERO/ATF product pump
GA41012A/B LGO product pump
GA41013A/B HGO product pump
GA41014A/B/C RCO pump
GA41015A/B Stabilizer reflux pump
GA41016A/B LN product pump
GA41017A/B Kero splitter over head pump
GA41019A/B/C Kero splitter. bottom pump
GA41020A/B/C Nap. splitter bottom pump
GA41070A/B MN product pump
GA41022A/B 1stage desalter water pump
GA41101A/B VDO pump
GA41102A/B, LVGO pump
GA41103A/B/C HVGO pump
GA41104A/B/C Vac. slop pump
GA41106A/B VR pump
GA41029A/B DM water Pump
GA42201A/B HP Lean amine pump
GA42202A/B LPG booster pump
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GA41107A/B Hot well sour water pump

GA41108A/B Hot well slop oil pump
GA41070A/B MN product pump
Service water system:
A 6" service water header supplies service water to the unit. It is provided with isolation valves and
spectacle blind along with a local pressure gauge at the battery limit. A flow indicator FI-4301 has
been provided in DCS. The service water header supplies water to various hose stations in the plant.
Service water connection is provided to the following equipments.
FA41104 For quenching heater effluent during SAD

BC41002/BC41006 For APH washing
FA41101 For level build up in hot well
FA41006 For quenching heater effluent during SAD
BC41102/BC41106 For washing of APH
FA41020 For sour water quench from FA41005
FA41025 For steam blow down quenching
GA41005A/B Atm. over head reflux pump suction
GA41015A/B Stabilizer reflux pump suction
GA41101A/B VDO pump suction
GA41016 A/B Nap. splitter Reflux pump suction
GA41017A/B Kero splitter. reflux pump suction
DM water system:
A 6" DM Water header supplies DM water to the unit from off sites. It is provided with an isolation
valve and spectacle blind, a local pressure gauge, temp. gauge and flow indicator FI-4303 at the
battery limit.
From this header tappings have been taken to FA41032, FA41013, FA41010, A41011, FA41007A/B
and GA41029A/B suction. DM water is routed to tube bundles of EC41001A to P and EC41002A/B
for washing.
Boiler Feed Water System:
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Boiler feed water (WB or BFW) is supplied to the unit through a 4" line. TG - 4302 indicates BFW
temperature at battery limit FI 4302/ PI 4301 indicate BFW flow and pressure battery limit. Boiler feed
water is preheated in EA41055 A/B before flowing to steam generators.
A 2" line is given to preheat train -1 for hot water washing. It is also routed to desuperheating station
located near VDU heater. Desuperheating is to reduce MP steam temperature which is used as
atomizing steam in heaters. TIC4103 maintains the temperature of atomizing steam. Presently this
desuperheater not is use due to condensate carry over in atomizing steam.
LP steam system:
Low pressure steam header of 16"size has been provided to the unit with isolation valves and
spectacle blinds at battery limit. Local pressure and temperature gauges have been provided at
battery limit. PI-4102, TI-4102 & FI-4102 indicate pressure, temperature & flow of LP steam to unit.
local pressure and temperature gauges is provided battery limit.
Valve with spectacle blind provided at battery limit. This arrangement is provided in view of the fact
that CDU is net exporter of LP steam, generated in EA41054 & FA41024, during normal operation. LP
steam is used for following services.
 Steam for tracing of process lines.

 Steam for utility hose stations.
Following sub-headers are taken from the main header:

To FA41021 As body steam/vent diffusing steam/ coil steam
To DA41002 Steam out connection
GA41002 A/B/C As quench steam for pump mech. Seal.
GA41003 A/B/C/D As quench steam for pump mech. Seal
GA41006 A/B/C As quench steam for pump mech. Seal
GA41007A/B/C As quench steam for pump mech. Seal
GA41010 A/B As quench steam for pump mech. Seal
GA41019 A/B/ As quench steam for pump mech. Seal
GA41070A/B As quench steam for pump mech. Seal
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BA41001 As snuffing steam
Duct C, Duct D At air preheater inlets for snuffing of CDU/VDU Heaters.
GB41001A/B,GB41002 For soot blowing of fan blades.
GB41101A/B,GB41102 For soot blowing of fan blades.
FA41026 LPG vaporizer Coil
EA41017 Crude pre heat train
PA41001 Desalter-1 tricock flushing
PA41002 Desalter-2 tricock flushing
MP Steam system:
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A 16" Medium pressure steam to the unit is provided with isolation battery limit. PI-4101, TI-4101 &
FI-4101 are provided to indicate pressure, temperature and flow of MP steam to unit.
MP steam is used in the following services:
 To BA41001 and BA41101 as atomizing, decoking, soot blowing and emergency steam.
 To BA41002 as atomizing and soot blowing steam.
 To steam ejectors EE41101/EE41102/EE41103 A/B/C of vacuum column for creating vacuum.
 To DA41001, DA41003, DA41004, DA41005 & DA41101
 As stripping steam.
 A 4" line, for steaming out crude line, at the up stream of PV1201.
In the case of atomizing steam MP steam is desuperheated by BFW injection in steam desuperheater
BH41001. 03-TIC-4103 maintains MP steam temp at desuperheater outlet by varying BFW injection to
MP steam. The desuperheater is located near vacuum heater. MP steam can be admitted into LP
steam header for superheating the LP steam generated in FA41024. 03-TIC-4104 is provided for the
purpose of temperature control of LP steam. 03-TAH-4104 provides protection against abnormal
temperature increase in LP steam header due to admission of MP steam in uncontrolled manner.
Actuation of 03-TAH-4104 indicates abnormally high temp. of LP steam, indirectly indicating admission
of high pressure MP steam into LP steam header. This condition will actuate SOV-4104 to close TV-
4104 provided on MP steam let down to LP steam.
Fuel gas system:
Sour fuel gas from various units is received for sweetening by Amine treatment and routed to DA42202 of
Amine treating unit through a 12" size header. Sour fuel gas from naphtha stabilizer reflux drum FA41003
is also routed to DA42202 of ATU through the same header. Sweetened fuel gas from FA42203 of ATU is
sent to fuel gas knock out drum (KOD) FA41027. When no FG is being produced in the unit or during first
start-up LPG can be backed to the LPG vaporizer from GA42202 pump discharge through a 2" line or LPG
can be taken from OM&S. LPG from OM&S can be routed to amine absorber through CCR LPG line. A
modification has been made to this effect at the battery limit.
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LPG can be vaporized in LPG vaporizer FA41026 with the help of LP steam to produce FG. LPG flow
to FA41026 is indicated by 03-FI-3202. It is admitted into vaporizer under level control 03-LIC-3212.
Independent high & low level alarms are provided on LPG vaporizer. LPG vaporizer pressure is
maintained by 03-PIC-3202, by manipulating 03-PV-3202 provided on LP steam to vaporizer. Flow
of vaporized LPG is indicated by 03-FI-3201. Vaporized LPG is admitted into fuel gas KOD FA41027.
Sweet fuel gas from other units like CCR&HCU can also be routed directly into FA41027 for
condensate de-entertainment. Condensate free sweet FG from this KOD is taken out for distribution
through a 10" header under pressure control 03-PIC-3204. Its flow is measured by 03-FI-3204. 03-
PSV-3201/3202(set at 14.0 kscg) are provided to protect FA41026 & 03-PSV-3203/3204(set at 6.0
kscg) are provided to protect FA41027 from over pressurization. Drains of FA41026 & FA41027 are
normally routed to flare due to flashing nature of streams handled.
FG consumption in CDU/VDU is indicated by 03-FI 4502. Sweet fuel gas is delivered to BA41001,
BA41002, BA41101, FA41002, FA41003,FA41004,FA41005 DA41101. It is also connected as purge
to flare header. PSV-4501A/ 4501B (set at7.0 kscg) on sour gas line has been provided to protect ATU
piping / equipment from over- pressurization. Local pressure and temp. gauges have been provided
at battery limit on sour and sweet fuel gas lines.
Fuel oil system:
Fuel oil is supplied to fired heaters of the unit through a 6" header. Local pressure gauge and
temperature gauge have been provided near respective heaters. It supplies fuel oil to atmospheric
furnace, vacuum furnace and naphtha splitter unit furnace. Fuel oil flow to furnaces is measured by
flow meters on respective FO (Supply) headers. A return fuel oil line has been provided from each
furnace. Each return line has been provided with a globe valve, shutdown valve and flow meters.
About 50% of the supply fuel oil is allowed to return through these lines. This circulation of fuel oil is
required to prevent congealing in the line during idle conditions. Net flow of fuel oil to atmospheric
furnace and vacuum furnace is recorded by flow differential recorders. Fuel oil return header with
individual bypasses have been provided from individual supply lines to allow independent FO
circulation in any of the furnaces.
Electrical system:
Electric power requirements of CDU/VDU are met by Captive Power plant. Captive Power Plant
(Phase-2) in MRPL has 3 steam turbines of 25MW each. During normal operation, two steam turbines
shall take care of entire electrical load of MRPL refinery. In the event of Power failure, back up power
supply arrangement to the extent of 25MW from state grid exists through emergency tie-up. Electrical
load for CDU/VDU is anticipated as 7000KW. Electrical system of CDU/VDU comprises of a no. of sub
systems. These are briefly described as under:
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Electrical Power for pumps:
Motors above 160KW ratings are fed from 6.6KV switch board.
Following pump motors are fed by High Tension Feeder at 6.6 ± 10% kV AC from unit substation,
individually for each of following the motors.
GA41001 A/B/C Crude charge pumps
GA41002 A/B/C Preflashed crude pump
GA41003 A/B/C Desalted crude pump
GA41004 A/B Stabilizer feed pump
GA41011A/B Kero/ATF product pump
GA41020A/B/C NSU bottom pump
GA41102A/B LVGO pump
GA41103A/B/C HVGO pump
GA41106A/B/C VR pump
GB41001A/B CDU Heater FD fan
GB41002 CDU Heater ID fan
GB41102 VDU Heater ID fan
Above motors are termed as HT motors. Remaining motors are fed from Low tension feeder at 415 ±
10% V, 3 phase, 50 amps AC power and therefore called LT motors.
Electrical power to motors is controlled according to following criteria.
Motor rating limit Control

Up to 55 kW Through switch fuse contractors
Above 55KW up to 160KW Through Air circuit breaker
Above 160 kW Through 6.6KV vac. circuit breaker
Motor start/ stop push buttons and local ammeters are provided at local control station for motors in
field. However, local ammeters are provided only for motors with rating 5.5 kW and above. All LT
motors fed through switch fuse contractor are provided with 240V AC control supply. 110V DC control
supply is provided for all HT motors and motors having rating excluding 55KW, and power control
cabin motors, interspersed in utilities, raw water block administrative block and process units. Running
status lamps for pump are provided on control room Auxiliary console panels as per P&ID with
potential free contacts, similar to Control room Instruments.
Plant Illumination:
All plant lightings are provided with 230 ± 10% V AC power. For maintaining emergency lighting,
emergency lighting fixtures are fed with 110V DC power feeder, so that in the event of power failure,
minimum lights in critical areas such as control room, substation, escape route etc., are sustained.
Instrumentation Power System:
Main features of electrical instrumentation power system are described below:

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Through a Battery Bank in main unit substation, 110 V DC supply is available to all solenoid valves in
field and Auxiliary consoles in Control room. On Auxiliary consoles are mounted Push buttons,
Running status lamps & Selector Switches to PLC interlocks etc. Few spare outlets of 110 V DC
supply are also provided in Control Room to carry out miscellaneous testing jobs etc. Battery backup
will remain available for a period of 1 hour for UPS & other Instrument requirements. 110V AC Power
supply (uninterrupted) is available to all Hard wired Alarms, Hooters, Multi point Digital temp.,
indicators (TJI), Density analyzers, Supervisory Computers, Printer, Video hot copier, DCS monitors
(CRT) and hand indicator controllers. In the event of power failure, 110 V AC supply will remain
available for a maximum period of 60 min to above instrument to facilitate safe shutdown of process
units. If power from main feeder is still not resumed, plant instruments will assume safe shutdown
position according to logic built in PLC. After power is resumed, DCS system and supervisory
computer should be booted before reverting back to normal operations.
Flushing oil system:
Flushing oil is normally a light oil with boiling range and properties comparing well with diesel oil. It is
used as flushing medium for displacing heavy, congealing and viscous material from equipment piping
sections during unit shutdown or other maintenance job when freeing of equipment from such
hydrocarbons is required. It is also used as pump seal flushing oil.
Three flushing oil systems, are supported from crude distillation unit. The flushing oil system consists
of
 Light Flushing Oil
 Normal Flushing Oil
 Heavy Flushing Oil
Light Flushing Oil:

Light flushing is LGO. From EA41009 out let one 3" line is taken and is connected to flushing oil
manifold . A 3" gas oil line from battery limit (flushing oil to & fro header) is also connected there. From
the manifold a 2" line is taken to FA41033, Lt. flushing oil drum . FI2712 indicates the FLO flow to
manifold. VDO from downstream of EA41108 can also be routed to the manifold. FI2613 reads the flow
of VDO to FLO. Diesel from OM&S (FB7016) can also supply flushing oil through to & fro header to
FA41033. LIC4801 controls the level in FA41033 by varying LV4801. FI 4801 measures the
consumption of flushing oil to pumps. GA41044 A/B (screw pump) supplies the flushing oil to the
pumps. The header pressure is maintained by PIC 4801 which is set at 10.0 kscg by manipulating
PV4801. PSL4802 is provided, which on actuation will start the stand by pump. PSV 4801 & PSV4802
(set at 16.5kscg) are provided at the discharge of individual pump to protect from over pressurization.
GA41044A/B supplies flushing oil to the following areas.
GA41001A/B/C
GA41002A/B/C
GA41008A/B/C
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GA41009A/B/C
GA41012A/B
GA41013A/B
DA41001 bottom
Normal flushing oil:
This is also called refinery flushing oil header. Flushing oil from flushing oil manifold goes to the
refinery flushing oil header through 3" to & fro line. Intermittent demand of Hydrocracker Unit for Start
ups, shut downs and any other requirement of any plant is met by flushing oil, which is the light gas oil
from Crude Distillation Unit.
Flushing oil from storage (FB7016) can also be routed to normal flushing oil header. This is used
during emergency. The OM&S pump is on emergency power drive.
In CDU/VDU the following equipment are connected with normal flushing oil ;
Exchangers :
1 EA41013 SHELL
2 EA41014 SHELL
3 EA41015 SHELL
4 EA41019 SHELL
5 EA41023 SHELL
6 EA41032 SHELL
7 EA41031 SHELL
8 EA41026 SHELL
9 EA41022 SHELL
10 EA41030 SHELL
11 EA41017 TUBE
12 EA41063 SHELL&TUBE
13 EA41056 SHELL
14 EA41012 SHELL
15 EA41021 SHELL
16 EA41012 TUBE
18 EA41023 SHELL
26 EA41109 SHELL
27 EA41103 SHELL
28 EA41104 SHELL
29 EA41105 SHELL
30 EA41107 SHELL
31 EA41058 SHELL
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32 EA41011 TUBE
33 EA41030 SHELL
34 GA41014 SUCTION
35 GA41101 SUCTION
36 GA41102 SUCTION
37 GA41103 SUCTION
38 GA41104 SUCTION
39 GA41106 SUCTION
40 GA41001 SUCTION
41 GA41002 SUCTION
42 BA41001 FO SUPPLY LINE
43 BA41101 F.O SUPPLY LINE
44 BA41002 F.O SUPPLY LINE
45 FD41101 VDO CR FILTER
46 FD41102 VDO IR FILTER
47 FD41103 LVGO CR FILTER
48 FD41104 HVGO CR FILTER
49 FD41105 HVGO IR FILTER
50 GA41038 CBD PUMP D/S
Apart from the above, connection is also given to Heavy Hydrocarbon piping. There is a jump over line
from normal gas oil to heavy flushing oil which is used during start up when HVGO would not be
available.
Heavy Flushing Oil System:

Heavy flushing oil is HVGO from Vacuum Distillation Unit. This oil is cooled to a temperature of 110°C
in EA41103 with tempered water. The flushing oil is then stored in the flushing oil drum FA 41113.
LIC4803 maintains the level in FA4113 by manipulating LV 4803 on the incoming line. FI4802
measures the flow. The pump GA 41110 A/B(screw pump) supplies to the header whose pressure is
maintained at 12.5 kg/cm2g by PIC4803 by manipulating PV4803 on pump spill back line. On actuation
of PSL4804 the stand by pump will get started , provided it is in auto cut in mode. PSV4805 &
PSV4806 (set at 20.0kscg) are provided on individual discharge lines to protect the pumps from over
pressurization.
GA41110 A/B supplies flushing oil to the following pump seals:
GA41014 A/B
GA41102 A/B
GA41103 A/B/C
GA41104 A/B/C
GA41106 A/B
GA41105 A/B
It also sends flushing oil to instruments of DA41101 & FA41112. This is needed for instrument
purging .
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Effluent system:
All off spec. Hydrocarbon streams, Hydrocarbon streams contaminated with water, water contaminated
with hydrocarbons/ chemicals and such liquid streams that cannot be disposed off directly are
collected and treated either for recovery of hydrocarbons or to render them harmless or for both the
purposes. For this purpose, slop system, CBD system, Contaminated rain water system are provided.
These systems are described sequentially as under:
Slop system:
Off spec. hydrocarbon streams that are not contaminated with water and need to be disposed off are
termed as slop. A slop tank is provided in off sites for this purpose. Two slop headers of 10" size are
provided in the unit to collect slop from CDU &VDU product run down streams.
All this slop can be recycled back to crude charge pump through a 6" line joining the suction manifold
of GA41001 A/B/C. Alternatively, slop can be received in slop tanks. Slop header is provided with a 2"
flushing oil connection and a utility connection at dead end.
Closed Blow down system:
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Those hydrocarbon streams that are either free of water or only slightly contaminated with water are
received in closed Blow Down (CBD) vessel, FA41021. Such Hydrocarbon streams are generated
especially during shutdown periods when equipment and systems are drained under gravity to clear
hold up oil. The hydrocarbons in the CBD vessel should be received at a temp. well below the flash
point of the lightest component present inside. Closed Blow Down network helps in reducing the
amount of hydrocarbon finding its way to effluent treating facility via OWS during equipment draining.
Uncontaminated hydrocarbon, from equipment draining, is collected and routed to CBD vessel via CBD
headers that cover all unit equipments.
Two underground closed blow down headers run across the plot in CDU/VDU. These are provided
with clean out pit and flushing oil connections at header ends. Flushing oil aids in flushing heavy
congealing hydrocarbon material accumulated in the header, if any. One utility connection is also
provided at each CBD header end, close to the FLO connection to flush the CBD header with any
other utility. However, care should be taken to avoid steaming of CBD header, as line is not designed
for steam out conditions due to absence of expansion provisions.
FA41021 is provided within CDU/VDU battery limit. CBD drum is a horizontal drum located
underground. The drum is provided with a coil through which cooling water or LP steam can be
passed. Hydrocarbon mixed with slight water is allowed to enter this drum from where it is pumped out
by CBD pump GA41038 to existing crude/ slop header. LAH-3202 and LAL-3202 are provided to
auto start and auto stop the CBD pump. LI-3201 indicates the level in the drum. TI-3201 & PI-3201
indicates the temperature of the contents in the CBD drum and pressure inside drum. Under normal
conditions, it is expected to remain at atmospheric pressure. A small purge of steam is provided at the
vent of the drum to guard against lightning and static electricity hazards.
One coil is provided inside CBD drum through which either cooling water or LP steam can be
circulated. Cooling water shall be introduced to bring down the temp. of hot material drained and
accumulated inside the vessel, while LP steam shall be introduced in the same coil, after isolating
cooling water, to de-congeal / heat up accumulated heavy material inside vessel and bring it to pump
able viscosity. TI-3202 indicates temp of contents going out of CBD vessel.
Oily Water sewer:
This system, also called OWS system, is mainly to collect water contaminated with hydrocarbon oils.
Such streams are usually generated during equipment draining and flushing during routine operations.
Streams suitable for OWS are also generated as a result of floor washing, cleaning of spilled oils etc.
Streams suitable for OWS should never be routed to CBD as it may ultimately lead to receipt of lot of
water in slop tanks. Drained streams at ambient temperature received through OWS funnels etc are
routed to API separator of ETP through a combined header. From this API separator, oil is skimmed
off and routed to slop tanks in off sites while remaining water is routed to water treatment section of
effluent Treatment Plant.
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All equipments having CBD connections are normally provided with OWS/ CRWS connections on
following basis.
 All continuous draining HC bearing streams having CBD connection are provided an additional
connection to OWS.
 All intermittent draining HC bearing streams are provided a CBD connection & a connection to
CRWS.
 All non HC streams are connected to CRWS.
Pump pedestals, TSV discharges and floor washing are also routed to OWS. Care should be taken
that at no time any spark reaches vapor space of OWS funnels. This may result in an immediate
explosion there or elsewhere in the network where there is an explosive mixture of Air & Hydrocarbon
vapors present in appropriate concentration for explosion.
Contaminated Rainy Water System:
CRWS is similar to OWS and is routed to ETP separately through underground piping. At ETP
provision to connect CRWS and OWS is also provided. The CRWS thus shares the OWS load as and
when necessary. Those effluent streams that contain only traces of Hydrocarbon or are completely
free of oil should be diverted to CRWS.
Storm channel around the plant is an open channel. As storm channel streams leave the plant without
any separation or treatment, free Hydrocarbons should not be allowed to escape in storm channel.
Elaborate arrangement exists to handle oil free effluent of unit. Effluent finally escaping through storm
sewer without any treatment must meet statutory specifications for safe disposal.
3.10 Flare system:
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In the event of abnormal operating conditions/ emergencies, the hydrocarbon operating system may
get pressurized. In order to prevent this pressure from shooting up and crossing design values of
respective system/ equipment and causing accident and / or equipment damage, it may become
necessary to relieve some amount of non condensable hydrocarbon vapors to a system that renders
them harmless. For this purpose, a net work of flare headers is provided for collection of relieved
vapors in the unit to which all relevant equipments are connected. Flare lines are designed for a
pressure of 3.5kg/cm2g and a temperature of 220°C. Flare lines should be tested pneumatically
because of line support considerations. Entry of steam and condensate in flare headers should be
avoided as it may lead to extinguishing of main flare flame and burning rain phenomena etc.
The combined flare header enters flare knock out drum FA41022 for de-entrainment of condensate
droplets. Local instrumentation is provided on FA41022. 03-LI-3201 is provided on flare KOD to
indicate level in the knock out drum. LAH -3208 is provided on the vessel to indicate high condensate
level in the vessel. It will open 03-SDV-3201 on vessel bottom outlet. Similarly, 03-LALL-3207 will
close 03-SDV-3201 and avoid vapor breakthrough in CBD vessel. One isolation valve with a spectacle
blind has been provided on flare header at battery limit of the unit. A 2” fuel gas connection has been
given to the flare header for purging purpose 03-RO -4602 is provided on FG purge line to flare to
maintain and control FG pressure entering flare header. The FG purge is provided in flare header to
prevent vacuum formation due to condensation of condensable hydrocarbons on account of weather
temperature change, chilling etc. and to maintain certain minimum velocity inside flare header.
A 36” flare header serves to collect the pressure relief valve discharges from CDU, VDU & NSU
equipments and certain hydrocarbon service piping. The PSV’s of the following equipments are
connected to the flare header:
Pre-flash vessel FA41001

Preflash vapor KOD FA41051
Atmospheric column reflux drum FA41002
Naphtha splitter reflux drum FA41004
Kero splitter reflux drum FA41005
Stabilizer reflux drum FA41003
Lt. Naphtha Caustic wash vessel FA41015
Lt. Naphtha Water wash vessel FA41016
Spent caustic wash vessel FA41017
Heavy Naphtha Caustic wash vessel FA41018
Heavy Naphtha Water wash vessel FA41019
LPG vaporizer FA41026
ATM distillation column DA41001
Naphtha stabilizer DA41006
Naphtha splitter column DA41007
Kero splitter column DA41008
Vacuum column DA41101
seal pots PSVs By pump vendor
PSV-4501 on 8" FG - 70-2802 A1N.
LPG/amine absorber DA42201
FG/amine absorber DA42202
Sour FG filter FA42202
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Sweet FG filter FA42203

LPG surge drum FA42201
PSV discharge from FG header
FG KOD FA41027
Stabilizer over head condenser EA41002
CHAPTER IV
FUEL GAS/AMINE AND LPG/AMINE SYSTEM
4.1 Fuel Gas Amine Absorber:
Introduction:
The Amine absorption unit is designed to absorb H 2S from Sour gas of CDU, VBU, HCU, Catalytic
Reformer Unit, ISOM and GOHDS unit by using Di-ethanol Amine (DEA) as the absorption medium.
Feed stock characteristics for off-gas to Amine Absorber:
Composition CDU HCU VBU CCR GOHDS Total

H2 0.0 32.86 0.0 19.3 50.55 102.85
C1 15.27 10.66 40.62 2.13 3.58 72.32
C2= 0.0 0.0 2.06 0.0 0.0 2.06
C2 16.38 6.74 19.1 3.3 2.71 48.27
C3= 0.0 0.0 5.44 0.0 0.0 5.45
C3 8.71 18.7 14.26 2.09 1.33 45.15
i-C4= 0.0 0.0 2.4 0.0 0.0 4.08
i-C4 0.0 9.65 3.94 0.68 0.0 12.64
n-C4 2.54 6.61 5.8 1.52 0.0 16.51
C5 plus 0.54 0.04 3.06 6.41 10.76 20.79
N2 0.0 1.14 2.06 0.0 0.0 3.21
H2s 1.27 80.36 15.74 2.27 12.95 112.83
H2o 0.0 0.99 0.84 0.53 0.83 3.15
Kg.mol/h 44.72 167.7 115.3 38.2 82.7 449.36
Kg/hr 1353 5002 3690 941 1460 12446
Nm3/hr 950 3760 2584 858 1854 10006
MW 30.24 29.82 32.0 24.6 17.65 27.85
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Design Basis:
The Amine Absorption unit is designed to handle H2S as following:
FG Absorber 3840 H2S (Kg/hr) and the absorber is designed to give sweet fuel gas containing not more
than 100 vol. PPM H2S and sweet LPG of not more than 100 PPM wt H2S.
Absorbent:
Type of Amine DEA
Concentration 25 Wt % in water
H2S Loading 0.03 mole H 2S / Mole DEA (Lean Amine) and 0.33 Mole H 2S / Mole DEA (Rich
Amine)
Utilities Specifications at Unit Battery limit.
4.2 Process Description:

The fuel gas absorption process consists of three stages ;
(1) Pre-filtration (2) Absorption (3) Post filtration
The off gases from various units enter the battery limit at following conditions ;
Stream Pressure (Kg/cm2g) Temperature °C.
1. HCU off gas 5.5 45
2. VBU off gas 5.5 40
3. CRU off gas 5.5 54
4. CDU off gas 5.5 45
5. GOHDS off gas 5.5 40
Lean Amine is received at a pressure of 7.5 kg/cm2 and a temperature of 45 oC.
Pre Filtration:
The above off gases are cooled in EA 42203, circulating cooling water on tube side, and enter the
sour fuel gas separator FA 42202. The fuel gas flow to the exchanger inlet is indicated by 19FI 1202.
The outlet temperature of the exchanger is measured by 19TI 1203. The sour fuel gas filter separator
consists of cartridges which separate liquid particles in the sour fuel gas. The liquid hydrocarbon
collects in an accumulator and is drained to hydrocarbon closed blow down and it can also be
drained to flare header. The liquid level in the accumulator is measured by 19 LI 1201. In case of
very low liquid level as sensed by 19LSLL1201, the valve19 UV 1201 gets shut off automatically, thus
maintaining a minimum liquid level as seal in the filter separator accumulator. High and low level
annunciation is provided (19LAHH 1201, 19LALL 1201). The filter separator is provided with a
pressure differential transmitter 19 PDI 1201. If the pressure drop across the separator exceeds 0.5
Kg/cm2g the filter separator is bypassed through a 10” bypass line that is provided, till the cartridges
in the filter separator are changed. A safety valve 19 PSV 1201 with set pressure of 7.0 Kg/cm 2g is
provided for the safety of the separator FA 42202. The safety discharge is connected to
hydrocarbon flare header.
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Absorption:
From the sour fuel gas filter separator the gas is routed to the bottom of the fuel gas amine absorber
DA 42202. The FG Amine Absorber is provided with 24 valve trays and a demister pad above the
top tray. The absorber operates at a pressure of 5.0 Kg/cm 2g and a temperature of 45°C. Lean
Amine from Amine regeneration Unit is introduced on the top tray under flow control 19FIC1201. Flow
is measured by19 FI 1201 and controlled by19 FV 1201. H 2S from the sour gas gets absorbed into
DEA and the reaction being exothermic the temperature of DEA solution measures to 57°C. Bottom
temperature is indicated by 19TI 1207 . Differential pressure indicator 19PDI 1202 is provided to
measure the pressure drop across the trays. The column pressure is measured by 19PI 1201 at the
top and is controlled by 19PIC 1201 by manipulating 19PV1201 provided at the outlet of sweet gas
filter separator FA 42203. The rich amine solution containing H 2S flows out of the absorber column
bottom through a level control valve 19LV 1202 to the flash column located in Amine regeneration unit
at 65 m elevation for regeneration. Since minimum level of amine should be maintained in the
absorber bottom to prevent gas breakthrough to low pressure regeneration section, level alarm very
low annunciation is provided 19LSLL 1203. A safety valve 19PSV 1202 with a set pressure of 7.0
Kg/cm2g is provided on the column top and discharge is routed to flare. The absorber DA 42202 is
provided with a vessel SF 42201 at the bottom to skim off hydrocarbon from rich DEA. SF 42201 is
provided with a Level gauge &view glass and hydrocarbons are drained to oily sewer.
Post Filtration:
From the top of the absorber the sweetened fuel gas under absorber pressure control is passed to
sweet fuel gas filter separator FA 42203. The sweet fuel gas filter separator consists of cartridges
which separate any amine entrained in the gas from the absorber. The amine collects in an
accumulator and is drained to amine sump header. The liquid level in the accumulator is measured by
19LT 1203. In case of very low liquid level as sensed by19 LSLL1202, the valve 19UV 1203, gets
shut off automatically, thus maintaining a minimum liquid level as seal in accumulator. High and low
level annunciation is provided 19LSHH 1202, 19LSLL1202. The filter separator is provided with a
pressure differential transmitter 19PDT 1204. If the pressure drop across the filter separator exceeds
0.5 Kg/cm2, the filter separator is bypassed through a 10” bypass line that is provided, till the
cartridges in the filter separator are changed.
A safety valve 19PSV 1203 with a set pressure of 7.0 Kg.cm 2g is provided for safety of the separator
FA42203. The downstream of the PSV is connected to hydrocarbon flare header in CDU. The
sweetened fuel gas flow is measured by 19FT 1203 and is controlled by Amine Absorber top pressure.
The fuel gas ex sweet fuel gas filter separator on pressure control of the amine absorption column is
routed to the 10" FG header to fuel gas knock out drum FA41027. From there it is distributed to the
whole refinery under pressure control .
4.3 LPG Amine Absorber-DA42201:
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The design flow rate shall be 110% of normal flow rate with the same composition considering flexibility
for different sulfur content. Treated LPG shall meet H2S content less than 100wt.ppm.
Lean amine circulation rate shall be determined based on pick up rate of 0.3 mol.H2S/mol .of DEA and
amount of H2S in total sour LPG.
The LPG Amine pre-wash from various units enter the battery limit at following conditions ;
Stream Pressure (Kg/cm2g) Temperature °C.
1. LPG from CDU 15 40
2. LPG from HCU 15 40
SOUR LPG COMPOSITION FROM CDU AND HCU:
Composition CDU HCU TOTAL

H2 0.042 0.03 0.072
C1 1.219 0.17 1.389
C2= 0.0 0.0 0.0
C2 23.76 0.87 24.63
C3= 0.0 0.0 0.0
C3 119.84 11.56 131.4
l-C4= 0.0 0.0 0.0
i.C4 65.455 20.05 85.505
n.C4 134.942 23.8 158.742
i C5 0.676 0.42 1.096
nc5 0.022 0.04 0.062
C6 PLUS 1.013 0.0 1.013
CO 0.0 0.0 0.0
CO2 0.0 0.0 0.0
N2 0.0 0.0 0.0
H2S 0.124 13.04 13.144
H2O 0.704 0.1 0.804
Kg mol/hr 347.797 70.08 417.877
Kg/hr 17800 3567 21367
MW 51.18 50.0 51.13
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Sour LPG from CDU , HCU & CCR is routed to amine absorber for removal of H2S. (Normally CCR
LPG is not routed to amine system). LPG Amine absorber DA42201 consists of 10 sieve trays .
Lean amine from regenerator, is pressurized to 18.8 Kg/cm2g by HP Lean amine pump GA42201A/B
and discharge of GA42201A/B is cooled down to 40°C in EA42201. Heat of absorption is removed in
cooler EA42202, where LPG/Amine mix is cooled to 40°C and fed to column DA42201 on 1 st tray
(blind tray). 19FIC1102 controls the flow of amine to mixer. Balance amine (20%-30%) is read by
19FC1101 routed to column top. Total LPG to column is read by 19FI1103. LPG from the column top
goes to LPG surge drum FA42201. Any amine carry over with LPG shall settle down in this surge
vessel. Column top pressure is indicated by 19PI1101. A PSV 19PSV1101 set at 30.0 kg/cm2g is
provided to prevent the column from over pressurization. From FA42201, LPG is pumped to merox
unit by LPG booster pumps GA42202A/B. Rich amine from column bottom is routed to regeneration
section under level control 19LIC1101. Level switch 19LSLL1102 is given to close 19UV1101 on low
level of DA42201. A pressure switch 19PSL1101 is provided in the discharge of GA42202A/B to start
stand by pump on auto. On actuation of 19PSLL/FSLL 1101 the pump will get tripped. From
GA42202A/B a slip stream is taken to LPG vaporizer FA41026 to be used when FG is not available. A
provision is made to treat off spec LPG from OM&S in LPG amine absorber. For this LPG line from
OM&S is connected to LPG line from CCR at CDU battery limit.
CHAPTER V
START UP
5.1 Introduction:
The most critical periods in plant operation are those of Start up and Shut down. It is then that
hazardous possibilities for fire and explosion are highest. The hazards normally encountered in start
up and shutdown of units are accidental mixing of air and hydrocarbons and contacting of water with
hot oil. Other hazards primarily associated with start ups are thermal pressure and mechanical
shocks. These can result in fires, explosions, destructive pressure surges and other damage to unit
as well as injury to personnel.
The steps outlined in this section should be strictly followed.
General Instructions:
Preparation for start up of the unit begins with a complete review of the start-up procedures by the
operating crew. Checklists should be made indicating each step that is to be performed. The
communication between personnel of one shift and next shift must clearly establish what has been
done in prior shifts and what is expected of them in the working hours.
Preparation of the unit:
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Prior to actual commissioning of the plant, it should be established that all preparatory works have
been successfully completed and all instrument / equipment are ready to function.
The following checks have to be made ;
 Check all equipments for mechanical completion.
 Check that all blinds are installed as per master blind list.
 All instruments should be in position and calibrated simulations are also to be checked.
 All electrical equipments should be available for start up.
 All fire fighting equipments like fire extinguishers, steam hoses, fire blankets, sprinkler system etc,
should be ready.
 All utilities have been commissioned.
 Fuel oil and fuel gas blinds are removed and both headers charged.
 All safety valves are in position after setting lock open position.
 Flare, CBD, OWS ,CRWS and FLO systems are in operable conditions.
 Area should be clear of debris, scrap material etc.
 Keep all transmitters orifice plates and gauges isolated.
 Inform all related agencies about start up
1. Power Plant 2. OM&S / Effluent TP 3. Fire station 4. Laboratory
5. Other down stream plants.
5.2 Start-Up Procedure:

Note : The unit is water flushed after mechanical completion
The Start up of the units involve the following consecutive main steps
 Pressure test the loops
 Tightness testing under steam pressure
 Elimination of air.
 Backing in fuel gas
 Cold oil circulation.
 Hot oil circulation
 Bringing the Unit on stream.
Pressure test of various systems:

After thorough flushing of the loops ,Pressure test to be carried with fire water which is at 10.0 kg/cm2
pressure. All product loops ,CR loops and IR loops to be tested at 10.0kg/cm2 pressure by connecting
the fire hydrant at the pump suction up to the last isolation valve .
 Line up all the isolation valves and bypass valves of exchangers.
 Isolate the pump suction valve
 Connect the fire hydrant at the pump suction strainer flange .
 Spade the last isolation valve up stream flange.
 For Atmospheric CR loops pressurize up to duty control valve. Control valve bypass to be spaded.
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 For product loops pressurize the system up to battery limit valve.

 Pressure test to be carried for feed charge loop from the GA41001 suction to battery limit. Preheat train
-1 loop up to desalter inlet can be included while testing this loop.
 Preheat train -2 from GA41003 suction to LV1301 .
 Preheat train-3 from GA41002 suction to Pass flow control valves.
 Vac. CR's & IR's loops to be tested up to filter down stream valves.
 Desalter 1&2 to be tested with plant air at 6kg/cm2g
 All vessels to be tested with plant air
 Lean amine system can be tested with fire water from the battery limit to flow control valve.
 HP lean amine system to be pressurized from the pump suction to 19FV1101 & EA42202 d/s isolation
valve.
 DA42201 & DA42202 to be tested with plant air.
 Gas service line can be tested with plant air & with soap solution after cardboard blasting.
 Pressurize all the systems and hold it for 30 minutes. Check all the flanges for any leak and watch the
pressure; if any leak is found rectify the leak.
Tightness, vacuum test and heater refractory dry out will form part of pre-commissioning activities for
the first start up. For subsequent start ups the tightness test and vacuum test can be done in
conjunction with the step of elimination of air.
Tightness test to prevent leakage:
For leak testing/ tightness test, ensure that all piping and equipment vents and drains are closed.
Pressurize the system upto 1.0kg/cm 2g with LP steam or air and check for any leak through the flanges
/ instruments. Usually for a very big system, pressurization by steam for tightness test proves
convenient except the system in vacuum service such as VDU. Limitations posed by design pressure/
design temperature should be strictly adhered.
The leakage identification is normally done visually when steam is used and by soap bubble test when
air is used. Liquid soap solution may be sprayed/ poured on all the joints one by one and checked for
any bubble formation. If a bubble is formed on joint or flange, there is an air leakage. Leaks are to be
attended after depressurizing. Big leaks can also be identified by pressure drop indication. In view of
large no. of joints requiring leak test by soap solution, it is suggested that only those system should
be taken up for tightness test by air which should not be subjected to steaming or are likely to get
exposed to vacuum during vacuum test and normal operation.
Tightness of other systems may be done along with steam purging and pressurizing by steam. Thus
tightness test by air and steam purging / tightness test by steam can be carried out almost parallel,
depending on availability of manpower and ease of monitoring.
Removal of Air from the process systems:

Elimination of air:
The idea of steaming is to remove air from the system before admitting hydrocarbons. Generally, as
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per refinery standard the oxygen content should be less than 1% before admitting hydrocarbons in the
system.
The following precautions are to be taken before introducing steam.
(I) Ensure that all coolers and condensers are isolated and water is drained from them.
Equipment No. Description

EA 41001 A/B Atm. Over head condenser
EA 41002 A/B Stabilizer Overhead Condenser
EA 41004 A/B Light Naphtha Cooler
EA41050A/B KSU overhead product cooler
EA41070A/B KSU overhead cooler
EA41071 MN cooler
EA 41007 Heavy naphtha side cut product cooler
EA41008A/B Kerosene /ATF product Cooler
EA41050 KSU overhead product cooler
EA41009 Lt. Gas Oil product Cooler
EA41010 HGO Oil product cooler
EA41042 Naphtha splitter bottom product cooler
EA41057 Brine cooler
EA41108A/B VDO product cooler
EA 41111 Ejector first stage inter condenser
EA 41112 Ejector second stage inter condenser
EA 41113 Ejector third stage after condenser
EA 41040 HGO (Tempered Water) cooler
EA 41041 LGO (Tempered water) cooler
EA 41101 VDO CR (Tempered water) cooler
EA 41102 VDO product (Tempered water) Cooler
EA41103 HVGO (Tempered water) cooler
EA41104 LVGO (Tempered water) cooler
EA41105 Vac. Slop (Tempered water) cooler
EA41007 LVGO (Tempered water) cooler
EA41009A/B VR (Tempered water) cooler
(II) The following Fin fan coolers are electrically locked out and tagged at substation.
EC 41001 A to P Atm. column Overhead air cooler condenser

EC 41002 A to H Naphtha splitter over head air cooler
EC41004 LGO product air cooler
EC41005 HGO product air cooler
EC41006 Kero/ATF product air cooler
EC41007 Naphtha splitter bottom product air cooler
EC41008 A/B KSU overhead air cooler
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EC41012 Heavy Naphtha side cut product air cooler

EC41009 A/B/C/D Tempered water main circ. air coolers
EC41010 A/B Tempered water aux. circ. air coolers
EC41101 A/B VDO CR air cooler
Air from various equipment, piping etc., is eliminated by steaming. Steaming of various sections of the
unit to expel air can be carried-out simultaneously or in a convenient sequence.
The following basic points should be taken care during steaming of the equipment / systems.
 Cooling water to the condensers and product coolers to be isolated and water should be drained
out from the condensers, coolers etc.
 Keep water side vents and drains of condensers/ coolers opened.
 Keep instrument tapping like, PT, FT etc., isolated from main process piping.
 Electric supply to the desalter should remain cut off.
 Over head and product fin fans motors should be switched off.
 All exchangers and control valves bypass should be open in the system.
 All column & vessels PSV up stream bleeders should be open condition
For purpose of air removal, unit is divided into following sections:
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 Crude preheat system, desalter and crude pre-flash drum.

 Atmospheric heater, atmospheric column, overhead system and circulating reflux systems.
 Stabilizer and its overhead system.
 NSU heater, Naphtha splitter, Kero / ATF splitter and related circuits.
 Caustic wash system.
 Vacuum column and overhead circuit.
 All product and slop circuits inside unit battery limit.
LP steam connections are given at appropriate places on piping and equipment to introduce LP steam
in above sections. Before introducing steam, water to all coolers and condensers should be isolated
and drained. This is to avoid condensation of steam in large quantity in these equipment due to flow
of cooling media, ie: cooling water. It may lead to frequent hammering in unit equipment. LP steam
from hose stations can also be used to boost up external steam supply. Initially there may be
condensation of steam inside unit equipment due to cold equipment internals.
In such conditions, LP steam supply may need augmentation of small quantity of MP steam through
heater pass flows and other available points. Care should be exercised while using MP steam for
steaming to ensure that none of equipment is subjected to operating conditions exceeding their design
parameters. The low point drains of pipes and equipment should be kept open to remove condensate.
During initial steaming, line rust etc may frequently keep coming and choking of drains may be rather
frequent. Special care should be taken to ensure that none of the drain points are choked due to
accumulation of foreign material. High point vents should also be opened for air removal. Once
system warms up, less and less steam will condense in the system and few steam points may be
pinched. Steaming is done till clear steam starts coming out from all vents. Clear steam venting for
at least four hours shall be an indication of fairly good air removal. Excessively high steaming rate
may dislodge column internals and cause damage. Hence it is a good practice to keep a watch on
steam consumption during steaming.
No steam condensate should be allowed to get accumulated inside unit equipment. Vigorous steam
venting from various points of the unit as described below, will be continued for about four hours. It is
expected that oxygen will be eliminated at the end of this period. Samples may be checked from
different locations to ensure that O 2 content is less than 1%. During the period of steaming, systems
should also be checked for leakage. Attend the leaks by depressurizing the system. Retest and
purge as applicable. When sufficient steam comes out from all the vents and drains, reduce steam
inlet to maintain positive pressure.
Following major points may be followed for steaming out of the unit:
Steaming out procedure for crude inlet line from battery to crude charge pump
suction:
Admit steam into the feed system by connecting temporary hoses to the crude oil feed line at the
battery limit of unit. Open steam slowly into the system and allow piping and equipment to gradually
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warm up. Drain condensate frequently from low points. Steaming should be done upto crude charge
pump suction.
Crude preheat train-1, Desalters, Preheat train-2, Preflash drum, Preheat train-3 ,
CDU Heater, CDU column & over head system, Product strippers up to product
pump suction and CR loops:
1. Introduce steam into preheat train I using 4" MP steam line located at downstream of crude charge pump.
Keep watch on desalter pressure which should be maintained around 0.5kg/cm2g. If necessary, throttle
steam. Steam purge desalter safety valve inlet lines also. Open the upstream bleeders of desalter PSVs.
Air should be completely purged out from both inlet and outlet lines of each safety valve (outlet line
steaming to be done from column side). Desalter water circuit should not be included for steaming out.
However lines upto mixing valves, and chemical injection lines upto first isolation valve from desalter should
be included for steaming. Allow steam to vent from desalter top and other high point vents.
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2. Line up atmospheric column overhead condensers, and atmospheric column reflux drum with the column.
Ensure cooling water to condensers is isolated and water is drained out. Open vents of overhead naphtha
reflux drum and crude column. Line up heavy naphtha, Kero, LGO & HGO strippers and product circuits,
and circulating reflux circuits upto the respective pump suctions . Keep open pump suction and close
discharge valves . keep open pump common suction drain valve and casing drain valves ,casing vent valves.
Introduce LP steam in the circuit from permanent steam connections as well as steam hoses at a controlled
rate to warm up the system. Slowly introduce atm. column stripping steam and also stripper stripping steam
if required.
3. Slowly also open some MP steam into all the passes of atmospheric heater coils through emergency steam
connections (provided at downstream of pass flow control valves).MP steam is used as augmenting stream
to adequately carryout steam out. Too high a flow rate of steam may dislodge the column internals and
damage them.
4. Vigorously steam for at least four hours and then throttle crude column vent. Allow steam to vent from
atmospheric column reflux drum.
5. Maintain 1.0 - 1.5 kg/cm 2g pressure in column flash zone by regulating the quantity of steam being
introduced into the system. During this time leak test can be carried, if any leak is found it can be tightened
after depressurizing.
6. Drain condensate from low points and allow system to warm up. Regulate the steam flow to heat up the
system gradually.
7. Continue purging till steam comes out from the top of the crude column, crude column reflux drum and side
stripper vent connections. For steaming out Heavy Naphtha and kero side strippers, back-up steam from
crude column and vent through 2" vent of stripper column. Or alternatively, connect steam hose to the 2"
utility connection in these strippers. Release condensate through pump casing drains & pump common
suction drains., where ever applicable.
8. Back up steam from atm. Column to pre-flash vessel through pre-flash vapor line and from pre-flash vessel
to preheat train II. LP steam from hose stations can also be connected in desalted crude pump discharge
circuit and also connected at pre-flash vessel utility connecting point to boost up external steam supply.
Back steam from atm., furnace to preheat train III. Increase atmosphere column pressure slightly if
required. LP steam from hose stations can also be connected to pre-flashed crude pump discharge to
augment external steam supply. Open all bleeders of control valve to drain condensate. Line up all CR loops
duty control valve downstream isolation valve & upstream isolation valve so that steaming can be carried up
to CR pump discharge isolation valve. Line up the downstream isolation valves of the control valves,
FV1705&FV1706, on the minimum flow lines of Kero pump & LGO pump.
Steam out for naphtha stabilizer, Kero splitter & naphtha splitter:
Line up stabilizer overhead condenser and reflux drum to stabilizer column. Open vent valves of
stabilizer column and its reflux drum, and other high point vents in piping. Close the cooling water to
stabilizer over head condenser and drain water. De-blind utility LP steam connection at the stabilizer
column bottom. Admit steam slowly by connecting a steam hose. Drain condensate from low points and
allow the system to warm up.
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1. When steam comes out from stabilizer top vigorously steam for about half an hour. Then throttle this
vent and allow steam to come out of reflux drum vent. Connect steam hose to utility point of reflux drum.
This is to boost up the steaming.
2. Maintain stabilizer column pressure at 1.0 - 1.5 kg/cm2g by regulating the quantity of steam. Open the
pressure control valve and globe valve on its bypass line. Steam for about half an hour then shut off the
control valve and the globe valve mentioned above.
3. Back up steam into the reflux line and vent from the bleeder valve up stream of flow control valve.
4. Back up steam to FG line from reflux drum to amine absorber up to pressure control valve up stream.
5. Purge feed line by backing up steam from stabilizer column and vent from the bleeder valve, upstream of
feed control valve. LP steam should be backed in stabilizer feed line upto NRV by connecting a
temporary steam hose connection at conveniently available low point and by bypassing minimum flow
control valve of stabilizer feed pump. Purge stabilizer bottom outlet circuit.
6. Line up Kero splitter overhead condenser and reflux drum to splitter column. Open vent valves of splitter
column and its reflux drum, and other high point vents in piping. De-blind utility LP steam connection
at the KSU column bottom. Admit LP steam into splitter slowly. Drain condensate from low points and
allow the system to warm up. Open coil steam to coils to boost up the steaming in the splitter &
stabilizer. Care should be taken while opening coil steam as it is MP steam.
7. When steam comes out from splitter top vigorously steam for about half an hour. Then throttle this vent
and allow steam to come out of reflux drum vent. Connect steam hose to utility point of reflux drum. This
is to boost up the steaming.
8. Maintain splitter column pressure at 1.0 - 1.5 kg/cm 2g by regulating the quantity of steam. Open the
pressure control valve and globe valve on its bypass line. Steam for about half an hour then minimize
the opening of the control valve and the globe valve mentioned above.
9. Back up steam into the reflux line and vent from the bleeder valve upstream of flow control valve.
10. Purge feed line by backing up steam from KSU column and vent from the bleeder valve, upstream of
feed control valve. Purge kero splitter bottom outlet circuit also.
11. Line up naphtha splitter overhead condenser and reflux drum to splitter column. Open vent valves of
splitter column and its reflux drum, and other high point vents in piping. De-blind utility LP steam
connection at the splitter column bottom. Admit LP steam into splitter slowly. Drain condensate from
low points and allow the system to warm up. Open coil steam to coils to boost up the steaming in the
splitter & stabilizer. Care should be taken while opening coil steam as it is MP steam.
12. When steam comes out from splitter top vigorously steam for about half an hour. Then throttle this vent
and allow steam to come out of reflux drum vent. Connect steam hose to utility point of reflux drum. This
is to boost up the steaming.
13. Maintain splitter column pressure at 1.0 - 1.5 kg/cm2g by regulating the quantity of steam. Open the
pressure control valve and globe valve on its bypass line. Steam for about half an hour then minimize the
opening of the control valve and the globe valve mentioned above.
14. Back up steam in MN drum.
15. Back up steam into the reflux line and vent from the bleeder valve upstream of flow control valve.
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16. Purge feed line by backing up steam from splitter column and vent from the bleeder valve, upstream of
feed control valve. Purge naphtha splitter bottom outlet circuit also upto battery limit.
17. Purge all product and pump around / circulating reflux circuits by backing up steam from respective
column. Steam the product circuit up to battery limit and vent through sample points or any convenient
low point drains. It may be necessary to augment steam supply at the discharge of product pump by
connecting temporary hoses to vent or drain points in the lines. Battery limit valve flange may be wedge
opened for good steaming. Box up the flange under slight steam pressure.
18. Excessive condensation of steam in cold circuits and problems of removing steam condensate from
heater coils, in particular may cause hammering during steaming. In such cases, it may become
necessary to fire the heater at the time of steaming itself for evaporating water. Commission flare
header and fuel gas header to furnace after removing battery limit blind. Fire the heater at a small rate.
Heater is fired to avoid condensation in tubes and subsequent hammering when steam is introduced in
cold tubes. Maintain fire box temperature at about 250°C. Pilot burners will be lighted initially. Main
burners can be lighted afterwards, if required. Keep open the vents at crude column top and reflux drum.
Steaming out the vacuum column and its associated system for leak test:
1. Close the cooling water to ejector condensers. Drain the water and keep drain open.
2. Line up the process side valves of all ejectors.
3. Close the discharge valves of GA41101, GA41102, GA41103, GA41104, GA41105, GA41106, GA41107
and GA41108 and keep open the suction valves and casing vent valves.
4. Keep open common suction drains and also pump casing drains.
5. Keep open hot well off gas KOD drain and hot well to CDU heater isolation valves upstream flanges to
be wedged open.
6. Keep open the downstream valves of all CR &IR filters (column side) and open filter drain.
7. Close the pass flow control valves and also close the upstream isolation valve.
8. Note :- RCO from GA41014 discharge to pass flow control valve would already be steamed out or it can
be included now (including VR product loop).
9. Open vacuum column top vent. Open top vent of FA41112.
10. Light vac. heater with pilots.
11. Open stripping steam to vacuum column. Slowly pressurize the column.
12. Increase the box temperature to 150°C before introducing coil steam. This is to avoid hammering while
introducing coil steam. Open emergency steam to coils very slowly.
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13. Throttle all drains & vents and pressurize the system up to 2.0 kg/cm2g .
14. Check all flanges for leaks. If any leak is there attend it immediately.
15. After getting full steam everywhere slowly reduce steam. Care should be taken while reducing steam.
Vacuum Test :
Air can be eliminated during vacuum pulling from downstream of vacuum heater pass flow control
valves up to vacuum column, hot well and the product circuit piping up to pump suction isolation valves.
1. Commission cooling water to all ejector condensers EA41111/12/13.

2. Ensure normal level in hot well & that the vent is closed. Ensure that hot well seal compartments are
filled with water & the water seal is maintained. Ensure that all dip legs in hot well are sealed in water.
3. Isolate the suction valves and the vent valves of the vacuum column product pumps, hot well overflow
seal line and hot well vent to furnace to achieve perfect sealing of vacuum system from atmospheric
section. Water in hot well seal overflow may be filled.
4. Isolate all CR & IR filters d/s isolation valves.
5. Commission MP steam to ejectors. Commission one of the third stage ejectors, to be followed by
second stage ejector and then by first stage ejector. Slowly start pulling vacuum in the vacuum column
and connected systems up to 5 -7 mm mercury column by operating ejectors. Vacuum pulling should
be done slowly. PIC-2501 may be used for this.
6. Air will be gradually sucked out from the system that would comprise transfer line (downstream of
BA41101 pass flow control valves), vacuum column and all product / CR draw off lines. It is to be noted
that hot well shall not be under vacuum. All other equipment including pumps, exchangers etc., may be
kept isolated.
7. Watch pressure in the system. Gradually lower the pressure to the maximum possible. When there is
no further lowering of pressure, block off the system and hold under such condition and check for
vacuum holding. Isolate the ejector inlet and outlets. Shut off steam. Isolate PV-2501.
8. Initially there may be rapid drop during the process of blocking off. If the rate of fall of vacuum does
not exceed 0.013kg/cm2g per hour (approximately 10mmHg per hour), the system is assumed fairly
tight. Otherwise thorough leak checking has to be carried out by pressurizing the system to about
1kg/cm2g with air and applying soap solution on every joint or pressurize the system with steam up to
1.5 kg/cm2g and check all the connected flanges for leak.
9. If pressure testing is carried out rigorously, the vacuum testing is expected to be satisfactory for
vacuum column and its connecting piping and equipment. Please check equipment / piping design
conditions before including in vacuum test.
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10. Steam out RCO circuit and all VDU product circuits up to isolation valve at the battery limit. Elimination
of air in VR circuit up to OM&S can be done by steaming and after that it will be filled with flushing oil.
Air elimination from product run down circuits in off sites should be done by filling water in the line and
displacing the same by products when the same are available except for water sensitive products like
ATF & products like VR whose rundown temp, is high. Air elimination from water circuits and chemical
dosing circuits need not be carried out except up to first isolation valve where these lines may be
subjected to hydrocarbons. At fag end of steaming, just before fuel gas back up, all pumps may be
included for steaming for a short duration and air elimination.
Backing in Fuel gas to Prevent Air ingress:
Air from all the hydrocarbon systems must be removed thoroughly before proceeding for fuel gas back
up. During first start up, LPG should be vaporized and used as a source of fuel gas. Suitable temporary
modifications may have to be carried out. During LPG vaporization, care should be taken to avoid
freezing of water in the circuit due to pressure let down of LPG. Before backing in fuel gas into the
system, flare header inside the unit should be commissioned and flare should be activated. Fuel gas
purge to flare header should be established. Fuel gas into furnace fuel piping should be charged at this
stage, only if proper monitoring is available. Cooling water circulation is started through all coolers and
condensers. Purpose of fuel gas backing into the system is to drain steam condensate from unit
equipment as well as replace steam with fuel gas. In the absence of fuel gas, condensation of steam
may result in vacuum formation inside unit equipment; most of which may not be designed for such full
vacuum or part vacuum conditions.
Steam in the system is cut-off slowly and fuel gas is backed in. Cutting off steam results in
condensation of steam inside unit equipment due to heat loss from bare piping and equipment
surfaces. Fuel gas can be backed from separate headers into atmospheric column, stabilizer,
naphtha splitter and vacuum column. It is advisable to back in fuel gas section wise. This helps in
better monitoring of operation and avoids excessive withdrawal of fuel gas from FG pool. Adjust gas
backing rate in such a way that fuel gas system is not disturbed resulting in low fuel gas pressure due
to excessive withdrawal during this operation. Pressure surges during fuel gas backing should be
avoided. Ensure that all vents are closed and properly capped just before FG backup.
Gas backing in vacuum section:

Vacuum in the vacuum circuit is broken by the entry of fuel gas in the vacuum column overhead circuit
through 2" fuel gas line for start up (joining the column overhead line to ejectors.) Slowly admit fuel gas
to break the vacuum. In vacuum section, fuel gas pressure of 0.5kg/cm2 can be maintained.
Hot well vents and overflow line shall be isolated and water seals shall be maintained in hot well. Care
should be taken to ensure that fuel gas does not enter ejector steam network. Isolate the liquid seal at
the hot well during fuel gas backing. Valves in hot well vent, drain and overflow line are to be closed.
Maintain positive pressure in the system at 0.5kg/cm 2g by regulating the fuel gas inlet valve or by
opening the vent to atmosphere on the hot well. Open the low point drain one by one and drain out
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condensate completely. Check list to be prepared to ensure that all drains are made free of condensate.
A log should be kept for drain check showing the time of check, absence of condensate and initials of
the person who made the final check on the drain. Each drain must be closed as soon as gas issues
from it. Back up gas from column to all circulating reflux circuits, internal reflux circuits and to VR pump
discharge through start up line (2"-P-02-1236-B1F) connecting VR pump discharge to vacuum furnace
feed line. Back up gas from column to all the product run-down lines through internal and circulating
reflux lines from the column.
Drain out water from the following points:

 Transfer line
 Pump around and reflux lines.
 All product circuits up to battery limit.
 Quench line through control valve bleeders.
 All pumps, exchangers and coolers.
Repeat draining operation every half an hour till no more condensate is drained. Maintain the whole
system at 0.5 kg/cm 2g fuel gas pressure. Ensure all vents are closed and capped off. Shut all drain
points and cap off. After all the sections have been floated on fuel gas, water is drained from low point
drains. Positive pressure in the system will facilitate draining residual water. Removal of water from the
system is an important step for smooth start up.
Gas backing in atmospheric section/stabilizer/splitter:
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Before admitting fuel gas into the system, all vents in the hydrocarbon system will be closed and drains
in the system will be throttled. Steam entering the system is throttled slowly. Furnace fires are cut off.
Cooling water is commissioned to the overhead condensers and coolers and air coolers started.
Proper care should be taken during gas backing to ensure that vacuum does not form in the system
due to condensation of steam.
As the system cools, condensate will accumulate. The drain at each low point is opened and the
condensate is drained. Never leave open drains unattended. Each drain which is opened and
checked, should be listed in the startup procedure. A log should be kept for draining activities showing
the time of check and absence of condensate. Each drain must be closed as soon as gas issues out
from it. When the draining is complete, the system is ready to take crude oil.
Major steps for fuel gas backing into the systems are as under:
 Reduce steam to the various points in all the columns, furnace coils and at points receiving steam
through temporary hoses. Close all drains and vents except any one vent at a convenient point to
approach and operate for venting steam to maintain system pressure.
 Close all the vents one by one. Adjust steam inlet rate to maintain system pressure about
0.5kg/cm2g. Cap off all vents properly to avoid leakage of gas through these points. Throttle the
drain valves to allow only condensate to flow to keep the system hot. Keep watch on the system
pressure. Adjust steam inlet if necessary.
 Open the pressure control valve on FG line to atmospheric column reflux drum and the isolation
valves on the fuel gas lines to stabilizer reflux drum, naphtha splitter reflux drum and Kero/ ATF
splitter reflux drum. Excess FG pressure may be released to flare as and when required by
operating the control valve to flare.
 Maintain the pressure in the system around 0.5 - 1.0 kg/cm 2g.
Cold oil circulation for removal of water:
The purpose of cold oil circulation is further removal of water from piping network and bottom of
equipment which could not be removed during water draining after fuel gas back up. Cold oil carries
liquid water into low points of the circuit. During circulation drains at low points must be opened
frequently to ensure that no more free water is drained. The circulation rate must be sufficiently high to
sweep the water and not merely flow over it. All plugged drains must be cleared for draining during
circulation. While draining water, unnecessary loss of oil to OWS should be avoided for reasons of
safety and economy. Normally one hour of settling time is allowed after every four hours of circulation.
Settling time may be reduced progressively at advanced stages of coil circulation. Cold oil circulation
gives further opportunity of trying out various pumps and control systems prior to increase in
temperature in sequence of start up. All instruments should be commissioned during cold crude oil
circulation. It should be ensured that flow rate during cold circulation remains well above minimum
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continuous flow through various pumps involved, as suggested by pump vendors. Similarly flow
through control valve should be maintained above minimum flow stipulated in control valve data sheets
to avoid possible chattering.
Crude Distillation Unit:
For crude distillation unit, crude oil is used for cold oil circulation.
Following major points may be followed for cold circulation in the CDU section:
Receiving Crude in the unit:
Crude tank that will feed the unit, will be prepared in advance by thorough draining of water. Sample
will be analyzed and dips will be taken. It will then be lined up to the unit. Open suction valves of
OM&S crude transfer pumps and crude charge pumps GA41001A/B/C. Slowly charge crude from the
crude tanks. Crude will begin to flow under gravity into the line and displace air. This air is vented out
from the crude pump vents and other high points vents of piping in OM&S between crude tank outlet
and crude pump suction. In subsequent start ups this operation may not be required, as OM&S crude
line up to the battery limit will always remain full of hydrocarbon.
Make sure that electrical supply to desalters is cut off. Open the discharge valve of crude charge
pump and allow the crude to flow to the desalters. Alternatively, desalters can be kept filled with gas
and oil bypassed. Desalters shall be commissioned separately. Fill the circuit up to crude pre-flash
drum via crude preheat trains and desalted crude pumps.
When flow of crude oil in OM&S piping is no longer possible under gravity, start OM&S crude transfer
pump, crude charge pump, desalted crude pump and then crude pre-flash pump. Continue charging
crude oil at a slow rate to atmospheric column bottom via atmospheric heater. Regulate the crude
flow through heater coil in such a way that crude flow to unit records about 350-400M3/hr (about 50%
of normal throughput or turn down ratio of the unit). Also divide the flow equally through all crude
preheat exchanger trains by operating respective FV & HV.
Release displaced fuel gas into the flare from atmospheric column reflux drum, and do not exceed
column pressure of 1.0kg/cm2g. Operating all the pumps above their respective minimum continuous
flows is essential. If desalters are included in circulation, carefully operate desalter (second stage)
pressure controller PIC-1202 on manual and build up a pressure of 8.0 to 9.0kg/cm2g in the second
stage desalter outlet line.
Establishing cold circulation:
Before establishing cold oil circulation line up the refinery flushing oil header and fill up the light
flushing oil tank FA41033. After getting sufficient level start Lt. Flushing oil pump and adjust the
pressure to 12-14.0 kg/cm2g by operating PV4801. Open flushing oil to individual pumps when
required. Open flushing oil to heavy flushing oil drum FA41113 and fill it. After getting sufficient level
start Heavy Flushing oil pump and adjust the pressure to 12-14.0 kg/cm2g by operating PV4803. Open
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flushing oil to individual pumps when required. Once level in the crude column has been built up,
establish cold oil circulation from crude charge pump – PHT1 - desalter – PHT2 - prefalsh – PHT3 -
CDU heater – CDU column – VDU heater – VDU column – battery limit manifold to Crude pump suction
for cold oil circulation in atmospheric section. Maintain circulation rate of 350-400 m 3/hr.
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Stabilize the second stage desalter pressure at around 9.5 - 11.5kg/cm 2g and put PIC-1202 on auto.
Observe the performance of all control valves in the circuit. Crude oil will gradually displace fuel gas
and build up level in crude column. Crude oil passes through crude preheat train I, desalters, crude
preheat train II, pre-flash vessel, crude preheat train III, atmospheric furnace and then to atmospheric
column bottom. Activate all control valves and exchanger bypasses. Reduced Crude Oil (RCO) pumps
take suction atmospheric column bottom. When sufficient level has built up in the column bottom, start
RCO pump.
The discharge of RCO pump can be lined up to either of the following two destinations:
 To vacuum furnace for VDU operation
 To VR + Quench circuit through discharge of VR pumps.
During crude circulation, lines towards vacuum furnace and VR quench remain closed. RCO pump
discharge bypasses the vacuum heater and flows through VR product run down circuit to the unit slop
header. From the combined slop header crude flows back to crude charge pump suction through start
up circulation line. The cold crude oil circulation is thereby established. The cold circulation should be
continued for at least 6 - 8 hours to displace free water. Ensure that there is no flow of crude oil to
vacuum furnace. Excess levels in the vessels due to flushing oil injection to be bled to a specified tank
(either slop tank through slop header or 35 series tanks through cold VR line).
Keep the crude feed tanks floating with crude oil pump suction. Keep watch on crude column level and
maintain it around 50% by adjusting the RCO pump discharge flow rate. Crude stream flow can be
controlled by manipulating flow and level control valves of the cold oil circulation circuit. Maintain crude
column top pressure between 0.5 and 1.0kg/cm 2g during cold circulation. By operating PIC-1601
(DA41001 top pressure controller) column top pressure can be maintained at a desired value.
Displaced FG will be released to flare from the reflux drum. Desalters and a few heat exchangers can
be bypassed during initial commissioning. Activate exchanger by passes and control valve bypasses
to displace free water trapped in these sections.
After establishing and maintaining cold crude oil circulation for 4-6hrs., stop all running pumps and
allow settling for 2-4 hours. Drain water from all the low points in the system including column and
exchangers. Restart cold crude circulation. Repeat the operation till the system is free of water. This
operation of circulation, settling and draining will be repeated till no further water separates out. A
check for water content of circulating crude oil is an useful information.
The above description was for short loop circulation.

For the case of long loop circulation RCO pump discharge is routed to vacuum column through
vacuum heater. Once sufficient level builds up in the vacuum column GA41106 is started. The
discharge of GA41106 is routed through cold VR line and slop header to crude charge pump suction.
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Vacuum Distillation Unit:
In vacuum column all the beds will be circulated with gas oil or flushing oil. Take flushing oil in each
bed by opening flushing oil to respective pump suction. Fill up the beds to adequate levels. Start the
pumps. Establish CR's at low rates. Establish IR's at low rates. Ensure adequate suction to pumps.
After 30 minutes stop IR's. Take flushing oil to vac. slop drum by opening flushing oil to GA41104
suction and establish closed circulation. Levels in LVGO, HVGO & vacuum slop sections can also built
through IR systems of vacuum diesel, LVGO & HVGO respectively.
During circulation activate exchanger bypasses and control valve bypasses to remove gas pockets.
Line up all instruments. Sometimes larger flows may be required through individual control valves to
clear plugging or establish thorough circulation. The purpose of establishing cold gas oil circulation in
CR circuits is to prove pumps and control valves in CR services and remove stagnated water. After 3-4
hrs stop circulation of all beds . Allow sufficient settling time. Difference in densities of gas oil and
water helps in settling of the latter at a fast rate without apprehension of emulsification. Drain the
condensate from the lowest points. After draining start circulation again by running stand by pumps
this time. Circulation of VDU should be started simultaneously with that of CDU to delay in unit
stabilization.
VR pump discharge can flow to the following locations:

 To VR + Quench rundown.
 To the top of vacuum column through a start-up connection on vacuum diesel CR line, downstream
of 04-FV-2401.
 To vacuum heater through the start up circulation line.
For establishing circulation VR + Quench circuit should be kept isolated. Crude oil is pumped by the
VR pumps to the vacuum heater through the start up circulation line. The heater coil outlet flows to
vacuum column bottom. This circulation path is also called short circulation. Establish oil flow at a rate
of 35.0 - 40.0 m3/hr per pass through vacuum furnace , keeping all vacuum heater pass flow controls
on manual.
Proper assessment should be made in advance regarding gas oil quantity that will be required for
filling of pipelines and equipment in VDU before actual commencement of gas oil circulation. The
vacuum column is maintained at 0.5 kg/cm2g pressure during cold circulation. Release the excess gas
to flare through column vent if column top pressure goes beyond 1.0 kg/cm 2g
Kero Splitter/ Naphtha splitter/ Naphtha stabilizer units:
These units shall be kept condensate free under fuel gas pressure till required lighter streams are
available from operation of CDU .
Hot Oil Circulation:
Line up the CDU & VDU for hot circulation as given below.
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Atmospheric section:
CDU commissioning can be accomplished by completing the following steps once cold circulation has
been established and units are ready for hot circulation:
 Firing the Heater
 Raising temperature to 120°c
 Raising temperature to 250°c
 Raising temperature to required COT
 Commissioning of Desalter
 Commissioning of NSU
 Commissioning of KSU
Firing the heater:
When cold circulation has been well established and water in the atmospheric system has been
thoroughly drained out, BA41001 firing will be done as per procedure spelt out in heater operating
manual.
Following to be ensured again which pertains primarily to commissioning of utilities, and proper lining
up of unit before firing the heater.
a. Cooling water flow is established in all product / overhead coolers/ condensers. Cooling water flow to
overhead coolers/ condensers should be done gradually to avoid sudden condensation of fuel gas
leading to subsequent depressurization of column/ strippers etc. Fuel gas purge to be augmented if
required.
b. Before warming up the stand by pump of any hot service through the 3/4" warm-up line across NRV
of stand by pump, it is to be ensured that suction valve of stand by pump is kept crack open or fully
open. This is to avoid pressurization of the pump and its suction line to the discharge pressure of
running pump. This operation ensures flow of hot fluid back to pump suction, thus attaining good
warm up of pump body.
c. Set level controllers of HN, Kero, LGO & HGO strippers in auto mode. Check that the level control
valves remain open as there is no level in the strippers.
d. All safety valve isolation are kept lock opened. Spare to be kept isolated as per P&ID stipulations.
e. Charge atomizing steam header to the heater. Commissioning fuel oil supply and return lines and
establish FO circulation. Tracing steam is commissioned.
f. All safety interlocks / trips on combustion air circuit, heater pass flows and heater body should be
made operational. However, few selective trips may be bypassed appropriately for short duration
only to achieve steady operating conditions. The bypassed trips should again be taken in line at
earliest opportunity. Proper recording and communication should be maintained regarding bypassed
or ineffective trips.
g. Commission tempered water system by admitting BFW in FA41014. To maintain crude at proper
temperature this BFW should be cooled in EC41009 & EC41010. This is required for cooling the
crude column bottom steam that will be diverted to VR circuit (down stream of discharge of VR
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pumps) Heat exchangers not relevant for operation at this stage, ie; heat exchangers in vacuum
service can be bypassed. Since exchangers subjected to hot crude will not have cold media flow on
the other side, during start-up, it is better to keep the isolation valves of the exchangers on the cold
media side lined up.
Raising Temperature to 120°C:
Fire the pilot burners of atmospheric heater one by one as per heater start up procedure. After
warming up of heater, main FG burners can be lit up. The rate of increase of transfer line temperature
will be restricted to 30°C per hour. When the transfer line temperature reaches 120°C at heater
outlet, hold firing rate to maintain this temperature for four hours. At this COT, column bottom
temperature shall be around 90 - 100°C.
Bring down column pressure to 0.5kg/cm2g or less to facilitate water removal as steam - hydrocarbon
vapor mixture to the column overhead. Keep a watch on column pressure. The excess pressure will
be released to flare. Higher column pressure may interfere with evaporation of hydrocarbons and
water vapor.
Monitor all flow, temperature and pressure readings of atmospheric column and heater. While raising
the temperature it will be observed that crude passing through preheat train-I, II and III gains heat from
the Vacuum residue. Watch performance of RCO pump as its performance may become unsteady
initially with rise in crude oil temperature. Maintain temperature of crude at the outlet of VR product
cooler at about 50°c - 60°C to prevent hot RCO/VR from entering crude charge pump suction as this
may result in cavitation of the pumps. At the end of four hours, carry out test for water content in
circulating crude oil. A value of about 0.2% wt. of water content is often obtained at this stage of hot
circulation and is acceptable. Unit is put on once through circulation once the VR product cooler outlet
temperature reaches 70C as COT is raised.
Raising temperature to 250°C:
Purpose of raising the temperature to 250°c and holding at this value is to check the performance of all
equipments, instruments and controls in hot service and rectify the snags if any. After holding the
temperature at 120°c for four hours, transfer temperature will be further raised at a rate of 30°c/hr to
150°c and held at this temperature for four hours with column top pressure held at 0.5kg/cm2g. Most
of water in circulating crude shall be evaporated during this period. COT is then raised to 250°c at a
rate of 30°c/hr. Closely watch all instrument readings and check their performance. Re-calibration of
few of the instruments may be necessary. Top temperature of the column will rise gradually. When it
reaches 100°c, steam will not condense in the atmospheric column and will escape from column top.
It will finally condense in the column overhead condensers and accumulate in the reflux drum. When
level appears in the reflux drum check for presence of water and drain it out. Local check for levels
must be made.
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As top temperature rises further, slowly raise column pressure to its normal value of 1.5/ 2.14
kg/cm2g. After steadying column top pressure, put pressure controller PIC-1601 on auto to maintain
this value. Higher pressure will help in condensation of vapors which would otherwise escape to flare.
Increase of column top pressure will result in increase of top temperature due to increase in boiling
point and dew point temperature of the vapors, provided all other parameters are constant. As
temperature goes up atmospheric column pressure also goes up due to vaporization of lighter ends.
Excess pressure has to be released to flare.
Check for appearance of oil level in atmospheric column reflux drum. Start total top refluxing when oil
level builds up. Watch water and oil levels in column reflux drum. Commission water and oil level
controllers LIC-1801 and LIC-1802 and put them on auto to maintain about 50% level in vessel and
boot respectively. Watch performance of these instruments closely. Care should to be taken to prevent
water from going along with top reflux stream.
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Start hot bolting of column bottom manholes, of all the flanges in the transfer line, RCO circuit and VR
circuit and the flanges of any other piping that is in hot service i.e. temperature exceeding 200C. Cap
off all drains securely that were used to drain water.
Raising Temperature to 300°C / Normal COT:
Once hot bolting is complete, start raising the transfer temperature at 30 °c/hr by taking F.O firing in
heater.
When only CDU is on line hold the column bottom temperature at around 280°c till RCO could be
diverted to vacuum section. Regulate top refluxing to maintain a column top temperature of 120°c.
When naphtha make increases as indicated by an increase in oil level in reflux drum, route it to slop
till stabilizer is commissioned.
NOTE:- Normally naphtha is not slopped. Stabilizer is kept ready to receive un-stabilized naphtha.
As crude column top temperature and pressure reach their normal values, line up all circulating reflux
streams starting with Heavy naphtha CR. Ensure by draining that there is no water in any of circulating
reflux circuits. Start refluxing at minimum flow rate after draining water from pump casing drain. This
operation will gradually maintain the temperature profile of the column.
When levels appear in side strippers, drain water from respective pump suctions and line up product
pump discharges (HN, Kerosene, LGO, & HGO) to slop header. Heating medium (HGO CR) to
stabilizer re-boiler EA41003A/B can be commissioned. When sufficient level builds up in the side
strippers (about 40%) start product pumps and route the products to slop till they are on grade. When
flows stabilize, all level controllers, LIC-1701/1702/1703/1704, can be put on auto. During start-up
circulating reflux flows through the exchangers of preheat train 1, 2 and 3. This will necessitate the
readjustment of crude flows in both the sections (viz section A/B) of every preheat train in order to
bring parity in outlet temperatures.
Commission atmospheric column bottom stripping steam header. When crude column bottom
temperature reaches 300°c, admit steam of desired quantity in steps of 250kg/hr, On introduction of
stripping steam the vapor load of the column will increase. Adjust cooling water to overhead
condensers to maintain reflux temperature of about 45°c. Introduction of stripping steam to crude
column helps in achieving proper mass transfer. Steam to product strippers can also be introduced.
If the vacuum section is not yet ready to receive RCO, divert entire quantity of atm. column bottom
stream to slops/ IFO tanks through VR circuit.
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Watch column top pressure and temperature. Re-adjust circulating refluxes and top reflux if
necessary. Raise the circulating reflux flow to about 60 - 70% of its normal rate. The return
temperatures of top reflux, HN CR, Kero CR, LGO CR and HGO CR would be about 45°C, 120C,
130C, 170°C and 230°C and these temperatures may have to be maintained, if required, by operating
the exchanger bypasses in the CR loops. The duty controllers should not be put in operation till steady
state operating conditions are established. Adjust withdrawal rates of HN, Kerosene/ATF, LGO &
HGO through FIC-2702, FIC-2706, FIC-2707 & FIC-2708 to maintain proper draw off temperatures.
When the coil outlet temperature reaches its normal value of 340-360°C, cascade TIC-1512 with fuel
firing controller and steady out all operating conditions. Commission hot medium to HN and kero
stripper reboilers. Normalize stripping steam flow to LGO and HGO strippers. Adjust the steam flow
rate by FIC-1703 for LGO and FIC-1704 for HGO stripper. Ensure that condense is already drained
before allowing steam flow to the strippers. The HN side cut liquid is stripped of it's lighter ends using
LGO product as the reboiling medium. Introduce stripping steam to kero stripper, as HVGO is not
available as heating media for EA41012. Adjust cooling water, if necessary to all product coolers to
maintain run-down temperature of HN, Kerosene, LGO and HGO at about 40°c. Care should be taken
to ensure that combined slop temperature ex CDU does not exceed 60°c.
Vacuum section
Case-1 RCO is passing through the vacuum column:
In this case cold oil circulation and hot oil circulation of VDU is not done independent of CDU.
1. Ensure that circulating reflux of each bed is on line and vac. slop quench loop is on line.
2. Ensure water from the loops is drained. Before firing the heater ensure that atomizing steam,
snuffing steam and emergency steam to heater are commissioned.
3. Safety interlocks/ trips in combustion air system, fuel system, heater body and heater pass flows
should be activated, similar to atmospheric heater.
4. Establish fuel oil circulation through Fuel oil circuit of vacuum furnace. Charge fuel headers. Ensure
that all pilots of VDU heater are on.
5. Ensure that cooling water to ejector condensers are lined up condition.
6. Take main Fuel gas burners on line and slowly start raising the temperature at the rate of 30°C/hr.
Extreme care to be taken about skin temperatures of all passes. Pass flow and COT of each pass
should be maintained more or less as that of the other.
7. Warm up ejector steam ,stripping steam and velocity steam headers.
8. Start hot well sour water pump GA41107 on spill back. Keep hot well slop oil pump in auto mode. Hot
well slop to be lined up to Heavy slop header.
9. When VDU COT reaches 350°C start taking ejectors one by one starting with smallest.
10. Once ejectors are taken on line sour water generation will start. Route sour water to SWS.
11. Establish IR flows as required.
12. When COT reaches 380°C introduce stripping steam in steps of 250kg/hr to required quantity. Care
should be taken while introducing stripping steam as a sudden surge would pressurize the column
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and damage the internals. Velocity steam has to be introduced to the coils at not less than 350kg/
pass.
13. When COT reaches 380°C firing can be switched over from FG to F.O.
14. Start over head chemicals like corrosion inhibitor and ammonia.
15. Commission all product coolers and tempered water coolers.
16. When bed levels start rising products are routed to slop till they are on grade.
17. Once level starts building in vacuum slop drum FA41112 start vacuum slop recycle to vacuum heater.
18. When sufficient HVGO CR temperature is reached cut off stripping steam to kero stripper and route
HVGO CR to kero stripper reboiler.
19. Once HVGO is available change over from light flushing oil to Heavy flushing oil for pump seals and
instrument flushing.
20. Check the color of product and if it meets specification then route it to it's specified destination.
21. Maintain column bottom temperature at 350C through adequate VR quench flow.
22. Once required COT is reached switch the heater firing to cascade mode.
23. Maintain bed levels, CR draw & return temperatures as per requirement by adjusting CR and IR flows.
24. Vacuum column bottom to be routed to either VBU/BBU or to cold VR line to LSHS or 35D depending
on crude processed.
25. Vacuum slop can be routed to either MFO blender or VR loop.
Case-2 RCO is not passing through the vacuum column:
In this case cold oil circulation and hot oil circulation of VDU is done independent of CDU. It is to be
ensured that RCO does not enter the vacuum section during oil circulation of VDU if it is not ready.
Blinding at the appropriate places may be necessary if valves are suspected passing. When cold oil
circulation has been well established and water in the system has been thoroughly drained out, the
system is ready for hot circulation. Utmost care should be taken and system should be de-watered
completely to prevent water splash and damage to the column internals. Here vacuum column bottom
is filled with crude oil and circulation is established with crude. All beds are filled with gas oil and bed
circulation is also established.
The steps involved in bringing VDU on stream are basically same as those of atmospheric section
except for vacuum pulling. These are elaborated as under:
 Firing the heater
 Hot circulation
 Cutting in RCO feed.
 Vacuum pulling
 Normalizing the unit.
 Stabilization
Hot circulation in VDU should not be kept in abeyance till RCO from CDU is available. Starting hot
circulation in VDU even at lower CDU temperatures saves time at a later stage.
Before proceeding for hot circulation in VDU:
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 Commission cooling water to ejector condensers and all product coolers.

 Commission tempered water system if not already commissioned by taking BFW water in
tempered water drum. Establish closed circulation of tempered water in the system by running
tempered water pumps GA41035&GA41036. Proper temperature of BFW in TW system, shall be
maintained by air coolers EC41009 A/B/C/D. (NOTE:- Tempered water system was commissioned
for hot oil circulation in CDU because RCO was flowing in VR circuit. EC41010 was started).
 Establish fuel oil circulation through Fuel oil circuit of vacuum furnace. Charge fuel headers.
Steps for VDU hot circulation are elaborated below:
Firing the heater:
Before firing the vacuum heater, please ensure that atomizing, snuffing and emergency steam headers
of the vacuum furnace are commissioned. This is typical to all fired heaters.
 Safety interlocks/ trips in combustion air system, fuel system, heater body and heater pass flows
should be activated, similar to atmospheric heater.
 Continue cold oil circulation through all passes of vacuum heater including circulating refluxes as
mentioned earlier. Maintain vacuum column bottom level at around 50%.
 Fire the furnace as per normal procedure. Light 1 or 2 burners initially and increase the number of
burners as the temperature is raised gradually. The lit up burners should be equally spread in the
fire box. When flame is steady , increase COT to 120 °c at 30 °C/hr rate with the help of 04-TIC-
2312. Hold the temperature for about 4 hours. Stop circulation to allow settling of water. Drain
water and restart circulation.
Hot circulation:
Ensure that entire vacuum column is heated up to about 110°C through internal reflux as elaborated in
section on cold circulation. Water accumulated in the trays will be removed as steam in the overhead
system. After holding COT at 120°c and removing water completely from entire system transfer line
temperature will be raised further. Any oil level build up in the hot well may be pumped out to slop by
operating the slop oil pumps.
When COT is held at 120°c for four hours and vacuum column is included in circulation, it is expected
to get warmed up uniformly to around 110°c. Before raising COT beyond 120°c, stop flow of all
circulating refluxes. Water draining from all pump suction lines should be done. Now column heating
will be controlled by increasing COT and rising vapors only.
Continue oil circulation in the bottom section of column, from the column to the vacuum furnace and
back to the column through VR pump. This circulation is normally called as short circulation.
Replacing Gas oil with RCO / Cutting in RCO feed:
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1. Raise the vacuum furnace COT to 240°c at the rate of 30°c/hr.

2. Reduce the column bottom level to about 10% by routing excess oil to slop by diverting a part of VR
product pump discharge to rundown which was lined up only to vacuum furnace so far. As a result of
this line up, VR pump discharge and RCO pump discharge shall follow common routing in VR
rundown circuit. This will cause shifting and slight adjustment of VR as well as RCO pump discharge
pressures and capacities on respective pump characteristic curves. To avoid possible limitation in
VR pump head/ capacity, valves on VR pump discharge to RCO pump discharge (identified as valve
4 and 7 on sketch 2) may require close monitoring / adjustment. Cavitation of VR + quench pumps is
likely to occur due to vaporization of gas oil at temperatures beyond 240°c.
3. Hot bolting of flanges, heater coil plugs, manholes etc in hot service should be completed at this
stage.
4. Maintain the vacuum column pressure around 0.2kg/cm 2g with fuel gas back up from header if
necessary. Release excess FG from column top to bring top pressure to around 0.2kg/cm 2g.
5. Divert RCO from RCO pump discharge to vacuum furnace, while simultaneously closing RCO to VR
product and Line up VR pump discharge to VR circuit which should ultimately be lined up to the slop
tank, while simultaneously closing valves 1 and 2 on VR pump discharge to vacuum furnace. Valve 3
is already closed at this stage. Put vacuum column bottom level controller on auto. During
circulation, column bottom level should be maintained as low as possible to avoid wastage of gas oil.
Prevent tripping of heater on account of low pass flows during change over from VR pump to RCO
pump discharge. RCO pump discharge is completely diverted to vacuum furnace and VR pump
discharge is lined up to rundown.
6. Monitor vacuum furnace firing. As RCO temperature is 300°c firing in furnace requires to be reduced
to keep the COT around 300°c. Cut off some burners during change over operation, if necessary.
7. Activate VR quench oil circuit and maintain some flow through it. With diversion of RCO pump
discharge to vacuum furnace, once-through flow will be established. Now gas oil will be gradually
displaced to slop.
8. Ensure that the drain line of hot well middle compartment (housing barometric legs from condensers)
is blinded downstream of block valve to prevent mal-operation of drain valve and loss of seal level.
During this period also ensure that hot well water side has water level above or at least equal to its
baffle height and oil side has no level. If sufficient water is not present, fill up with fresh water through
utility connection.
9. Once RCO is diverted to vacuum heater, raise the COT to 370°c at the rate of 25- 30°c/hr.
10. Light fractions will start collecting in small quantity in the upper sections of the vacuum column as
transfer temperature is increased. Please check density of circulating material at suction of VR
pumps and ensure that no more gas oil is circulating along with hot RCO. All gas oil intake points
should be blinded.
11. With diversion of RCO flow to vacuum furnace operating at COT of 370°c, it is expected that VR +
quench pump discharge circuit shall handle lower flow and shall be capable of handling RCO pump
discharge flow both in terms of flow as well as cooling capacity of the circuits.
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12. As level builds up on vacuum diesel, LVGO & HVGO draw off trays route products to slop, until they
are on grade, and maintain proper bed levels. Watch run-down temperature while routing products to
tank. They should neither be too hot nor too cold.
13. Commission slop recycle stream from the discharge of slop + recycle pumps to RCO feed stream to
vacuum heater.
Vacuum pulling:
Vacuum pulling can be done after complete diversion of RCO to vacuum column and when vacuum
bottom temperature reaches 300°c with RCO. Shut off FG to vacuum column overhead if open.
Ensure that vacuum column pressure is not more than 0.15kg/cm2g to 0.2kg/cm2g. Also ensure that
hot well vent is opened to atmosphere and liquid water seals are maintained in hot well. Opening of
hot well vent to atmosphere with higher FG pressure in vacuum column may lead to rise of water from
dipped hot well legs.
 Adjust VR quench flow to keep vacuum column bottom temperature at 350°c.
 Commission steam to ejectors after thorough draining of condensate from the steam header.
 Commission PIC-2502 and maintain MP steam pressure to ejectors at 10.0 kg/cm2g.
 Pull vacuum slowly by increasing the steam flow rate through PV-2502 on motive steam to ejector.
Care should be taken that the pumps connected to the column are not affected by way of loosing
suction.
 Commission hot well sour water pump at hot well bottom and route sour water to SWS. After
vacuum reaches 25 mm Hg raise COT to around 375°C.
 Carryover of light oil from vacuum column trays into hot well is expected when vacuum is pulled.
Pump out the oil from hot well by slop oil pump to slop.
 Once system is stabilized with the ejectors in operation, pull vacuum to about 25 mm of Hg absolute
pressure at the top of the column.
 With vacuum column operating in vacuum , there will be lot of vaporization. Put column top
pressure controller PIC-2501 on auto and set the top pressure.
Normalizing the unit:
Raise the COT to normal value of (as per previous data). Adjust quench rates, draw off rates etc. on
pro data basis and steady out conditions. Send samples of vacuum diesel, LVGO, HVGO & Vacuum
residue. Route them to respective tanks when they are on grade.
Normalizing the Operating Conditions in CDU/VDU:
At this stage normal operating conditions are established for both atmospheric section as well as
vacuum section at turn down capacity of the plant. All products are routed to their respective storage
tanks/ downstream plants.
Feed rate of the plant is to be raised to its normal capacity in steps as outlined below:
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 When the atmospheric heater transfer line temperature of 340/355°c has been attained, maintain
this temperature and make no further adjustments. Adjust heater firing to maintain 340/355°c at
heater outlet at turn down operating conditions.
 Increase stripping steam to side stream strippers by adjusting individual FICs to achieve designed
ratio of steam to hydrocarbons. Make adjustment in the stripping steam flow to the atmospheric
column bottom also.
 Adjust draw off flows of HN, kerosene, LGO & HGO to maintain respective draw off temperatures.
Raise circulating refluxes proportionately to maintain column temperature profile.
 When conditions have become steady take all remaining controls on auto one by one. Particular
care should be taken in case of heaters control. Safety shutdown system for low fuel gas pressure
(which was on bypass initially) should be made operative.
 Make adjustment on operating parameters to bring the products on grade. Check doctor test for
products where ever possible. Check for normal product rundown temperatures.
 When products are on spec., route them to respective tank/ down stream units. These routings
should be recorded meticulously and should be known to unit operators. If any product goes off
spec., divert it to slop tank (except LPG) and make adjustment as detailed under operating
variables to bring the product to specification.
 Raise the throughput further only when all products are on spec. Raise the throughput in steps in
accordance with the procedure outlined. Establish steady operating conditions in each step.
Increase the throughput to normal rate as per requirement and maintain the parameters. Steady
out transfer temperature of atmospheric furnace at 340/355°c. Check all furnace controls for
proper functioning. Raise the feed to atmospheric furnace at 25m 3/hr.
 Check local temperature, pressure, flow and level of different equipments and streams. Please
keep a watch on running equipments such as pumps, heaters and other equipments. Keep a
watch on ejector performance. Look for leaks, hot spots and any other abnormalities.
 Record and analyze two hourly log readings and report any abnormal condition to the next higher
supervisor immediately.
Bringing up Naphtha Stabilizer system:
 Commission PIC-1901 (stabilizer top pressure) on auto, with set point at about 9.0 kg/cm2g. PIC-
1901 being split range controller with characteristics so selected that initially the control valves PV-
1901 A & B will remain fully closed. On increase of pressure, the valve PV-1901 A shall start
opening and go to full open condition to allow maximum condensation. If pressure increase still
persists, PV-1901B shall also start opening and go to full open condition to relieve maximum fuel
gas from stabilizer reflux drum.
 Start admitting naphtha from crude column reflux drum into naphtha stabilizer bottom with the help
of stabilizer feed pumps. Build up about 75% level in stabilizer bottom through FIC-1901. It can be
cascaded with LIC-1801 (reflux drum level controller) once steady operating conditions are
achieved in stabilizer section.
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 To commission stabilizer reboiler, divert some quantity of HGO CR slowly to raise the temperature
at the rate of 10 -15°c/hr through stabilizer reboiler EA41003 A/B by adjusting FV-1904B. This
shall increase stabilizer bottom temperature gradually. Do not exceed rise in temperature beyond
20 °c/hr.
 Stabilizer pressure will tend to rise as the bottom stream gets heated by HGO CR. HIC-1902
should be manually operated to gradually open PV-1901 A, at condenser outlet, and then PIC-
1904, towards fuel gas system, to maintain the pressure of the column. Condensable accumulated
in condensers should be continuously released to reflux drum. With rise in stabilizer temperature,
stabilizer top pressure setting should be increased, typically 1.0kg/cm 2g at a time. This avoids
unnecessary flaring.
 When normal stabilizer pressure (8.0/ 12.0kg/cm2g at PIC-1901) is reached, normal working of the
column will be established. During the process of heating up, stabilizer bottom level will fall if rate of
heating is too fast. Necessary make-up should be done through FIC-1901.
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 Raise gradually stabilizer tray-3 temperature by adjusting TIC-1905/FIC-1904. When tray-3

temperature stabilizes at around 155°c-160°C, put TIC-1905 on auto. Sudden increase of
temperature and pressure will destabilize the column making heavy fraction to go to the top,
requiring longer time to stabilize. So increase or decrease of temperature or pressure of stabilizer
shall be done gradually .
 When level appears in stabilizer reflux drum, drain water from boot and stabilizer reflux / LPG
pumps suction. Start total refluxing to the column keeping FIC-1902 on manual control. Maintain
top temperature at about 65°c. Start diverting LPG when there is excess accumulation in reflux
drum.
 Till NSU/KSU is to be operated, stabilized naphtha stream from naphtha stabilizer bottom should
be routed to discharge of naphtha splitter bottom product pumps GA41020 A/B/C from up stream
of FV-2001. The stabilized naphtha stream shall go to caustic water / wash section meant for
Heavy naphtha.
 Caustic solution of required strength of 10% is filled in the caustic wash vessel. Quantity of caustic
make up in the vessel should be verified with flow indication FI-2208 on make up line.
 Caustic circulation in the vessel is established by operating caustic circulation pumps GA41027
A/B through FIC-2203. HV-2203 at vessel inlet should be kept to full open position by operating
HIC-2203.
 Similarly water circulation is established in water wash vessel FA41019.
 Naphtha stream from stabilizer bottom is routed to FA41018 and then to FA41019 by operating
HIC-2203 / HIC-2204. Specifications of outgoing naphtha should be compared with specified
stream properties to establish efficiency of washing.
 When caustic strength goes down to less than 1.0%, spent caustic should be drained to spent
caustic drum and fresh caustic should be made up.
 Water from water wash vessel shall also be drained to spent caustic degassing vessel. However
basis of draining of wash water to this vessel shall be increase in inter phase level LIC-2202 in the
water wash vessel. Quantity of water drained should be made up by running water make up
pumps GA41029 A/B. Streams collected in the degassing vessel after degassing shall be sent to
ETP by spent caustic pumps GA41026 A/B.
Commissioning of Desalters:
Desalter can be brought into service before commissioning vacuum section. Stabilize desalter
pressure at about 9.5 - 11.5 kg/cm2g by PIC-1201. Control the desalter temperature at about 130°c
by adjusting the flows of hot medium streams passing through preheat train-I. Check oil - water
interface level using the tri-cock valves and check for presence of any vapor. Switch on the power
supply to desalters. High voltage and low amperage should be indicated by voltmeters and ammeters
respectively. Line up service water/ stripped water to desalter inlet and start injection at about 4%
volume of crude throughput and then raise to the levels specified by the desalter vendor. Also line
up effluent water circuit. Start caustic injection pumps and inject caustic solution into crude feed to
CDU, to maintain a pH of about 7 in the effluent brine from the desalters. Start demulsifier injection
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pump and inject demulsifier to crude feed to CDU at the rate of about 1.5 to 2ppm on crude charge.
The rate of injection to be confirmed / readjusted based on actual operating data. Commission
desalter level controllers LIC-1201 & LIC-1204 and route desalter water to effluent treatment plant
via brine coolers.
Take samples of crude before and after desalter and readjust operating conditions for getting the
following results:
 Salt content at the outlet should be <0.5ptb of crude.
 The insoluble water content in desalted crude should be less than 0.2% volume and the effluent
brine should have oil content less than 200ppm.
Commissioning of NSU:
NSU start up shall be similar to CDU naphtha stabilizer column start up and hence basic steps for this section
shall remain same. It is assumed that Naphtha splitter column and related systems are kept water free,
under FG pressure till CDU and naphtha stabilizer operation is stable and streamlined.
Stabilized naphtha from stabilizer bottom is fed on either tray 13 or 16 of naphtha splitter column under a flow
control which is cascaded with stabilizer bottom level controller. Naphtha from splitter column bottom is fed
to NSU reboiler by a pump under pass flow controls . Heated and partly vaporized naphtha enters splitter
column bottom. Tray 3 temperature of the column or heater coil out let temperature (COT) is selected for
controlling heater firing. Naphtha vapors leave column top under top pressure control and are condensed in
an air cooler. These are collected in a reflux drum. Uncondensed hydrocarbons shall leave from reflux drum
top to flare header under reflux drum pressure control. From reflux drum, one part of the condensed Light
naphtha is sent to storage via caustic wash after cooling and second part of it is used as reflux to splitter
column by naphtha splitter reflux pumps. Heavier stream is run down to storage via caustic wash section
from splitter column bottom by naphtha splitter bottom product / furnace feed pumps.
Basic steps for commissioning of NSU are elaborated as under:

 Commissioning of the naphtha splitter column.
 Commissioning of the fired heater reboiler.
 Heating up of the splitter column
 Routing of top product
 Routing of bottom product
 Normalizing the unit and stabilization.
Above steps are elaborated below:
Commissioning of the Naphtha splitter column:
Start admitting naphtha from stabilizer column bottom into Naphtha splitter column bottom via splitter
feed/bottom exchanger. Build up about 75% level in splitter column bottom through FIC-2001. It can
be cascaded with LIC-1901 (Stabilizer bottom level controller) later, once steady state operating
conditions are achieved in splitter section. Watch rise in indication of bottom level controller LIC-
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2001. While raising column bottom level, shut off the NSU bypass line. Commission PIC-2001
(Splitter top pressure) on auto, with set point at about 1.1 kg/cm 2g. Also put reflux drum pressure
controller PIC-2002 in auto, which shall remain close initially due to less pressure in the system.
DPIC-2001 should be kept fully opened initially. Establish naphtha circulation through all passes of
naphtha splitter heater. Check tripping of heater firing controls on actuation of low - low flow alarm in
one or more passes. Closed naphtha circulation should be established through heater and naphtha
splitter column bottom.
Commissioning of the fired heater reboiler:
Establish fuel oil circulation through fuel oil circuit of NSU furnace and charge FG header. Continue
cold naphtha circulation through all passes of splitter heater as mentioned earlier. Maintain column
bottom level around 50%. Fire the furnace as per normal procedure. Light 1 or 2 burners initially and
increase the number of burners as the temperature is raised gradually. The lit up burners should be
equally spaced in the fire box. When flames are steady, increase COT in individual passes in steps.
Heating up of the splitter column:
This will be achieved when hot vapors disengage from heater outlet and rise up the column. Raise
gradually the coil out let temperature TIC2110 . When tray -3 temperature stabilizes at around 70°c,
drain water once again from all low points in the system. Increase COT of each pass to 120°c and put
TIC-2110 on auto. Sudden increase of temperature and pressure will destabilize the column making
heavy fraction to go to the top, requiring longer time to stabilize. So increase or decrease of
temperature or pressure of splitter shall be done gradually. Ensure that entire column is heated up to
about 100°c by establishing proper vapor - liquid transport through all trays of the column. Water
accumulated in the trays will be removed as steam in the overhead system.
Continue naphtha circulation in the bottom section of column, from the column bottom to the furnace
and back to the column with periodic make up. During the process of heating up, splitter bottom level
will fall if rate of heating is too fast. When the tray 3 temperature, as indicated by TIC-2001 is more
than 100°c, the system is assumed to be dry and products from it are expected to be available
continuously.
Routing of top product:
With increase in temperature, circulating stock shall start vaporizing. Vaporized stream shall rise in the
column and condense in overhead condensers. The condensate shall accumulate in the reflux drum. Oil
level build up in the reflux drum should be put back to splitter column as reflux by operating the naphtha
splitter reflux / overhead product pumps under top reflux flow control FIC-2002.
Splitter pressure will tend to rise as the bottom stream gets heated in Naphtha splitter reboiler. Start fans of
Naphtha overhead air cooler keeping in view vapor load from the column. Inadequate condensation shall
be indicated by rise in splitter column top pressure controller opening, increase in DPIC-2001 opening and
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ultimately in reflux drum pressure rise. At a splitter column top temperature of about 100°c and pressure of
1.3kg/cm2g, light naphtha accumulation is likely to occur in reflux drum. This is sent to run down after
cooling in product cooler EA41004 under reflux drum level control.
Routing of bottom product:
When normal splitter pressure of 1.3 kg/cm2g at PIC-2001 is realized, normal working of the column
will be established. After holding COT at 140°c and removing water completely from the entire
system, COT of the heater will be raised further to final value of 140°c-160°c depending on naphtha
quality requirement.
When tray 3 temperature and all other parameters are normal, composition of column bottom stream
at bottom pump suction is expected to be same as that of furnace feed. Hence a part of it can be
diverted to storage through splitter feed/bottom exchanger and product coolers under column bottom
level control.
Normalizing the unit and stabilization:
Please raise splitter bottom temperature and feed rate to its normal value. TIC-2001 cascade
arrangement should be watched. Start draining water from boot of reflux drum to CBD or OWS by
watching LI-2003 provided at reflux drum boot.
Commissioning of KSU:
KSU start up shall be similar to CDU naphtha stabilizer column start up and hence basic steps for this section
shall remain same. It is assumed that kero splitter column and related systems are kept water free, under FG
pressure till CDU and naphtha stabilizer operation is stable and streamlined.
Stabilized naphtha from stabilizer bottom is fed on either tray 10 or 14 or 17 of kero splitter column under a
flow control which is cascaded with stabilizer bottom level controller. Naphtha from splitter column bottom is
fed to KSU reboiler by a pump under pass flow controls . Heated and partly vaporized naphtha enters
splitter column bottom. Tray 3 temperature of the column or heater coil out let temperature (COT) is
selected for controlling heater firing. Naphtha vapors leave column top under top pressure control and are
condensed in an air cooler. These are collected in a reflux drum. Uncondensed hydrocarbons shall leave
from reflux drum top to flare header under reflux drum pressure control. From reflux drum, one part of the
condensed Light naphtha is sent to ISOM feed or storage via caustic wash after cooling and second part of it
is used as reflux to splitter column by naphtha splitter reflux pumps. Heavier stream is run down to NSU
feed from kero splitter column bottom by Kero splitter bottom product / furnace feed pumps.
Basic steps for commissioning of KSU are elaborated as under:
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 Commissioning of the Kero splitter column.

 Commissioning of the fired heater reboiler.
 Heating up of the splitter column
 Routing of top product
 Routing of bottom stream to NSU feed
 Normalizing the unit and stabilization.
Above steps are elaborated below:
Commissioning of the Kero splitter column:
Start admitting naphtha from stabilizer column bottom into kero splitter column bottom via splitter
feed/bottom exchanger. Build up about 75% level in splitter column bottom through FIC-3301. It can
be cascaded with LIC-1901 (Stabilizer bottom level controller) later, once steady state operating
conditions are achieved in splitter section. Watch rise in indication of bottom level controller LIC-
3301. While raising column bottom level, shut off the KSU bypass line. Commission PIC-3301
(Splitter top pressure) on auto, with set point at about 1.1 kg/cm 2g. Also put reflux drum pressure
controller PIC-3302 in auto, which shall remain close initially due to less pressure in the system.
DPIC-3301 should be kept fully opened initially. Establish naphtha circulation through all passes of
kero splitter heater. Check tripping of heater firing controls on actuation of low - low flow alarm in one
or more passes. Closed naphtha circulation should be established through heater and kero splitter
column bottom.
Commissioning of the fired heater reboiler:
Establish fuel oil circulation through fuel oil circuit of KSU furnace and charge FG header. Continue
cold naphtha circulation through all passes of splitter heater as mentioned earlier. Maintain column
bottom level around 50%. Fire the furnace as per normal procedure. Light 1 or 2 burners initially and
increase the number of burners as the temperature is raised gradually. The lit up burners should be
equally spaced in the fire box. When flames are steady, increase COT in individual passes in steps.
Heating up of the splitter column:
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This will be achieved when hot vapors disengage from heater outlet and rise up the column. Raise
gradually the coil out let temperature TIC3410 . When tray -3 temperature stabilizes at around 70°c,
drain water once again from all low points in the system. Increase COT of each pass to 120°c and put
TIC-3410 on auto. Sudden increase of temperature and pressure will destabilize the column making
heavy fraction to go to the top, requiring longer time to stabilize. So increase or decrease of
temperature or pressure of splitter shall be done gradually. Ensure that entire column is heated up to
about 100°c by establishing proper vapor - liquid transport through all trays of the column. Water
accumulated in the trays will be removed as steam in the overhead system.
Continue naphtha circulation in the bottom section of column, from the column bottom to the furnace
and back to the column with periodic make up. During the process of heating up, splitter bottom level
will fall if rate of heating is too fast. When the tray 3 temperature, as indicated by TIC-3301 is more
than 100°c, the system is assumed to be dry and products from it are expected to be available
continuously.
Routing of top product:
With increase in temperature, circulating stock shall start vaporizing. Vaporized stream shall rise in the
column and condense in overhead condensers. The condensate shall accumulate in the reflux drum. Oil
level build up in the reflux drum should be put back to splitter column as reflux by operating the naphtha
splitter reflux / overhead product pumps under top reflux flow control FIC-3302.
Splitter pressure will tend to rise as the bottom stream gets heated in kero splitter reboiler. Start fans of
kero splitter overhead air cooler keeping in view vapor load from the column. Inadequate condensation
shall be indicated by rise in splitter column top pressure controller opening, increase in DPIC-3301 opening
and ultimately in reflux drum pressure rise. At a splitter column top temperature of about 80°c and pressure
of 1.3kg/cm2g, light naphtha accumulation is likely to occur in reflux drum. This is sent to run down after
cooling in product cooler EA41050 under reflux drum level control.
Routing of bottom stream to NSU feed:
When normal splitter pressure of 1.3 kg/cm2g at PIC-3301 is realized, normal working of the column
will be established. After holding COT at 135°c and removing water completely from the entire
system, COT of the heater will be raised further to final value of 135°c-150°c depending on naphtha
quality requirement.
When tray 3 temperature and all other parameters are normal, composition of column bottom stream
at bottom pump suction is expected to be same as that of furnace feed. Hence a part of it can be
diverted to NSU feed through KSU feed/bottom exchanger under column bottom level control.
Normalizing the unit and stabilization:
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Please raise splitter bottom temperature and feed rate to its normal value. TIC-3401 cascade
arrangement should be watched. Start draining water from boot of reflux drum to CBD or OWS by
watching LI-3303 provided at reflux drum boot.
CHEMICAL INJECTION
Caustic injection:
Receive caustic solution of 10°Baume strength in FA41010or FA41007A/B. Start caustic injection
pumps GA41033 A/B/C and inject caustic (about 5 % to 8 % solution in water) through crude mix
stream joining suction of desalted crude pumps GA41003A/B/C. And also inject caustic in desalting
water at EA41046 outlet for controlling pH of the brine.
Rate of caustic injection in crude should be restricted to avoid caustic embrittlement of down stream
equipment and process lines at higher temperatures.
Demulsifier Injection:
Prepare, with kerosene, or receive demulsifier solution of recommended strength in FA41009 with
kerosene. The demulsifier solution is injected by GA41032A/B in the crude stream (about 1% of the
feed) upstream of both the desalters to avoid emulsification of crude oil and desalting water.
Ammonia Injection:
Receive ammonia cylinders and connect at liquid ammonia cylinder manifold. Prepare ammonia
solution of required strength in FA41011 with DM water. Utilize ammonia cylinders one by one.
Activation of PAL-2901 shall indicate exhausting of ammonia cylinder.
Inject ammonia solution to atm. over head line & vacuum over head line using GA41034 A/B . Adjust
the rate of injection of ammonia to such an extent that the crude column overhead reflux drum water
pH & hot well sour water pH is around 6.0 ± 0.5.
Corrosion inhibitor injection:
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Prepare, with kerosene, or receive corrosion inhibitor solution of recommended strength in FA41008.
Start corrosion inhibitor dosing by GA41031 A/B & GA41043A to overhead lines of vacuum column
,atmospheric fractionation column and also to the atmospheric over head reflux line. Before dosing the
solution, closed circulation from pump discharge to suction vessel should be established. Pump
capacity should be achieved by adjusting stroke length as per vendors recommendations. This is
typical for all similar applications and service systems. Samples should be drawn from sample points
provided at pump suction line and checked for correct strength before dosing.
Tri-sodium phosphate injection:

Prepare the Tri-sodium phosphate solution as recommended strength by vendor in FA41032. Start Tri-
sodium phosphate solution dosing by GA41043 B to steam generator vessels FA41023, FA41024 &
EA41054. Adjust the rate of injection as per requirement.
Steam Generator Circuits:
As part of startup preparation as follows:

 line up BFW and fill the drums up to 50% level.
 Warm up all steam generators using out let NRV bypass.
 Once steam generation starts from the vessels FA41023, FA41024 & EA41054 slowly pressurize
the drum .
 Once drum pressure is equal to header pressure slowly line up to header by opening pressure
control valves.
 Maintain the drum level by opening BFW to drums through level controllers.
 Inject TSP if required by starting GA41043B.
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CHAPTER VI
NORMAL OPERATION
The normal operating conditions are mentioned IN ANNEXURE for various crudes.
6.1 Normal Operating Variables:
In order to ensure normal operation of the unit with optimum yield of on grade products, it is necessary
to observe the operating conditions in all sections of the unit as any upset of operating conditions in
one section brings about upset of operating conditions of the entire unit and, as a result the quality of
the products gets deteriorated. Also, appropriate control should be exercised on certain operating
parameters to prolong the life of the equipments. The following discussion gives guidelines about
effects of the variables and measures to be taken to achieve the desired results.
6.2 Crude Distillation Unit
Desalting operating variables:
Only operating experience with desalter can determine optimum operating conditions. No two crudes
behave alike at the same desalting conditions, but all are affected similarly by change in desalting
conditions. Thus, only the generally accepted, and not necessarily the optimum operating conditions
can be discussed.
Water Injection And Pressure Drop:
Water injection should be started only after the crude temperature reaches the specified level. Initially
the injection rate should be between 4 and 6 % of crude and the point of injection should be just
upstream of the mixing valve. The pressure drop across the mixing valve should be adjusted to give
the required degree of desalting . The higher the pressure drop the more efficient the contact between
the salt in the crude and the injection water. Too high a pressure drop will result in excessive
emulsification and poor separation of oil, and water will carryover in the desalted crude. A pressure
drop between 1 and 2 Kg/cm 2 is normally sufficient. Optimum water injection rate and pressure drop
across mixing valve should be established to get the desired desalting of crude. Once this is done the
conditions should be maintained steady and should be varied only for changes in feed rate.
Oil / Water Interface level:
The oil/water interface level should be kept below the center line of the desalter(the middle tri-cock
valve) vessels to avoid water and sludge from escaping with crude, if sudden pressure surge takes
place. Incorrect operation of the interface level controller can result in water carry over with crude if
the water level builds up and in oil carry over with brine if water level falls very low. Also too high an
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interface level may push water up between the electrodes and cause them to short circuit.
Desalter Vessel pressure:
The normal pressure in the vessel should be maintained at about 10.5 Kg/cm 2g or as specified by
vendor. A low pressure will cause vaporization of crude and a higher pressure will result in actuation
of the safety valve on the desalter.
Desalting Temperature:
Desalting temperature is another important variable which affects oil-water separation in desalter. The
optimum operating temperature in the desalter is around 130°C. Lower the temperature , higher the
viscosity of oil and lower the separation rate. As crude conductivity and solubility in water increases
with temperature, operating temperature below this range will lead to drop in grid voltage and high
amperage which imposes limitation on good separation. Excessive amperage will eventually cause
the circuit breaker to open tripping the electric grid rendering the electrical system in operable until
thermal relay is closed. A very high temperature increases the possibility of vaporization in the
desalter.
Demulsifier Injection:
Stable crude-water emulsions can be broken by use of demulsifiing chemicals. The rate of injection of
this chemical will be dependent upon the nature of the emulsion, type of crude and other operating
conditions like residence time, temperature etc. Tests should be made to ascertain the required
chemical injection rate for optimum operation of the desalting unit.
Voltage and amperage:
The electrical panel houses, pilot lights, a voltmeter and ammeter. The voltmeter gives the voltage
across the primary circuit of the transformer. The ammeter gives the current flow. These give
indication of the performance of the grids inside the desalter. In case if the crude/water emulsion is too
tightly bound or if the interface level is too high there will be flickering of the pilot light, the amperage
will increase and the voltage will drop. Take corrective action to break the emulsion or reduce the
interface level. For more details about the operation of the desalter the vendors operating and
maintenance manual should be referred to.
Heater outlet temperature and column pressure:
The quantity of crude oil vaporized during its passage through the heater is dependent on transfer
temperature and the pressure at the flash zone of the column. In order to achieve proper recovery of
distillates, a little over flash is maintained by keeping the transfer temperature slightly higher. This
quantity is measured by FI1606 and is normally at 3 to 5 %vol on crude charge rate. High over flash
will result in more consumption of energy. This also indicates the presence of liquid level in the trays
below the HGO draw off section. Dry operation of these trays should be avoided to minimize coke
forming tendency.
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Heater outlet temperature is controlled by TIC 1512. Lower temperature will not give desired distillate
recovery. Bottom product (RCO) will be lighter and all side draws will also be proportionately lighter.
Higher than normal temperature enhances cracking possibility inside heater tubes, leading to coke
deposition and higher pressure drop. This may reduce overall run length of the unit and may force a
planned shut down. At the same time specification of heavy products may not be met and higher
recovery may be experienced at a given temperature.
Crude column pressure:
The effect of top pressure is more pronounced on lighter streams. The pressure in the column is
maintained by PIC 1601. A lower pressure aids in greater vaporization; all products will tend to be
heavier, there will be gas loss from reflux drum. There will be more load on overhead condensers.
Higher than normal pressure will have reverse effects. Increase in column top pressure will increase
column flash zone pressure also. Increased flash zone pressure will result in lower product yield of all
side draw off streams. The effect will be reflected in RCO also which will become lighter. It is important
to note that column pressure is largely dependent on equilibrium conditions in reflux drum. Efforts
should be made to operate the column at the design pressure only depending up on type of crude and
adjust cooling water to overhead condensers in such a way that there is total condensation and both
control valves of split range controller remain shut.
Crude column top temperature:
The column top temperature is controlled by regulating amount of overhead reflux through FV1605.
FIC1605 is cascaded with TIC1601. Increasing the top temperature at the same operating pressure will
result in increasing FBP of column overhead product and increase the IBP of first side draw. Similarly
lowering of top temperature will reduce FBP of over head naphtha and also reduce the IBP of first side
draw. To over come effect of change in top temperature, HN draw off should be suitably adjusted to
maintain its draw off temperature. Too low a top temperature will start steam condensation at the top
section of the column which may increase rate of corrosion in top section.
Circulating reflux flow:
The circulating refluxes serve mainly to remove heat from the column and reduce the vapor load in the
appropriate sections of distillation column. There are four circulating refluxes - HN CR, KERO CR,
LGO CR and HGO CR. These flows are respectively controlled by duty controllers/flow controllers
FIC 1601/1602/1603/1604. Increase of circulating reflux flows will result in higher crude preheat
temperature by greater heat recovery in heat exchanger train. Even though various CR return
temperatures will be governed by functioning of respective duty controllers, these may be maintained
by operating the bypasses of respective exchangers also. Any change in circulating reflux will alter
quality and quantity of its own product and those products which are immediately above and below it.
The effect of change of CR variation on other streams is not discussed, as it is not much pronounced.
A higher HN CR flow will remove more heat from column in HNCR zone, resulting in decline in top
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temperature and therefore a lower overhead reflux .This will cause lower liquid transport between top
tray and HN draw off ,causing poor fractionation between over head and HN. It will affect the quality of
Naphtha making it heavy. The overhead condenser duty will come down as there will be less
overhead product. The Kerosene cut will be correspondingly lighter. Similarly, a high LGO CR flow will
tend to lower the plate temperatures of Kerosene and LGO draw off resulting in lighter products in
these trays. The gap between Kerosene and LGO will decrease. Likewise, a high HGO CR will tend
to lower the draw-off temperatures of HGO and LGO.
Product withdrawal temperature:
The withdrawal temperature of the product from the tower influences the end point of the product. This
is determined by the quantity of the product withdrawn from the stripper. An increase in the withdrawal
rate of one side stream increases the withdrawal temperature and end points of that stream and
increases the IBP of the Streams lower down the column unless their rates are reduced
correspondingly. For example, if LGO withdrawal rate is increased LGO product will increase with an
increase in End Point. If HGO withdrawal rate is not reduced to maintain its plate temperature, its
initial boiling point (IBP) will be higher increasing the flash point. Reverse action takes place when
withdrawal temperature is lowered by reducing the quantity of withdrawal.
Stripping steam:
The initial boiling points and flash points of Kerosene, LGO and HGO will be directly influenced by the
quantity of stripping steam flowing to each stripper. Increasing stripping steam rate raises the flash
point and IBP of that side stream.
Stabilizer:
Stabilizer removes the majority of butanes and lower hydrocarbons from the Naphtha stream. These
are recovered as overhead LPG product. Higher stabilizer top temperature will make overhead product
heavy; even pentanes may be carried into LPG, making it off-spec. Lower temperature will reduce
LPG make; vapor pressure of LPG may go beyond the specified limit if top temperature is too low.
Too low a bottom temperature, will result in higher than allowable vapor pressure (RVP) of Naphtha
and at the same time will reduce LPG make. Low pressure in the column will cause higher amount of
hydrocarbons (Propane and butane) to escape into fuel gas system. This has got similar effect as that
of higher temperature in the column.
Kero & Naphtha Splitter temperature/pressure:
Kero & Naphtha splitter splits stabilized naphtha from stabilizer bottom into light naphtha (top product)
and reformer feed naphtha (bottom product). Higher column top temperature will make the over head
product heavy and some of the bottoms will go along with the top product, making it heavy and off
spec. Lower column top temperature will make bottom stream lighter and reduce yield of top product.
Low pressure in the splitter column has same effect as that of high temperature. It will cause heavier
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hydrocarbons to carry over to top product. Vapors leaving the top may not be totally condensed due to
low pressure, causing reduction in bottom product yield.
6.3 Vacuum Distillation Unit

The following variables of the vac. column influence the quality of the products and should be
controlled to meet the product specification.
Coil outlet temperature:
This is the coil outlet temperature of vacuum heater. This temperature determines the degree of
vaporization and the level of heat content in the liquid-vapor mixture entering the column. This
temperature is varied to a certain extent to control the quantities of all the side cut distillates and
bottom product. Care should be taken to ensure that COT does not go very close to upper limit for
prolonged period or even marginally exceeds it for a short periods. This is because after this
temperature the degree of cracking of partly vaporized RCO inside heater tubes increases rapidly.
Cracking of RCO molecules breaks them into smaller, more reactive molecules which can polymerize
on prolonged contact with each other at elevated temperatures. This results in coke formation.
Detrimental effects of cracking are coke deposition in heater tubes, transfer line and column bottom
sections forcing reduced run length. It also increases generation of non condensable hydrocarbons
ultimately entering into the over head system. Cracking can also have a detrimental effect in the curing
qualities of asphalt. Too low transfer line temperature will result in lower yields of vacuum distillates.
These distillates will find their way into vacuum residue, making it lighter.
Column pressure:
The column top pressure is controlled by 3 stage ejector with 3 ejectors in each stage. The non
condensibles from the after condenser are spilled back to the inlet of I stage ejector through a pressure
valve, PV 2501, to load the ejector in case of excess vacuum. Increase in pressure will result in
reduced yield of vacuum distillates and may also lead to cracking of the feed. Operating at a very low
pressure may affect the end point of VGO due to carryover of asphaltenes. It is utmost important to
maintain steady vacuum and temperature in the flash zone for obtaining maximum yield and correct
specifications. Increasing the flash zone temperature will result in increased distillate yield but cracking
possibility is enhanced. If for any reason vacuum starts falling, heater COT should be reduced.
Fluctuation in vacuum will impair product quality and produce mechanical stress in column internals.
Vacuum product/ Circulating Reflux/ Internal Reflux:
Vacuum diesel Section:
The column top bed is provided basically to minimize diesel component in vacuum gas oil (VGO) as
well as to reduce hydrocarbon load on the overhead system. The flow of VDO CR is maintained such
that almost entire diesel component can be condensed in this zone. Higher CR flow will cause
increased energy consumption with out much benefit. Decrease in CR rate increases top temperature
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which will cause carryover of hydrocarbons into the ejector system. Increase of CR rate will cause
more pressure drop in this section. The IR is distributed over the packing below vacuum diesel draw
off tray. The IR rate should be sufficient enough to wet the packing to facilitate proper mass transfer
and improve distillation efficiency. The product withdrawal is maintained in such a way that the draw off
temperature of diesel is maintained as per stipulation. Decrease in withdrawal rate of product will
result in VDO going into LVGO tray affecting the VGO feed quality. Increased withdrawal rate may
result in carryover of LVGO component in diesel.
LVGO Section:
Increased LVGO circulating reflux may result in carryover of VDO component in LVGO withdrawal
whereas decrease in circulating reflux may lead to loss of LVGO component to vacuum diesel. The
flow rate of LVGO internal reflux should be maintained such that packing in HVGO section is
adequately wet for proper mass transfer. Higher product withdrawal rate of LVGO will increase heavier
component resulting in improper fractionation. Lower withdrawal rate will result in low draw off
temperature. This may lead to overloading of HVGO section.
HVGO Section:
Heat transfer requirement of HVGO section is largely met by HVGO CR flow. A higher than the design
CR rate will result in flooding of packing in HVGO section. A CR flow lower than requirement will result
in carry over of heavier ends to LVGO section. Withdrawal rate lower than the design will result in low
recovery of VGO and a higher withdrawal rate may lead to carryover of asphaltenes in VGO, thereby
increasing the end point of VGO, hence affecting the catalyst in Hydrocracker reactor. HVGO internal
reflux rate should be such that it arrests carryover of asphaltenes and metals and restricts VGO FBP to
560°C.
Slop distillates & Recycle:
Slop distillate product, slop recycle, and slop quench are all withdrawn from the chimney tray above
flash zone. The objective behind providing slop recycle to furnace is to get desired over flash so as to
ensure proper recovery of distillates. Recycle rate is normally 4 to 6 %vol of RCO feed. Higher recycle
rate will unnecessarily increase energy consumption. A proper slop quench flow is very important to
maintain VGO quality. Coking possibility on slop draw off section is more likely to occur because of
availability of ample residence time on tray. A lower flow rate may result in the carryover of
asphaltenes in the HVGO section. More recycle rate will increase the load on flash zone & lead to
carryover of asphaltenes to HVGO section.
VR quench:
A quench stream is provided at the bottom of the column to maintain bottom temperature around
350°C. This is to prevent coke formation which may block piping, instrument and equipment. Higher
flow rate may lead to a lower bottom temperature but this is inconsequential.
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Stripping steam:
Low vacuum wet process is used in this plant in preferences to light vacuum dry process. The
reason for this is to maintain strict VGO product specification (absence of asphaltenes metal etc.) as
required by hydro-cracking unit. Higher than design flow rate of stripping steam will result in over
vaporization and over loading of the overhead condenser and ejector system. Lower steam flow will
affect vaporization requiring higher transfer temperatures or higher vacuum for maintaining same
degree of vaporization.
CHAPTER VII
NORMAL SHUTDOWN PROCEDURE
7.1 Introduction:
Information regarding the planned shut down should be passed to all related sections i.e., power
plant, OM&S, maintenance, inspection and other concerned units. Closed blow down system should
be emptied out and should be in a position to handle drawing/flushings from all equipments. Sufficient
flushing oil should be available for flushing operations during shutting down of the unit. During
shutdown care should be taken not to admit air into the system until all hydrocarbon vapors have been
removed. It is important that process unit operators involved in shut down under stand the purpose and
effect of each activity. In particular, operators should make sure that their actions will not result in
creation of hazardous conditions either because actions taken were wrong or these were taken at
wrong time. Rate of temperature drop in process unit equipment should not be very sharp to induce
thermal stress in piping and equipment. Ullage of slop tank has to be ensured to receive the off spec
product and slops. Flushing oil should be made available in adequate quantity.
7.2 Summary of the Procedure
The shut down involves the following important steps ;

a) Reduction in throughput
b) Shutdown of Naphtha Splitter Unit.
c) Shutdown of Vacuum Section.
d) Shutdown of Naphtha Stabilizer
e) Shutdown of Desalter
f) Shutdown of Crude Column
g) Emptying and Steaming out the System
7.3 Detailed Procedure:

The steps involved in the shut down of the Unit are detailed below.
Reduction in throughput:
Gradually reduce the throughput to about 55-60% of the normal value in steps.
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1. During reduction in feed rates, necessary adjustments would be made in the withdrawal rates of
Naphtha, Kerosene, LGO, HGO, HVGO etc.,
2. Also stripping steam to DA 41001 & DA 41101 is reduced proportionately.
3. The circulation reflux rates are adjusted.
4. Cut a few burners in BA 41001 and BA 41101 and reduce COT by 10°c if required.
5. Take pass flow control valves in manual.
Shutdown of Vacuum Section:

 After throughput reduction in CDU, RCO make will come down. Start reducing vacuum furnace COT
by operating TIC 2312 at 30°C/hr to 300 °C.
 At VDU cot 300°C , stop velocity steam to heater coils and stripping steam to vacuum column.
 Stop slop recycle at this temperature.
 Stop side stream withdrawal and increase internal refluxes to make the vacuum column bottom
more light. Route the products to slop as and when they go off specification.
 Cut off fires to vacuum heater .Leave only pilots on. Depressurize FG ring header after closing SDV
2301 through one of the lit burners.
 When ID fan suction temperature falls below 170°C bypass APH .
 Route VR to specified tank. VR can not go as bitumen. It will be too light.
 Decommission the ejector system.
Note : Close hot well liquid seal valve and non condensable return valve along with the last
ejector. Care must be taken to prevent air entry into the system.
 Cut off hotwell off gas to CDU heater by closing SDV1504 & route the hotwell off gas to atmosphere
through PV1513. Depressurize the hot well off gas header down stream off SDV1504 by opening to
one the burners .
 Isolate hot well water seal goose neck by blinding the flange next to hot well. Close hot well off gas
vent valve, near atmosphere heater, PV1513.
 Bring the vacuum column to around 0.5 kg/cm2 by backing in fuel gas by the 2” F.G line provided at
the inlet of first stage ejector.
 Stop chemical injection to vacuum column.
 Introduce stripping steam to kero stripper as HVGO is not available for reboiling.
 Take light flushing in heavy flushing oil drum.
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 Take flushing oil to pump suction and activate all CR loops to cool down the tower and also to
lighten the vacuum bed contents. Watch VDU top temperature. Do not allow hot well slop
generation. Route hotwell slop to heavy slop tank.
 Allow the system to cool down to 200°C. Ensure that the bed material and bottom material is light.
Pump out heavy material to slops. Vac. bottom pump is still running.
 Take the fuel oil through ring header bypass in VDU heater. Close the fuel oil supply and return
SDVs.
 Let FD fan continue to run to cool down the furnace.
Shutdown of Kero Splitter Unit:
 Start reducing COT at the rate of 25 °C/hr.

 Stop light naphtha withdrawal from reflux drum and put the KSU column on total reflux.
 Keep reducing burner fires. Stop admitting naphtha feed. When cot falls below 100 °C and fire box
temperature is around 200 °C cut off fires in KSU heater and keep pilots on. Depressurize the FG ring
header after closing SDV 3403 through any lit burner. Start F.O circulation through KSU heater ring
header bypass.
 Continue the naphtha circulation through heater till column bottom temperature is brought down to
ambient. Continue top reflux as far as possible till there is no level in the reflux drum.
 Put column top pressure in manual mode.
 To maintain the splitter pressure, first stop fin fans of kero splitter over head condensers and then admit
FG from fuel gas refinery header if required.
 Bypass the splitter. Stop light naphtha to ISOM feed and storage through caustic wash and water wash.
Full range naphtha is still being produced. Therefore use naphtha caustic & water wash .
 Cut off circulation through heater by stopping kero splitter bottom pump at the very end.
Shutdown of Naphtha Splitter Unit:
 Start reducing COT at the rate of 25 °C/hr.
 Stop light naphtha withdrawal from reflux drum and put the NSU column on total reflux.
 Keep reducing burner fires. Stop admitting naphtha feed. When cot falls below 100 °C and fire box
temperature is around 200 °C cut off fires in NSU heater and keep pilots on. Depressurize the FG ring
header after closing SDV 2103 through any lit burner. Start F.O circulation through NSU heater ring
header bypass.
 Continue the naphtha circulation through heater till column bottom temperature is brought down to
ambient. Continue top reflux as far as possible till there is no level in the reflux drum.
 Put column top pressure in manual mode.
 To maintain the splitter pressure, first stop finfans of naphtha splitter over head condensers and then
admit FG from fuel gas refinery header if required.
 Bypass the splitter. Stop light naphtha caustic wash and water wash. Full range naphtha is still being
produced. Therefore use heavy naphtha caustic & water wash .
 Cut off circulation through heater by stopping splitter bottom pump at the very end.
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Shutdown of Naphtha Stabilizer:

 Control system of stabilizer column shall be changed from total condensation to partial
condensation. LPG merox to be informed.
 Cut off LPG feed to merox. Isolate LPG run down to amine absorber. HCU is feeding LPG to amine
absorber so amine circulation is on.
 Reduce feed to stabilizer. De-cascade atm. column reflux drum level controller from stabilizer feed
flow controller.
 De-cascade stabilizer column top temperature controller TIC1920 from reflux flow controller
FIC1902.
 Operate stabilizer column on total reflux.
 Reduce the column top pressure very gradually by operating PIC1901 .Care must be taken to
reduce pressure slowly to avoid lifting of heavy ends and sudden release of heavy components to
FG system. Watch FG KOD level.
 Reduce heating media to stabilizer reboiler. Operate TIC 1905 to lower the temperature . Throttling
of FV1904A and increase of FV1904B opening on manual mode can be done for this operation.
 Pump out stabilizer reflux drum liquid to stabilizer till reflux pump looses suction.
 Keep receiving feed to stabilizer till atmospheric section starts operating on total reflux in course of
shut down and then cut off feed to stabilizer. Close the isolation valve in the stabilizer feed line.
 By utilizing the available pressure reduce the stabilizer bottom level and route stabilizer bottom to
naphtha r/d. Do not allow lighter components to go to tank.
 Stop heavy naphtha caustic and water wash circulation.
Shutdown of Desalter :
 Switch off power to both desalter power grids & stop water injection to the both desalters. Open
mixing valves of both desalters widely..
 Discontinue chemical injection to the desalter as well as the column overhead section.
 Shut off desalter effluent water (brine) lines after ensuring the water level is lowered to minimum.
Isolate the following pumps after stopping injection :-
GA - 41034 A/B = Ammonia solution injection pumps
GA – 41032 B = Demulsifier injection pump
GA - 41031 A/B &GA41043A = Corrosion inhibitor pumps
GA – 41033 A/B/C = Caustic injection pumps.
Shutdown of Crude Column:
 CDU section is running with minimum through put.

 RCO is still going to VDU through VR route.
 Start reducing furnace COT gradually by operating TIC1512 @ 30°C/hr. All controls to be taken on
manual.
 As the temperature of crude oil drops, there will be less of distillate products and column pressure
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will tend to fall. Admit fuel gas to reflux drum if required.

 Cut off atm. off gas to CDU heater burners and close SDV1603. Cut off FG back up to atm. off gas
header by closing PV1517. Depressurize the atm. off gas header to one of the lit burners.
 As column top temperature drops, quality of products will suffer .Route the products to slop if
needed. Inform related units. Naphtha quality to be watched. After stabilizer shut down naphtha
RVP will be high.
 Cut off stripping steam to side strippers as and when side streams are cut off. Cut off re-boiling
media to HN stripper & kero stripper.
 At a column bottom temperature of 300°C,cut off stripping steam to atm. column.
 With drop in temperature, the over head product yield will gradually come down. Cut off feed to
stabilizer and put the atm. column on total reflux. Stop heavy naphtha caustic and water wash.
 Liquid in reflux drum will be emptied out into crude column.
 Stop products withdrawal and stop product pumps.
 Cut off fires to heater leaving pilot alone. When FO firing is cut off, keep open purge steam to F.O.
guns. Close FO supply and return SDVs. Depressurize the FG header by opening to one of the lit
burners after closing SDV1501.
 Reduce CR rates slowly and stop CR pumps when pumps loose suction.
 With lowering of heater COT, RCO yield will increase and its viscosity will come down.
 Establish closed circulation. Please confirm that hot well slop oil is routed to either sour HSD tank or
Heavy slop tank.
 Once the closed circulation is on cut off pilots in all heaters.
 Once the ID fan suction temperature drops below 170°C bypass APH. Continue to run FD fan.
 Continue circulation till system gets cooled down sufficiently to about 100°C at the column bottom.
After this stop circulation.
 Ensure all battery limit product run down valves are closed.
 Keep a close watch on column pressure.
 After all jobs are over flush the ring header of individual heaters with flushing oil.
Emptying and Steaming out the System:
 If the unit is required to be emptied out for steaming, pump out all material to slop tank or specified
tank through VR circuit by running "long cold oil circulation loop" pumps till pumps loose suction.
 After maximum quantity of hydrocarbon material has been removed from the unit, drain all
equipments and lines to CBD one by one. Reverse blinds on CBD lines of various equipment to
open position. Drain all the oil to CBD. Ensure adequate ullage in CBD drum by pumping out CBD
drum contents to slop. Rise in CBD drum level should be watched periodically while draining.
 Using MP steam at crude inlet push Preheat I material to desalter.
 Pump out Desalter material to FA 41001.
 Connect MP steam at discharge of GA 41003 and push the line material to FA41001.
 Also through emergency steam of each pass of BA 41001 push the coil material to column DA41001.
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 Pump out DA 41001 material to slop.

 Pump out DA 41002, DA 41003 , DA 1004 and DA41005 material fully to slop.
 Push BA 41101 material to DA 41101 (Vac. column) using the emergency steam connection.
 Pump out DA 1101 material to slop till the pump loses suction.
 Connect steam hose where ever possible and push out the material from the lines to slop header.
Ensure that steam does not cross the B/L block valve, by checking the B/L bleeder.
 Drain the remaining material to closed blow down system after ensuring sufficient ullage is available
in CBD drum. Steaming out of the entire system is done as described during start-up.
 Ensure that the system is made Hydrocarbon free before handing over to maintenance. Steam
rigorously for about 6 hours.
 Before handing individual equipment to maintenance ensure blinds are inserted as per master blind
list and that the system is free of Hydrocarbon.
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CHAPTER VIII
EMERGENCY PROCEDURES
Introduction:
When safe running operation of the unit is interrupted due to some reasons, emergency procedures
are required to overcome the potential hazards. If continuation of unit operation on limited basis is
impractical , the unit should be shut down as quickly and safely as possible. Emergency procedures
attempt to overcome the hazard of quick shut down.
Emergencies are caused mostly by equipment failure, interruption of power or utility supply and
sometimes by fire. It calls for cool thinking and quick action on the part of operating personnel.
Operators should be thoroughly familiar with emergency procedures and understand the reasons for
each action.
The nature of the emergency can vary depending upon specific situation obtained at the time of its
occurrence. Therefore, no written procedure can cover all details or problems which might arise in an
emergency. Good judgment must be exercised. Operators judgment is likely to be more accurate to
meet the demands of the situation if prior planning has been made with adequate thinking. On specific
cases of known emergencies `Action-steps' have been listed briefly to be useful to carry out critical
operations immediately to ensure safety of the plant and personnel.
In tackling emergencies the aim should be, in order of priority:
 To restore normal operating conditions prior to the occurrence of the emergency, if possible.
 To continue operations on a limited basis, if thought desirable and feasible.
 To shut down and bring the unit to a safe condition adhering to normal shut down procedures as fast
as possible so that abrupt change in operating conditions are avoided thereby reducing chances of
`Hazards'.
 Time factor is very important during emergencies. Operators concerned are expected to take
necessary steps immediately without awaiting instructions from above. Therefore, they should have
a clear understanding of the steps to be taken in the event of an emergency and also the purpose
behind each move.
 Communication also is an equally important factor during emergencies as plants are interconnected
and co-ordination is required for effecting changes in flow streams, product routing etc. Operators
should inform the respective supervisors of the steps taken by them at the earliest to enable effective
co-ordination between different operating wings.
 Operators should be trained in action to be taken when trips occur in a particular section of unit.
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 To avoid development of emergency situations frequently, safe operating practices should always be
followed.
 Vents on unit equipment should be given same attention as relief valves & should be inspected
regularly as well as prior to putting them in operation. Right type of flexible hoses in good condition
should be used which should be suitable for material handled. For entering an utility, process stream
service valve should be opened first & should be closed at last. Sources of ignition should be
monitored very closely in plant which could arise from splash filling and charge of static electricity
accumulation on it. For this proper earthing of equipment should be ensured. Flash point of all
streams handled in the unit should be analyzed & recorded. Vacuum breaking of equipment handling
hydrocarbons should be done by FG, preferably nitrogen but never air. Water should not be put in a
vessel operating at 100°c. This may cause damage to the vessel.
 The panel operator must be fully conversant with the interlocks table given below to enable him to
handle the emergency in a proper way.
The major emergencies likely to be encountered during plant operation are discussed below.
Power failure:
Since the unit has many types of powers viz. HT,LT emergency power (AC & DC) etc. failure of each
type of power shall create a different types of emergency scenario. In this section power failure related
to unit equipment has been considered.
Effects:
1. All pumps will trip / stop.
2. All fin fan coolers will stop.
3. FD/ID fans to the heaters BA 41001, BA 41101, BA41002 & BA41007 will stop.
Interlocks Actuated:
BA 41001
Pass flow low-low or combustion air flow low-low will actuate the following:
1. Shut down of SDV 1501 on FG line.
2. Shut down of SDV1502 in fuel oil supply line.
3. Shut down of SDV1503 in fuel oil return line.
4. Shut down of SDV1504 hot well off gas
5. Shut down of SDV1603 atm. off gas
6. Shut down of PV1517 on FG back up to atm. off gas.
BA 41101
Pass flow low-low or combustion air flow low-low will actuate the following:
1. Shut down of fuel gas valve, SDV2301.
2. Shut down of SDV2302 in fuel oil supply line.
3. Shut down of SDV2303 in fuel oil return line.
ID / FD fans
Both fans will trip & stack damper will get opened.
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BA41002:
Low pass flow will actuate the following:-
Fuel gas valve SDV2103 will shut.
Fuel oil supply valve SDV2102 will shut off.
Fuel oil return line SDV2101 will shut off.
BA41007:
Low pass flow will actuate the following:-
Fuel gas valve SDV3403 will shut.
Fuel oil supply valve SDV3402 will shut off.
Fuel oil return line SDV3401 will shut off.
Both FD fan will trip.
Control room action:
If power fails for a short duration
1. Interlock actuation to be confirmed. Limit switches are provided for this purpose.
2. FG pressure valve PV 1501 of BA 41001 to be taken on manual and closed fully.
3. Fuel oil pressure valve PV 1505 of BA 41001 to be closed fully on manual mode.
4. Fuel gas pressure valve PV 2301 of BA 41101 to be closed fully on manual mode.
5. Fuel oil valve PV 2305 of BA 41101 to be closed fully on manual mode.
6. Close fuel gas pressure valve PV 2110 of BA 41002 on manual mode.
7. Close fuel oil pressure valve PV 2103 of BA 41002 on manual mode.
8. Establish coil flows on resumption of power supply and co-ordinate with field operators.
9. Column pressure will increase as there is no reflux flow & no fin fan in overhead. It should be controlled
by opening PV 1601A to flare.
10. Close the stripping steam control valves to DA41001, DA41004,DA41005 &DA41101 i.e.
FV1611,FVFV1704,FV1703 &FV2409 respectively.
11. Take all controllers on manual and close all control valves
Field operations:
If power fails for a Short Duration
1. Isolate FO & FG to individual burners and flush out oil from oil burner guns using burner purge steam.
However pilot burners should be kept on.
2. As soon as power resumes, start the ID and FD fans, after coordinating with the panel man. Purge out
the furnace.
3. Open velocity steam to VDU coils if MP steam pressure is available.
4. Break the vacuum in Vacuum column by admitting FG.
5. Open high vents of tempered water system.
6. If cooling water also fails open high vents of cooling water system.
7. Admit coil steam to CDU and VDU heater to push out the heavy material. Preferably to VDU heater.
8. If steam is not available and flushing oil from OM&S is available flush out the heavy material in the VDU
coils by opening flushing oil at GA41104 suction after closing suction valves. Flushing oil can also be
opened to GA41014 pump suction after closing suction valve.
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9. Open flushing oil to crude side of EA41035, EA41029 after closing crude in let valves. This is to flush
CDU heater coils.
10. If power is available start atm .over head reflux pump, over head finfans, and tempered water
circulation pumps & fin fans.
11. Start GA41106 pump and push out the heavy material from vacuum bottom.
12. Block the stripping steam to columns.
13. If flushing oil is not available and power is available start long loop cold oil circulation by taking crude
inside. Flushing oil to seals should be available.
14. If vacuum column pressure is coming up open, PV1513, hot well off gas to atmosphere.
If the power fails for a longer duration:
1. Isolate fuel oil/fuel gas valves in the field.
2. Isolate all the pilot burners.
3. Start emergency steam to coils.
4. Shut off Velocity steam to BA 41101
5. Close isolation valves of stripping steam.
6. Block off feed and run down valve.
7. Shut off ejectors and isolate vent and overflow line in hotwell.
8. Break vacuum with fuel gas and maintain system pressure of 0.5 kg/cm 2 in DA 41101.
9. Monitor system pressure and temperature in field.
10. If required cut in gas oil at the pump suction and dilute the materials. The flushing oil pumps are on
emergency power drive.
11. Close all pump discharge valves, including warm up lines to avoid reverse rotation of the pumps. If
check valves on pump discharge are not holding properly possible emptying out of the system may take
place.
12. Hold pressure in crude column, stabilizer and splitter by manually operating respective over head
pressure control valve.
13. Hold levels in column and vessels by manually closing the respective product run downs.
14. If flushing oil is available activate the vacuum slop circuit, HVGO circuit & LVGO circuit with flushing oil.
Cooling water failure:
Failure of cooling water supply to unit shall cause insufficient heat removal from various streams.
Effects:
1. Pressure in atmosphere and vacuum towers will go up; probably resulting in lifting of relief valves
2. Product rundown temperatures will go up.
3. Condensers and coolers will start hammering on the tube side.
4. Pump bearings will get heated up.
If cooling water failure is partial plant through put can be reduced and cooling water to consumption
points can be controlled.
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If cooling water failure is total, the unit has to be brought down urgently.
1. Firing to all the three heaters excluding pilots will be cut off.
2. Close stripping steam to all columns.
3. Column pressure should be watched for increase. If necessary some flaring may be done. Start more
over head fin fans if required.
4. Co-ordinate with field operator for all the steps.
Field operations:
1. Block off fuel oil and fuel gas individual isolation valves of all the furnaces . Oil burner guns to be steam
purged. Keep pilot burners on.
2. Open cooling water system high vents immediately.
3. Close all stripping steam isolation valves in the field and also velocity steam to coils.
4. Route all rundown products to slop.
5. If cooling water is not restored within 10 minutes, shut off all pilot burners.
6. Shut off ejector steam main valve. Hold positive pressure in vac. towers not exceeding 0.5 Kg/cm2; if
necessary back in fuel gas, isolate vent and block overflow line.
7. If sufficient flushing oil is available RCO circuit can be flushed out to VR run down circuit.
8. Alternatively coil steam can be opened and to push out the heavy material from vacuum heater coils to
vacuum column from there to VR run down.
9. All product pumps can be run to empty out and cool the system as far as possible (if pump bearing &
product run down temperature permits).
Steam failure:
Effects:
1. No atomizing steam to fuel oil burners

2. No stripping steam to towers
3. No steam to vacuum ejectors
4. No velocity steam to BA 41101 coils
5. No tracing steam.
6. No seal quench steam to pumps.
In the event of loss of steam, the unit will have to be brought down
1. Cut off fires to all heaters. Keep pilots on. Keep FD fan is on.
2. Close the stripping steam control valve to all columns.
3. Hold the levels & pressures in all columns &vessels by taking all controls in manual mode as far as
possible.
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4. Reduce the crude feed rate Co-ordinate with the field operator for resorting to closed circulation.
5. Close the ejector steam control valve manually.
6. Cool down the system by putting CR flows.
Field operations:
1. Isolate all fuel oil, fuel gas and atomizing steam valves to the burners. Keep pilots on .
2. Close all stripping steam block valves in the field.
3. Close velocity steam to vacuum heater.
4. Close the steam to vacuum ejectors and break vacuum by backing in fuel gas.
5. Admit flushing oil into GA41104 suction and also into GA41014 suction and flush out the heavy
material from the vacuum heater coils.
6. Stop all the pumps except atm. column over head reflux pump.
Instrument air failure:

Failure of instrument air will cause the various control valves to go to fail safe condition as stipulated in
P&ID and control valve data sheets. Instruments having pneumatic provisions such as closed loop
control valves etc. shall stop functioning. However, open loop instruments ( such as pressure,
temperature, flow and level indications only) involving only electronic data transmission shall remain
available on DCS in the control room. In the event of local instrument air failure of control valve it can
either be bypassed or operated with the aid of hand wheel where provided.
1. Keep a watch on BA 41001, BA 41101, BA41002 and BA 41007 outlet temperatures, and co-ordinate
with field operator.
2. Ensure that safety shut down valves cut off fuels to all running heaters.
3. Atomizing steam valves will go to full open condition.
4. All control valves will go to fail safe condition. Please watch it. For example BFW make control valves
to steam generators will go to full close condition.
5. The atm. column, stabilizer column top pressure control valves (CR control valves) shall go to full open
condition. The same should be regulated.
6. Keep all control valves in manual and keep ready at output of 0%.
Field operations:
1. Block fuel oil and fuel gas control valves to BA 41001, BA 41101, BA41002 and BA 41007.
2. Isolate fuel gas and fuel oil valves to the individual burners
3. Run FD fans to purge & cool the heater box.
4. Back up vacuum column with FG.
5. Regulate CR flows with bypasses.
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6. Close all rundown block valve and route product to slop.

7. Close all stripping steam block valves to the column.
8. Isolate ejector steam.
9. Start circulation and pump out the material to slop and dilute with gas oil.
10. Once instrument air is resumed Start up the unit as per normal procedure.
Furnace tube failure
If the tube leak is very small, say a pinhole leak it does not warrant an emergency shut down. The
unit can be brought down normally. However, if it is severe the following actions have to be taken
immediately. It is generally identified by heavy smoke coming from the stack and sharply rising flue gas
temperature.
Tube leak in CDU Heater (BA 41001):
Vacuum section will be put under circulation and will be shut down as per normal procedure.
Atmospheric section will be brought down either by emergency procedure or by normal procedure
depending on extent of leakage. A pin hole or a small crack in the tube may eventually coke up and
may not warrant an emergency shutdown.
1. Cut off all fuels to BA 41001.
2. Cut off firing in BA 41101.
3. Open stack damper.
4. Stop ID Fan.
5. Stop FD fan.
6. Close feed to heater and introduce coil emergency steam slowly.
7. Watch the column over head pressure. Column pressure may go up if coil emergency steam is
introduced.
8. Stripping steam to main column and side strippers to be cut off.
9. Top reflux will be continued as long as possible including other circulating refluxes.
10. To avoid gas backing to heater coils emergency steam to coils to be increased.
11. Co-ordinate with the field operator and associated departments.
Field operations:
1. Isolate all individual burners including pilot burners. Block the main FG and FO control valve. Flush all
FO guns with purge steam.
2. Stop pre-flash crude booster pump GA 41002 A/B. Isolate pass flow control valves.
3. Open snuffing steam to radiation & convection sections of furnace and purge .
4. Open emergency steam to coils depending on the requirement.
5. Pump out the column material to slop. Flush the column with flushing oil and empty to CBD.
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6. Steam out the system as per normal procedure .

7. Install blinds as per master blind list and hand over the system to maintenance.
Tube leak in VDU heater (BA 41101):
Atmospheric section can be continued diverting RCO through VR circuit and will be shut down with
normal shut down procedure depending up on RCO handling facility.
1. Cut off firing in BA 41101.

3. Stop ID fan.
4. Stop FD fan
5. Cut feed in BA 41101 by closing the feed flow control valves.
6. Close ejector steam.
7. Close stripping steam to column.
8. Stop IR flows and maintain CR flows as long as possible to cool down the system.
9. Cut of off gas to CDU heater. Open atm. vent if required.
10. Co-ordinate with field operator and other associated departments.
Field operations:
1. Block the main fuel gas and fuel oil control valves.
2. Isolate all individual burners in BA 41101 including pilot. Flush FO guns with purge steam.
3. Back up vacuum column with FG. And avoid gas backing to furnace by increasing steam to coils.
4. Cut off velocity steam to coils.
5. Divert RCO to VR circuit.
6. Open snuffing steam to radiation & convection sections of furnace and purge.
7. Open emergency steam to coils slowly.
8. Cut steam to ejectors and stop water to condensers. Drain the water.
9. Pump out all products to slop after diluting it with flushing oil. Empty out the column and drain.
10. Steam out the system as per normal procedure.
11. Install blinds as per master blind list and hand over to maintenance after steaming out.
Tube leak in NSU heater (BA 41002):
1. Cut off fires in BA 41002.

3. Stop ID fan.
4. Stop FD fan.
5. Close feed pass flow control valves.
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6. Close feed to Naphtha splitter.

7. Cool down the column by putting overhead reflux.
8. Cut off light naphtha production and put column on total reflux. And empty out reflux drum.
9. Pump out the column bottom to slop after coordinating with field.
10. Close air and heater out let damper to BA41002.
Field operations:
1. Isolate the fuel gas and fuel oil control valves. Close all the individual fuel gas and fuel oil valves
including the pilot burners. Flush FO guns with purge steam.
2. Start flushing steam to the coils.
3. Start snuffing steam to the heater and purge.
4. Route stabilizer bottom naphtha to naphtha run down bypassing Naphtha splitter.
5. Stop Lt. Naphtha product pump after emptying out reflux drum. Close run down.
6. After pumping out the column fully. Stop the pump GA 41020 A/B/C.
7. Drain the column material. Steam the system as per normal procedure.
8. Install blinds as per master blind list and hand over to maintenance.
Tube leak in KSU heater (BA 41007):
1. Cut off fires in BA 41007.

2. Stop ID fan.
3. Stop FD fan.
4. Close feed pass flow control valves.
5. Close feed to Kero splitter.
6. Cool down the column by putting overhead reflux.
7. Cut off light naphtha production and put column on total reflux. Empty out reflux drum.
8. Pump out the column bottom to NSU column after coordinating with field.
9. Route stabilizer bottom to NSU and bypass the KSU system.
Field operations:
1. Isolate the fuel gas and fuel oil control valves. Close all the individual fuel gas and fuel oil valves
including the pilot burners. Flush FO guns with purge steam.
2. Start flushing steam to the coils.
3. Start snuffing steam to the heater and purge.
4. Route stabilizer bottom naphtha to naphtha run down bypassing Naphtha splitter.
5. Stop Lt. Naphtha product pump after emptying out reflux drum. Close run down.
6. After pumping out the column fully. Stop the pump GA 41019 A/B/C.
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7. Drain the column material. Steam the system as per normal procedure.
8. Install blinds as per master blind list and hand over to maintenance.
CHAPTER IX
EQUIPMENT OPERATING PROCEDURES

Introduction:
Proper understanding of equipment operating procedures is key to smooth operation of unit and
minimum down time. In this section, general procedures for Startup/shut down and trouble shooting of
equipment are discussed. However, vendors operating manual should be studied for further details.
9.1 Pumps:
Pumps are one of the most vital equipments in this unit. The following general checks should be
performed on all types of pumps before putting them in operation.
1) Inspect and ensure that all the mechanical jobs are completed.
2) No load run of the motor to be carried out before coupling with the pump. Note the current drawn and
rotation. Get it corrected if not in accordance with pump rotation. De-energize electrical supply and
couple the motor with pump.
3) Rotate the shaft by hand to ensure that it is free and coupling is secured. Coupling guard should be
kept in place and secured properly.
4) Check oil level in bearing housing/gear box for correct level and quality. Flush and renew the same if
necessary.
5) Ensure that the cooling water supply and return lines are properly lined up.
6) Check whether suction/discharge blinds are removed and line up is proper. Suction strainer should be
clean and properly installed.
7) If pump does not operate at ambient temperature (i. e Hot Service/Cold Service pump) allow the pump
casing to attain correct pumping temperature to avoid damage of equipment and associated piping due
to thermal shock/vapor locking.
8) Care should be taken to avoid dry running of pump and back flow of liquid. Open suction valve fully and
energize the motor. Bleed if necessary to expel vapor/air.
9) Check for unusual noise, vibrations, rise of temperature of both motor and pump bearings.
Centrifugal Pumps:
Start-up:
a) Establish cooling water flow where there is such provision. Open external flushing liquid to seal in
pumps having such facility.
b) Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from the bleeder valve.
Keep discharge valve closed.
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c) Check the discharge pressure and see if it matches with stipulated shut off pressure. Open the
discharge valve slowly. Keep watch on the current drawn by ammeter. This should never exceed trip
setting value.
d) Check temperature of the bearings and if necessary adjust the cooling water flow (if provided).
e) Check the gland seal and if necessary adjust gland tightness/flow of the coolant to the seal.
f) Open seal quench steam if it is provided.
g) Close the warm up valve if the provision is available.
Shut-down:
a)Close the discharge valve fully and stop the pump. This is to avoid reverse rotation of pump.
b)If pump is going to remain as stand-by and has provision for keeping the pump hot/cold, proceed as
follows :-
i) Open the valve in the by-pass line(warm up valve) across the discharge valve and check
valve.
ii) The circulation rate should not be so high as to cause rotation of idle pump or overloading of
the running pump.
c) If pump is to be prepared for maintenance, proceed as follows :
i) Close suction and discharge valves.
ii) Close valve on check valve bypass line, if provided.
iii) Close cooling water to bearing, if provided. (after cooling the pump)
iv) Close external flushing liquid to mechanical seals, if provided.
v) Close seal quench steam to seals ,if provided.
vi) If pump is under vacuum service isolate vacuum vent line.
vii) Slowly open pump bleeder and drain liquid from pump to CBD. If the liquid is very hot or
cold, allow sufficient time before draining is started. Ensure that there is no pressure in the
pump. Open the casing atm. vent after complete draining and confirm that entire liquid is
drained. Open OWS drain.
viii) Blind suction and discharge valves and check valve by-pass line and vacuum vent line.
ix) Cut off electrical supply to pump motor prior to handing over for maintenance.
Trouble Shooting:
(a) Pump not developing pressure :
Bleed/vent pump casing.
i. Check the line up in the suction side.
ii. Check the Suction strainer for clogging.
iii. Check liquid level from where the pump is taking suction (physical verification).
iv. Check pump coupling and rotation.
v. Check the foot valve (in case of vertical lift pumps) for free movement of seat.
vi. Check the temperature of liquid, If it is higher than pump design NPSH will come down.
vii. Check for any air leakage in the pump suction line or pump casing.
This may occur at various joints and packing boxes as the packing ages.
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(b) Unusual Noise

i. Check if coupling guard is touching coupling.
ii. Check for proper fixing of fan and fan cover of the motor.
iii. Check for pump cavitation.
(c) Bearing Temperature Increase
i. Generally the bearing temperature upto 80°C or 50°C above ambient whichever is lower can be
tolerated. Refer Vendor's Instruction Manual.
ii. Arrange lubrication if bearing is running dry or oil level is low.
iii. Adjust cooling water to the bearing housing if there is such provision.
iv. Stop the pump, if temperature is too high. Call the pump technician.
(d) High Gland Temperature
i. Adjust cooling water if facility exists.
ii. Slightly loosen the gland nut, if possible.
iii. Stop the pump and hand over to maintenance.
iv. Arrange external cooling if pump has to be run for sometime.
(e) Unusual Vibration
i. Check the foundation bolts.
ii. Check the fan cover for looseness.
iv. Check alignment.
In case of pumps connected with the system operating under vacuum, pump vents shall be going back
to vacuum column flash zone through a common line. Such vent system is necessary so that a
vacuum can be pulled on a pump casing before the suction valve is opened for priming.
After isolating the pump from main system, pump can be drained in usual way. However, pumps will
have to be vented back to column, in the event of cavitation or vapor locking problems.
Positive Displacement Pumps:

Start Up:
1) Open suction and discharge valves fully including safety relief isolation valves, never start the pump
with discharge valve closed.
2) Adjust the pump stroke in case of reciprocating pumps and run the pump at desired settings.
3) Watch discharge pressure and check the rate of pumping using the flow meter or by taking suction
from the calibration pot.
4) The valve on the re-circulation line (provided in case of gear-pump, screw pump etc.) shall be adjusted
to obtain the required discharge pressure.
Shut Down:
1) Stop the pump and close the suction and discharge valves to isolate the pump.
2) If the pump is going to remain as standby and has provision for keeping its casing hot/cold, open the
valve in by pass line across the discharge valve and check valve.
3) If the pump is to be prepared for maintenance, proceed as follows
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4) Drain the liquid held up in casing. If the liquid is very hot or cold, allow sufficient time before draining is
started. Ensure that there is no pressure in pump.
5) Blind suction and discharge lines and warm up line.
6) De-energize the pump motor.
Trouble Shooting:
(a) Insufficient discharge pressure :
i. Check the line up in suction side.
ii. Check the functioning of the safety valve and pressure control valve on discharge to suction.
iii. Check up suction pressure.
iv. Check the strainer on the suction side.
v. Check for insufficient liquid level in the vessel from which pump is taking suction.
vi. Check pump coupling and rotation.
vii. Get the pump checked by pump technician.
(b) High Discharge Pressure
i. Check the line up on the discharge side.
ii. Check pressure control valve opening.
(c) Leaky Gland :
i. Check for normal pump discharge pressure
ii. Tighten the gland nut slowly if possible.
iii. Hand over the pump for replacing gland packing.
(d) Unusual Vibration
i. Check the foundation bolts.
ii. Check motor fan cover for looseness.
9.2 Heat Exchangers:

Introduction
Heat exchangers can be broadly classified into following types :
a) Water Coolers / Condensers
b) Steam Heaters
c) Chillers
d) Exchangers
Start up / Shut down procedures shall vary slightly from case to case. However, general start -
up/shutdown procedures are discussed in the following paragraphs.
Start Up:
After the heat exchanger has been pressure tested and all blinds removed, proceed as follows:
a) Open cooling medium vent valve to displace non-condensibles (air, fuel gas, inert gas etc.) from the
system. Ensure the drain valves are closed and blinded. This activity is not required if gas is the
medium.
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b) Open cooling medium inlet valve. Close vent valve when liquid starts coming out through it, then open
cold medium outlet valve and fully open the inlet valve also.
c) Open hot medium side vent valve to displace non condensibles (air, fuel gas, inert gas etc.) Check that
the drain is closed and blinded. This activity is not required if gas is the medium.
d) Crack open hot medium inlet valve. When liquid starts coming out from the vent valve, close it. Open
hot medium inlet valve and then open the outlet valve fully. In case of steam heaters, initially the
condensate shall be drained to sewer till pressure in the system builds up to a level where it can be
lined up to the return condensate header.
e) In case bypasses are provided across shell and tube side, gradually close the bypass on the cold
medium side and then the bypass across the hot medium side.
f) Check for normal inlet and outlet temperature. Check that TSVs are not popping.
g) The operation of inlet and outlet valves should be done carefully ensuring that the exchangers are not
subjected to thermal shock.
h) Blind the vents opened for bleeding.
In case of coolers/condensers, adjust the water flow to maintain the required temperatures at the
outlet. The return water temperature should not exceed 45°C.
For avoiding fouling, velocity of water should be 8 ft/sec in a cooler/condenser.
Shut down:
a) Isolate the hot medium first. In case both hot and cold medium are from process streams, exchanger
shall remain in service till the hot stream has cooled down enough.
b) Isolate the cold medium next.
c) Drain out the shell and tube sides to OWS/Sewer/closed Blow down system as applicable.
d) Depressurize the system to atmosphere /flare / blow down system as applicable.
e) Purge if required.
f) Blind inlet and outlet lines before handing over the equipment for maintenance.
9.3 Furnace :-
start-up: General points:
 Start FD fan and keep required combustion air flow.

 Open snuffing steam, soot blowing steam, coil emergency steam and atomizing steam main
isolation valves to heater.
 Check if atomizing steam PDV is working by opening steam to some burners. Open steam trap
bypass to remove condensate.
 Ensure fuel gas KOD is free of any liquid condensate.
 Commission steam/electric tracing on the fuel gas supply system of the heater.
Purging and testing of fuel lines:
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 Purge the fuel gas and pilot gas lines and each individual burner with nitrogen d/s of the main block
valve.
 Pressurize the fuel lines to 2.5kg/cm2 and carry out the leak test.
 Once leak test is negative de-pressurize the fuel lines to 0.3kg/cm2.
 Re-commission all instruments previously isolated for the pressure test.
Lighting pilot burner:
 Open pilot gas line main block valve.

 Check igniter.
 Open gas to the pilot burner and light with igniter.
 Check for flame and adjust the air control of the pilot burner if necessary.
If pilot has failed to ignite (for 15secs) then cut off burner and try the adjacent pilot (The multiple
attempts described might only occur following nitrogen purging of the pilot system).
 After all pilots are lit increase the air damper opening to ensure that they do not get put off.
Lighting fuel gas burners:
 The fuel gas header is kept pressurized with nitrogen at 0.3 kg/cm2 after completion of pressure
test.
 Open the main FG valve and pressurize the header to the recommended value.
 Adjust combustion airflow.
 Gradually open the burner gas valve until the burner ignites from the pilot. Continue opening the
valve until a steady flame is obtained. If at first burner fails to ignite within five seconds, shut the
valve and wait for 5 minutes before making a further attempt. Initial failure of the gas to ignite may
be due to residual nitrogen in the system.
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Lighting the fuel oil burners:
 Ensure that all individual burner valves are closed and all drains/plugs on the fuel oil supply and
return lines are plugged.
 Ensure that the steam tracing is on for FO ring header
 De-blank the fuel oil supply and return lines and establish circulation through the ring header.
 Ensure fuel oil system is circulating at required temp., pressure and flow.
 Commission the atomizing steam supply to the burners and adjust the differential pressure. Check
the atomizing steam temperature.
 Maintain the required heater draft.
 Open the individual burner purge steam valve and purge the gun barrel.
 Close the purge steam after ensuring that there is no leak at the fuel oil gun assembly.
 Open atomizing steam isolation valve fully to burner.
 Gradually open the burner oil valve until the oil spray ignites from the fuel gas flame.
 Adjust air registers for proper flame shape.
 Normalize the heater draft .
 After completion of lighting all burners take heater COT cascading with FO/FG control.
Furnace shut-down:
 Take the heater outlet TIC out of service and place the fuel pressure on manual.
 Reduce the number of burners as required with reduction in throughput.
 If combustion air pre-heater is on line then gradually bypass the combustion air in order to prevent
the flue gas being cooled below its dew point.
 Maintain the heater pass flows above the minimum specified until all the fires (including pilot) are
cut off.
 Gradually reduce the fuel oil firing and cut off all the burners.
 Flush the FO guns with purge steam.
 Gradually cut off the fuel gas burners. Close the fuel gas main supply valve (This assumes that
the fuel oil supply has been shutdown, purged and guns removed earlier).
 Ensure the pilots are burning satisfactorily, then open one main gas burner valve to burn off gas
and de-pressurize the system.
 Shutdown all pilots one at a time and keep only one burner on line (subsequent to closing the
main valve). This will ensure de-pressurization of the line.
Blank off FG and PG lines and keep them pressurized with nitrogen.
Furnaces:
General Instructions:
1) Always light all pilot burners first.

2) Use low voltage carbon arc igniter to light pilot burners.
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3) If electrical igniter is not available use FG manual torch for lighting pilots.
4) Do not use carbon arc igniter to light main oil burner ; use propane gun, since the carbon arc flame
does not have enough energy.
5) Always light main FG burner then main FO burner.
6) Shut off fuel oil burners and subsequently keep one main gas gun on and isolate main gas line
valve and depressurize through the single active gas burner. Finally stop all pilot burners except one
and close the pilot gas main valve and depressurize through the single active pilot burner.
7) The air required to produce a given heat output is the same irrespective of fuel burnt e.g. 1pound of
air produces 1230 BTU with carbon ( 0.088 Pounds) or 1.520 BTU with Hydrogen ( 0.029 pounds) .
This means heat releases are quite close for one pound of air used. Since the furnace heat duty is
fixed, the air requirement is roughly constant for fuel oil or fuel gas .
8) Every volume part of excess oxygen supplied brings in four parts of excess Nitrogen by volume.
Together they carry away the heat up the stack. So avoid using excess air.
9) One pound of carbon releases 14000 BTU and one pound of Hydrogen releases 52500 BTU on
complete combustion. But partial combustion of carbon to Carbon monoxide releases only 4000 BTU
for pound of carbon
10) To ensure complete combustion use excess air at 20% for gas and 30 % for oil. This means 5%
excess oxygen for gas and 8% excess oxygen for oil.
11) Oxygen analysis by analyzers of flue gas is a best method to determine furnace efficiency. The
percentage excess oxygen will directly correspond to excess air. There is hardly any difference
between fuel oil and fuel gas.
12) The percentage Carbon Dioxide, if measured, instead of percentage oxygen, will not give
percentage excess air directly. Percentage Carbon Dioxide and fuel composition both together affect
percentage excess air.
13) The pilot gas burner , burning low pressure fuel gas , has bigger diameter holes and hence does not
get choked by dirt. Pilot gas burners go off last since they use low pressure fuel gas and even in the
case of fuel gas failure, they continue to burn without backfiring for quite some time.
14) Do not clean the orifices of a gas gun or an oil gun with wire brush. This will enlarge the holes . So
use steam; or brass tools .
15) Excess air to a furnace can be increased in two ways to avoid black smoke coming out of the
chimney.
 Open stack damper slightly more. This also increases the furnace draft.
 Increase air through individual burner registers. This will decrease the furnace draft.
Hence opening the stack damper more is a better option .
16) Too much excess air can make the flame cold and even put out the flame.
17) Too much excess air will increase the temperature of flue gas.
18) It is very important to have a negative pressure in the furnace at all levels ( we open peepholes
confident of a negative pressure at this level). The least negative pressure is at furnace hip arch
(upstream of convection zone) . At this point the furnace pressure can become positive even if there
is a slight external chokage of finned convection zone tubes. This is the place from where pressure
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tappings are taken to check and stop FD fan incase the furnace pressure at this point becomes
positive. At stack damper level and at furnace bottom level the draft is quite negative, typically
22mm water column.
19) The gas flames must be bluish with yellow tinge at the tip .
20) The oil flames must be bright yellow.
21) Keep the atomizing steam valve open even if the corresponding oil gun is not working. This protects
the oil gun from the heat of the pilot flame and the gas flame.
22) Inclined tube manometers measure the negative pressure at the arch level better since we have to
measure very small negative pressures. E.g. : 2 mm water column.
23) The furnace pressure becomes positive because of either
 Stack damper is closed more.
 The burners are working full blast.
Normal Running Cases for Furnace:
If a few basic and simple rules are observed, the on stream time of the furnace and the life of the
equipment can be extended. The following points need attention in this respect:
1) Flame impingement on heater tubes or walls is to be totally avoided.
2) The flame at all burner points should be as uniform in length and size as possible.
3) All the burners are to be kept in trim condition all the time with cleaning of tips as necessary.
4) Burner flames should be bright and without tendency of smoking.
5) For even distribution of heat all the burners of the furnace are to be kept in operation even at reduced
throughput level.
6) Atomized oil behaves like gas, and is explosive, proper care should be taken in its handling.
7) While the fuel is burning, there is very little chance of explosion. Possibility of explosion is high while
lighting the pilot burner and when a main gas burner gets extinguished. The latter is more dangerous.
8) If by maintaining equal pass flows the pass outlet temperatures differ, first adjust the burners for
uniform firing rates. If still the temperatures are different, variation in flows among the passes upto a
maximum of 15% may be allowed in exceptional cases.
9) Individual pass flows must not be allowed to come below the stipulated minimum.
10) Studded tubes in the convection section may cause deposition of soot on the surface thus affecting the
heat transfer. Soot blowing operation is to be done in periodic intervals to ensure dislodging and
removal of the soot.
11) Frequent visual inspection of the furnace should be carried out with particular attention on the
conditions of tubes (bulging, blowing, hot spots etc ) and refractory. Any indication of defect on any of
the above points should be immediately recorded for action plan.
12) Watch the pressure differential across the individual passes. Abnormal rise indicates obstruction which
has to be investigated.
13) Any increase or decrease in COT is to be slow to avoid possible overheating. Also the limit on COT
should not be exceeded.
14) Operating instrument should be checked periodically, the period being decided based on experience
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with the instrument.

15) Any oil spillage, oil rag, cotton waste or any other inflammable material lying around the furnace is to be
cleaned immediately.
Cares for Refractory Lining:
Prime factors for deterioration of refractory lining are the following.

Care should be taken to protect the lining against these factors.
(i) High temperature Operation (long time exposure)
Bonding material may fail, fusion and loss of structural strength may take place, thermal conductivity of
insulation may increase, thus exposing the supporting steel to higher temperature.
(ii) Fluctuating Temperature of Operation (Heating Fluctuation)
Cracks may develop on the refractory lining, which may further deteriorate the condition of the lining.
(iii) Impingement of Flames
Localized overheating may result in fusion, sometimes associated with development of cracks in the
adjoining areas.
(iv) Presence of harmful constituent in the flue gases (i.e. Sulfur or vanadium compounds.)
The gases in contact with the lining at high temperature, react with and corrode the lining. Also if
cracks within the lining are present these gases may react with the metallic shell and affect it.
(v) Entry of water and moisture
Moisture can enter from outside through any opening or any crack in the metallic shell may also cause
deterioration in refractory lining.
9.5 Decoking Procedure:

The general description of the procedure in sequence of operation is as follows :-
1. After shutting down, steaming out of heater coil and transfer line, reverse the swing elbows at heater
inlet and outlet to decoking position.
2. Spalling will be done simultaneously in all the coils but steam air decoking will be done only in one coil
at a time. During the period when air is introduced to one coil steam flow to other coils will be
continued.
3. Fire heater as per standard procedure. At a firebox temperature of about 200 - 250°C. Introduce
steam at about 2000 Kg/hr per coil through decoking manifolds and open the outlet of the coils to the
decoking pot FA 41006.
4. Commission water spray to decoking pot.
5. For uniform heating of tubes, use every other burner preferably use fuel gas firing to obtain good
control.
6. During this period reverse the flow of steam to the coils every hour so that maximum amount of coke is
removed.
7. When the outlet temperature reaches about 475 - 500°C, hold at this level and continue reversal every
hour till no more coke comes out of the decoking pot outlet.
8. Through the coil connected to decoking manifolds gradually introduce air @ 150 M3/hr in steps of 30
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M3/hr. Burning is evident by presence of black color in effluent from decoking pot.
9. In tubes having heavy depositions of coke the tube will glow when the coke is being burnt. The tube
temperature must never exceed 650°C. In case the outlet temperature of the coil tends to increase
beyond 600°C, cut back the air or increase steam flow.
10. During this period, flow through the coils should be reversed every hour to obtain effective decoking.
11. Take samples at points provided at effluent line to decoking pot and analyze for CO 2. Flow should not
be reversed during sampling.
12. When two consecutive effluent gas samples show less than 1% CO2, the decoking is considered to be
complete.
13. Repeat this procedure of steam/air decoking for other coils.
14. When decoking is complete, gradually reduce the furnace firing till the box temperature comes down to
about 250 - 300°C, put off the fires. Blind fuel oil and flue gas headers.
15. Increase steam rates to coils to remove the residual ash and clean the tubes.
Precautions:
1) Heater temperature must be brought up slowly in order to obtain on even distribution of heat.
2) A close watch should be maintained on the fire box and skin outlet temperatures. But these alone
should not to be the guiding factors as thermocouples may be coked up or damaged during normal run,
visual inspection, therefore is most important for judging and controlling the severity of coking.
3) When burning takes place the coil should not be allowed to be overheated. In case cherry red color is
observed on the tubes which indicates the temperature in the range of 650°C cut back or stop the air
rate and reintroduce at a gradual rate. Also increase steam if required.
CHAPTER-X
10.1 CDU Section wise startup procedure:
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S.NO DESCRIPTION
STARTUP OF CDU 2 SECTION

Normally CDU and VDU will be started simultaneously, but due to unexpected reasons during shutdown if
VDU section is not ready then CDU section can be started individually and following startup procedures to be
1
followed for safe startup of this section. This startup procedure illustrates on normal startup of unit after annual
turnaround maintenance activity.
Atmospheric section including overhead drum and exchanger’s pressure test to be carried out at 1.5 kg/cm2.
2
After leak checks section has to be depressurized and loop to be prepared for steam out.
Steam out loop has to be first prepared as per available procedure. All low point drains and top vents to be
3 kept open. The heater coils may have water utilized for hydro test, therefore this has to be removed by slow
heating of coils.
4 Light up pilots and raise box temperature at a rate of 50° C per hour.
Hold the temperature at 120° C for 4hrs. (During this period the heater box along with refractory will get dried
5
out and coil holdup water also will also get displaced).
Raise the box temperature to around 150°C and admit steam to coils. Admit around 2000 kg/hr steam to each
6
coil.
7 Preflash vapor control valve and bypass to be kept open to carryout steam out of Preflash drum.
Desalter water filling to be done and PSV u/s bleeder to be kept open for displacing air pocket. The water in
8
the desalter to be drained with nitrogen to make the system air free.
9 Preheat train exchangers shell and tube side to be filled with flushing oil and kept ready.
Raise system pressure to around 1.0 kg/cm2 by increasing steam flow if required and check for leaks at
10
disturbed flanges. Steam out to be done for at least 4 hrs.
11 Slowly start closing vent and drain points and maintain column pressure by cutting down steam to coils.
12 Once steam out is completed system to be bached up with fuel gas as per procedure.
13 Cut fuel gas firing in heater, keep only pilots on.
Drain at all low points as lot of water may have accumulated due to condensation. After completion of draining
14
maintain system at 1.0 kg/cm2 pressure. Now system is ready for taking in hydrocarbon.
Startup circulation
Line up all cooling water exchangers. Charge slowly LPS and MPS header by keeping trap bypass open. Once
1
full header pressure is attained close steam trap bypass. Line up all equipment PSV’s
2 Start ID & FD fan and purge the heater.
3 Start FO pump and attain circulation.
4 Admit Crude at battery limit by starting OM&S pump.
Fill desalter by keeping vent to OWS open. Once crude comes from desalter vent close vent valve and line up
5
pre heat exchangers crude side and admit crude into preflash column.
Build up level and start preflashed crude pump and fill heater coils and CDU column bottom. Once level
6 appears in CDU column bottom start RCO pump and route to SR circuit u/s of EA41028 bypassing VDU
section.
The bypass valve of all exchangers connected with vacuum section crude side to be kept open and its inlet &
7 outlet valve to be kept closed. Its CR and Product side inlet outlet and bypass to be kept closed and to be kept
fully drained.
The Crude from SR circuit will be routed back to unit inlet i.e. GA41001 suction and circulation will be
8
established. Keep maximum flow through coils to displace all water traces.
Water Draining from Loops
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9 After circulating for 2 hrs stop circulation & allow settling for 1 hr.
Then drain water from all low points i.e. all exchanger bottom drain, Desalter bottom, Pass flow control valve,
10
Column, Preflash drum, all pump suction and U loop drains.
11 Start circulation again once draining is completed.
Start raising temperature in system by taking fuel gas burners in heater. Raise the Process temperature at a
12
rate of 30° C per hour.
When Process temperature reaches 150° C cut heater firing in heater and stop circulation and allow for 1 hr
13
water settling.
14 Drain all loops and restart circulation.
Startup
1 Raise the Process temperature at a rate of 30° C /hr. Raise the process temperature till it reaches 180° C.
2 Carry out preliminary round of hot bolting of all disturbed flanges.
3 Line up crude from battery limit and route RCO to SR tank.
4 Maintain a crude flow rate of around 400 m3/hr.
5 Raise temperature further at a rate of 30° C. At around 280° C carryout second round of hot bolting.
6 Start desalter grid when desalter inlet temperature reaches 100° C.
7 Start reflux pump and keep minimum reflux. Maintain top temperature higher that due point.
8 Overhead fans to be started to get required reflux flow.
9 When Column temperature starts building start HGO, LGO, Kerosene and HN CR pump.
10 Check product route up and keep it lined up to slop.
11 Open Stripper LV and raise levels in Strippers and start drawing product maintaining some over flash flow.
12 Start Overhead and Product fans as and when required.
13 At around 320° C admit stripping steam at column bottom and strippers.
14 Start chemical injection pump i.e. corrosion inhibitor and NH3.
15 Close Preflash drum pressure control valve bypass and put CV an auto control.
Desalter water pump to be started and bottom level to be made up. Brine from Desalter No 1 to be routed to
16
ETP.
17 Start Desalter u/s and d/s caustic if required depending upon the crude.
18 Raise the CDU heater COT to normal operating temperature and stabilize the unit.
Check colour of all product and if OK send check samples for density. If results are acceptable then products
19
can be routed to Tanks.
STARTUP OF VDU 2 SECTION
It is presumed here that CDU2 section is already running.
Following crude side and shell side bypass of exchangers EA41015, EA41027A/B, EA41024A/B, EA41033,
1 EA41036, EA41018A/B, EA41025, EA41034 & EA41029 to be kept in open condition, and its outlet in closed
condition.
2 The exchanger inlet should be kept partially open to avoid pressurization.
By the time VDU section temperature reaches 180° C, CDU section feed has to be brought down to 500
3
m3/hr.
Steam out of VDU Section
This section may have been kept shut down for various reasons, but following procedure illustrates procedure
1
for startup after maintenance activity and can be cut short depending upon the status of the unit.
2 Light up pilots and raise box temperature at a rate of 50° C per hour.
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Hold the temperature at 120° C for 4hrs. During this period the heater box along with refractory will get dried
3
out and coil holdup water will also get displaced.
Raise the box temperature to around 150°C and admit steam to coils. Admit around 2000 kg/hr steam to each
4
coil. Allow steam to come out from all drain and vent points.
5 Slowly start closing vent and drain points and maintain column pressure by cutting down steam to coils.
When all vents and drain valves have been closed open fuel gas backup valve and admit FG to system.
6
During this period system pressure will drop drastically and fuel gas flow to be appropriately increased.
7 Slowly cut steam fully and maintain positive pressure in System.
8 Cut fuel gas firing in heater, keep only pilots on.
Keep all 1st stage ejector process side isolation valve closed drain at all low points as lot of water may have
9 accumulated due to condensation. After completion of draining float system with flare by opening Column PSV
bypass. Now system is ready for admitting in hydrocarbon.
Startup circulation
1 Take flushing oil into Vacuum column and raise bottom level.
Start column bottom pump and start closed loop circulation i.e. column bottom to Vacuum heater coils and
2
back to column, keep maximum flow through coils
3 Take flushing oil into all the beds i.e. HVGO, LVGO, VDO and start circulation.
Take flushing oil in Vacuum slop drum and start circulation to VDU heater for some time and then circulate to
4
drum.
Keep Internal reflux for some time and then keep control valve closed, this is to avoid excess level build up
5
and bleeding from column bottom.
Keep circulating flow at maximum possible rate, except HVGO CR as it will suddenly cool kerosene stripper
6
(EA41012A/B does not have isolation valve on kerosene and HVGO CR side).
Water Draining from Loops
7 After circulating for 2 hrs stop circulation & allow settling for 1 hr.
Then drain water from all low points i.e. all exchanger bottom drain, pass flow control valve, Column, Slop
8
drum, all pump suction and U loop drains.
9 Start circulation again once draining is completed.
Start raising temperature in system by taking fuel gas burners in heater. Raise the Process temperature at a
10
rate of 30° C per hour.
When Process temperature reaches 150° C cut heater firing in heater and stop circulation and allow for 1 hr
11
water settling. Drain all loops and restart circulation.
Startup
1 Raise the Process temperature at a rate of 30° C /hr.
Open all exchanger hot media (Presently cold) outlet isolation valves and allow some amount of flushing oil to
2 flow through it. Care to be taken to see that exchangers do not get heated up suddenly and exchanger bypass
is kept in full open condition.
3 Once temperature reaches 120° C start closing exchanger bypass on CR/Product side.
4 Close exchanger CR side bypass fully by the time process temperature reaches 150° C.
5 Raise the process temperature till it reaches 180° C.
6 Carry out preliminary round of hot bolting of all disturbed flanges.
7 CDU COT has to be reduced to 340° C to minimize thermal shocks in pipeline and equipments.
8 Keep all CR/Product exchangers Crude side inlet valves fully open, (which were initially kept partially open).
9 Take additional burners in CDU heater to avoid drop in CDU COT at this time.
10 Start Opening Exchanger outlet on crude side and slowly open it fully.
11 VDU column temperature will start rising due to the heat transfer in exchangers from crude side.
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Reduce Vacuum column bottom level and slowly spike in RCO from atmospheric column bottom to VDU
12
heater coils.
Bleed excess level to SR circuit. (During this period, care to be taken to avoid RCO entering VDU column and
13
flooding).
14 Once hot bolting of all disturbed flanges is completed, start raising the VDU COT again at a rate of 30° C.
15 Line up cooling water to all exchangers. All VDU product tempered water exchangers to be kept lined up.
16 Fill water in hot well and line up atmospheric vent control valve.
Warm up ejector steam header and build up pressure. Open process side isolation valve of all ejectors except
17
3A & 3B.
18 Close VDU column PSV bypass to flare and line up ejector 3C.
Slowly increase RCO bleed to VDU heater coils and line up RCO fully to VDU heater and close VDU bypass
19
valve.
Isolate vacuum heater closed circulation valve and open VDU column normal outlet valve fully. Now column
20
bottom section is normalized.
21 Start VDU CR fin fans and maintain column top temperature.
Start taking ejectors in second stage also. Line up ejectors in this order 3A, 2C, and 2A. Keep ejector 1B and
22
1C process side in closed condition.
When VDU COT reaches 300° C start closing ONLY CR circuit exchanger’s crude side bypass valve slowly
23
and close it completely by the time COT reaches 350° C.
Start closing all CR exchangers crude side bypass valves and slowly close it fully.(At this time HVGO, LVGO
24
and VDO temperature might have raised to match its CR exchangers crude side temperature).
25 Start IR flow and slowly increase to desired flow.
All product route up to slops to be kept ready by this time. As and when bed level raises product to be routed
26
to slop through product exchangers.
Once product flow is established then product side exchanger’s crude outlet can be opened and bypass can
27
be closed slowly.
28 Introduce velocity steam to all coils at VDU COT of 375° C at all 3 points.
29 Start NH3 injection pump.
30 Hot well slop oil to be routed to slop and all beds excess levels to be pumped out to slops.
31 Introduce stripping steam slowly and increase to desired flow.
32 Take ejector 1A on line.
33 Increase CDU and VDU COT to desired value & stabilize unit.
34 Once unit is stabilized APH to be taken on line.
35 VDU off gas to be routed to heater.
10.2 CDU-2 UNIT STARTUP PROCEDURE:

S.NO DESCRIPTION
CDU 2 STARTUP :
1 Flare header is lined up
2 All the blinds are removed as per the list
3 Ensure all motors meggar value and earthing is checked
4 Ensure cooling water to all Equipments are lined up
5 All the blinds are removed as per the list except fuel gas, pilot gas and off gas
6 All control valves are stroke checked
7 All PSV are on line.
8 Cooling water supply and return headers lined up
9 Cooling water to all exchangers are lined up
10 Establish for circulation in BA41001 /BA41101 /BA41002
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11 All the pumps/motors are energized.

12 PA41001 & PA41002 transformers are energized
13 Keep 40% water in FA41015
14 Keep 40% caustic in FA41016
15 All vents and drains are isolated and blinded.
16 Ensure all the utilities are available
17 Inform Power Plant, OM&S and other associated unit regarding startup of the unit
18 Check all utilities availability, including tempered water circulation
19 Open lt. flushing oil to Hy.flo oil jump over to Hy.flo drum
20 Start Lt.flo pump GA41044 and Hy. Flo pump GA41110
21 Put unit on closed cold oil circulation
ROUTE :
GA41001-PHT1-DESALTERS-PHT2-PREFLASH VESSEL-GA41002-PHT3-ATM.HEATER-ATM.COLUMN
22 BOTTOM-GA41014-VAC.HEATER-VAC.COLUMN BOTTOM-GA41106-EA41028A/E-EA41063-
EA41058A/B-EA41109A/B-LT.slop header to crude oil inlet line
Note -- Lt.slop battery limit valve should be closed condition before staring cold oil circulation. And hy.slop
23
jump over should be closed
Maintain preflash drum, atm column bottom and vac column bottom level at 60%. While on circulation
24
excess levels can be bleeded to specified tanks
25 Preflash vapors to be routed to flash zone.
26 Warm up FA41023, FA41024 and EA41054 and keep vents open.
ATMOSPHERIC SECTION:
1 Start FD fans in Crude heater & Vac heater maintain draft at -5mmwc. Maintain minimum airflow.
2 Start lighting all pilots in crude heater and Vac. Heater
Start raising cot in crude heater and rate of increase should be restricted to 30°c/ hour. Do not raise Vac.
3
Heater cot till CDU stabilized.
When CDU cot reaches 120°c stop circulation, settle for 2hrs. Start draining water from all low point drains.
4 Repeat this procedure till all water is drained from the system. During circulation, Atm. Column pressure to
be maintained @ 0 .5 ksc to facilitate water removal. Keep watch on column pressure.
Raise the CDU cot @30°c/hour by taking FG burners in all 4 cells as per requirement. Adjust combustion
5 airflow as per requirement. When crude charge pump suc temp goes beyond 60°c start once thro. Circulation
of the unit. Route vac. Bottom to specified tank.
When CDU cot reaches 220°c start hot bolting of all flanges especially transfer line flange, radiation outlet
6
flanges. Cap off all drains securely that were used for water draining.
Atm.column top temp will start rising and initially water starts accumulating in reflux drum. Start overhead fin
7 fans as per requirement. Column top pressure to be increased as top temp rises further. Finally raise to
1.5ksc.
Crude rate to be increased gradually to 350 m3/hr. Maintain at this rate till CDU stabilized. Watch all levels
8
and preflash drum pressure to be set at 3.3 ksc.
Slowly start raising temperature @30°c/hr. Extreme care to be taken regarding skin temperatures of all
9 passes. Pass flow and COT of each pass should be more or less equal. All pass flows to be in manual mode
during start up and pass flow low low logic to be kept in bypass mode
10 Carry out hot bolting in other areas where temperature touches 200°c.
Check for reflux drum level and once level reaches 60% start reflux pump GA41005.before staring pump,
11 drain any water in pump suction through casing drain. Drain all water from reflux drum boot. if required start
sour water pump GA41045 and line up sour water to SWS. Inform SWS unit.
Set reflux drums Hydrocarbon level and water level at 60%. When naphtha make increases start stabilizer
12
feed pump and route wild naphtha to slop till stabilizer column is commissioned. Before starting stab feed
171 | P a g e
pump drain water from pump casing.

When cot reaches 300°c introduce stripping steam to atm. Column and gradually rise to 350 deg c. raise
13
column pr to 1.5 ksc. Note: - before introducing stripping steam ensure steam header is warmed up.
As crude column top temperature and pressure reaches its normal value, establish circulating refluxes one
by one based on column temperature profile care to be taken to prevent water shot to the column through
14
these pumps. Before staring pump, drain water from pump casing drain. Start CRs from top to bottom (HN
CR first)
When COT reaches 320°c switch over from FG to F.O burners one by one. Care to be taken, as there will be
15
a sudden surge in COT when oil burners are taken.
16 Adjust the combustion airflow to heater, watch the flame pattern.
17 When level appears in side strippers, drain water from respective pump suctions.
When stripper levels come to 50% start respective product pump. Route off- spec products to slop do not
18
draw side cut heavy naphtha till unit stabilized.
Introduce stripping steam to kero (HVGO not available), LGO and HGO strippers, after warming up individual
19
headers. When HVGO CR is available change over kero stripper's reboiling media.
If Kero color is o.k. , Route kero to respective storage through Merox unit (inform merox operator) or through
20 emergency bypass. If color of LGO and HGO are o.k. It can be routed to 2D tank or 5 series tank or
GOHDS.
21 Raise the CDU COT to 350 deg c.
22 Maintain over flash from 11th tray @ 3-5% of throughput.
23 RCO is going to vac. Bottom, and from there thro' vac. Residue circuit to specified tank.
Watch column top pr and temp. Adjust CR flows and top reflux if necessary. Put the top temperature control
24
with overhead reflux in cascade. Top temp should be above dew point of water at that pr.
25 Commission LP.MP steam drums and EA41054 and float with respective headers.
Start corrosion inhibitor and ammonia injection to overhead section and CI also to reflux line. Check sour
26
water pH. Start caustic injection to d/s of desalter if required.
27 Switch on transformer power to both desalters.
28 Commission desalter water drum initially with DM water, later with stripper sour water. Inform SWS unit.
Check oil water inter phase level in both desalters through tricocks and if water level is not sufficient
29 (maintain 50%) take water into desalter by starting 2nd stage desalter pump GA41021 and build up to 50%
level in desalter.
30 Stabilize desalter pressure at 9.5 -10.5ksc.
31 Check line up of brine to ETP, and inform ETP
Start GA41022 & GA1021 and route brine to ETP via brine effluent exchanger and brine cooler. No oil carry
32
over is permitted. Maintain wash water rate at 4-6% of t.p.
33 Start demulsifier injection at mixing valve, once brine is clear, divert it to charge pump suction.
34 Inject caustic at desalter -1 water injection point if required. Check brine pH and color.
35 Maintain desalter levels at 50% and adjust mix valve DP at 0.4 kgc.
Start ID fan with zero scoop. Start loading the fan after opening flue gas to APH inlet dampers slowly. Care
36 should be taken about GAPH inlet temperature. While loading id fan simultaneously close APH bypass HV
1520 slowly. Once APH is commissioned adjust ID fan suction temp.to 160°c by adjusting TV1517.
37 Once CDU is stabilized take hy.naphtha side cut as per requirement route it to diesel or kero.
Once CDU is stabilized take all possible controls in auto mode and put inter locks, on except pass flow
38
controls.
39 Drain atm. Off gas KOD for any condensate.
40 Line up FG back up to atm. Off gas by lining up PV1504.
Open SDV1603 in atm .off gas line and operate PC1601C and line up atm .off gas to heater. Close flare
41
valve. Take the controller in auto.
42 Check the heater for flame pattern.
172 | P a g e
NAPHTHA STABILISER
1 Line up unstabilised naphtha to stabilizer
2 Build up stabilizer bottom level to 65%.
Start taking HGO CR through the reboiler by operating FV1904B and raise temp. @ 10-15°c. This shall
3
increase stab. Bottom temperature gradually.
Stabilizer. Pressure will tend to rise as the bottom stream gets heated by HGO CR increase top pressure set
4 valve typically 1.0ksc at a time, by operating PV1901 and finally set at 10.2ksc.set reflux drum pressure at
10.0 ksc.
Once level starts appearing in reflux drum start reflux pump after draining water from the pump casing. LPG
5
r/d control valve to be closed condition.
6 During the process of heating up, stab. Bottom level will fall if rate of heating is too fast. Care to be taken.
7 Drain water from the boot to SWS system. Boot LSLL should be in normal condition.
8 Raise the bottom temperature to the required value and set tray-3 temp. And cascade it with HGO CR flow.
Once level starts appearing in reflux drum start reflux pump after draining water from the pump casing. LPG
9
r/d control valve to be closed condition.
Once bottom temp is 160°c route naphtha to storage through hy.naphtha caustic & water wash by passing
10
naphtha splitter.
Maintain top temp by adjusting reflux flow and start LPG with draw and route it to LPG/amine absorber,
11 merox unit and from there to LPG sphere -24. After getting Lab analysis route it to spec. Sphere. Before
routing, Merox operator to be informed. Weathering test to be done by merox operator
12 While routing LPG to ATU amine circulation should be on.
Sour gas from stab. Overhead drum to be routed to FG/amine absorber. While routing FG to amine
13
absorber, amine circulation should be on.
14 Check HN caustic & water wash drum levels & start circulation.
VACUUM SECTION
1 Check all VDU heater pilots are on. FD fan is running
2 Check cooling water to ejector condensers is lined up condition
3 Check hot well seal pot level., If it is not sufficient, make up the level and PV1517 is lined up condition.
4 RCO is passing through the VDU column.
Start circulating reflux of each bed. Put vac.slop drum with vac. Slop quench loop circn. If bed levels are not
5
sufficient, make up with Flo No need to keep IRs
6 Warm up ejector, stripping and velocity steam headers.
Slowly start raising VDU cot with FG burners @30°c/hr. Extreme care to be taken about skin temps of all
7 passes. Pass flows and cot of each pass should be maintained more or less equal. All pass flow control
valves to be in manual and pass flow low low switch in bypass mode.
Commission hot well sour water pumps GA41107 and put in spill back mode. Keep hot well slop oil pump in
8
auto mode. Line up hot well slop to hy. Slop header.
When cot reaches 350°c start taking ejector system starting with smallest, go one by one as per requirement.
9
Before taking ejectors inform power plant for steam consumption. Put PC2502 in auto mode.
10 Route hot well sour water to SWS inform SWS unit. Adjust the hot well pressure by operating PV1517.
When cot reaches 380°c introduce stripping steam to vac.column bottom slowly. see that vac.column bottom
11
level is around 50%. Set the steam value as per requirement.
12 At 380°C VDU COT, introduce velocity team to each coil of vac.heater at the minimum of 350kg/per/pass.
When COT reaches 380°c switch over to F.O.care to be taken, there will be surge in cot when oil burners are
13
taken. Before lighting FO burners increase combustion air.
14 Start overhead chemicals, corrosion inhibitor and NH3.
15 Check hot well sour water pH.
16 Establish IR flows as per requirement.
17 When bed levels are coming up, route products to slops.
18 When vac.slop drum level is coming up route vac.slop recycle to heater.
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When HVGO CR temperature is sufficient cut off stripping steam to kero and take HVGO CR as heating
19
media.
20 Change over Lt.flo to HVGO in the hy.flo drum.
21 When VDO color is o.k. Route VDO to diesel pool. Or GOHDS along with HGO. (Inform GOHDS).
22 If Color of LVGO and HVGO is o.k. Route to VGO storage.
When HCU is ready to take VGO, start VGO booster pump GA41109 and supply hot VGO to HCU at
23
production ratio.
24 Maintain bed levels and bed temperature as per requirement and adjust CR/IR flows.
25 Maintain column bottom temperature @350°c by putting VR quench.
26 VR to be routed to specified tank or VBU
When hot well off gas is available take it in CDU heater. Ensure that all condensate should be drained before
27
taking to burners.
28 Vac.slop to be routed to either VR or MFO blender as per requirement.
Start ID fan with zero scoop and start loading the fan. Before that, open flue gas inlet to APH. Care should be
29
taken about GAPH inlet temperature. While loading id fan simultaneously close APH bypass HV2363 slowly.
APH is commissioned; adjust the ID fan suction temperature to 160°c by controlling combustion air by pass
30
TV2374.
31 Route hot well slop oil to Lt.slop header by opening Hy.slop to Lt.slop jump over.
32 Check the VDU heater for flame pattern.
NAPHTHA SPLITTER UNIT
Open the combustion air damper FC2374 to naphtha splitter reboiler very slowly as VDU heater is on line
1
already.
2 Start lighting all pilots in NSU heater.
Line up splitter feed control valve and start admitting naphtha into splitter column thro; splitter feed bottom
3
exchanger EA41051C.
4 Build up splitter bottom level to 65%.
Start splitter bottom pump GA41020 and establish circulation thro' the reboiler furnace. Equal flow thro' all
5
passes to be maintained.
6 Route naphtha to storage via the splitter bottom circuit.
Start taking FG burners and raise the COT at 25°c/hr.while taking burners ensure equally spread of burners
7
in firebox.
8 Set the splitter top pressure to required pressure (0.9 to1.35) KSC & PDIC TO 0.4KSC.
While increasing the COT, circulating stock shall start vaporizing. Vaporized stream shall rise to column top
9
and NSU top pressure will tend to rise. Watch the pressure.
Start overhead fin fans as per requirement and allow the material to condense and it will accumulate in over
10 head reflux drum. Care to be taken that reflux drum pressure does not go to backside. Hot vapor by pass to
be operated PDV2001.
Once level start appearing in over head reflux drum, start reflux pump GA41016 and put the reflux to the
11
column. LN r/d to be closed condition.
Raise the cot slowly. Sudden increase of temp and pressure will destabilize the column and making heavier
12
fractions to go to top. Cot 150 deg c
13 LN route should be thro' the caustic and water wash drums.
14 Check caustic and water levels in respective drums and establish circulation.
15 Raise the COT to (150-160°c)
16 Top temperature controller TIC2001 set the required value and put in cascade with reflux flow.
17 Maintain reflux to top product ratio at greater than one.
18 Route Lt.naphtha to storage/CCR blender
19 Route hy.naphtha to storage/CCR feed and by pass HN caustic wash and water wash.
20 Switch over FG burners to F.O burners and control the cot.
21 Stabilise the unit.
START UP PROCEDURE FOR LPG/AMINE ABSORBER PHASE 2
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1 NOTE: - LPG/Amine system is normally on line when HCU/Naphtha stabilizer is running

2 Inform ATU unit and establish amine circulation through DA42201 by starting GA42201
3 Keep the sour LPG/sweet LPG system lined up
4 Admit sour LPG to DA42201 and route sweet LPG to Merox
5 Start LPG booster pump GA42202 if required
6 The amine circulation rate depending upon the H2S content in the product
START UP PROCEDURE FOR FG/AMINE ABSORBER PHASE 2
1 NOTE: -FG/Amine system is normally on line when GOHDS/CCR/VBU//Naphtha stabiliser is running
2 Inform ATU unit and establish amine circulation through DA42202
3 Keep the sour FG/sweet FG system lined up
Admit sour FG to DA42202 and route sweet FG to refinery header through Fuel gas KOD. This action to be
4 carried in coordination with the above plants to avoid any pressure build up in the system system/sour gas
header.
5 The amine circulation rate depending upon the H2S content in the product
GENERAL
1 Keep watch on all skin temperatures
2 Fine tune all control valves
3 Normalize all trip inter locks whatever is possible.
10.3 CDU-2 UNIT SHUTDOWN PROCEDURE:

S.NO DESCRIPTION
CDU2/VDU2/NSU2 SHUT DOWN PROCEDURE
1 Inform Power plant, OM&S and other related units regarding shutting down the unit.
2 Reduce CDU / VDU / NSU COTS by 10° immediately.
3 Take pass flow control valves on manual.
4 Whole Unit s/d will take 24 hours.
A NSU SHUTDOWN
1 Start reducing COT @ 25°c / hour.
2 Stop light naphtha withdrawal from naphtha splitter reflux drum and put the NSU column on total reflux.
3 Cut off fires in NSU heater and keep pilots on. Depressurize the FG ring header after closing SDV 2103
through any lighted burner.
4 Start F.O. circulation through NSU heater ring header bypass. Do not worry about IFO congealing
5 Continue the naphtha circulation through heater till column bottom temperature is brought down to ambient.
Continue top reflux as far as possible, till there is level in reflux drum.
6 Put column top pressure in manual mode.
7 To maintain splitter pressure, first stop fans of naphtha splitter overhead condensers and then admit FG
from refinery header if required.
8 Bypass the splitter. Stop light naphtha caustic circulation and water wash. Full range naphtha is produced
now. Wash using HN caustic wash / water wash vessels.
9 Stop splitter bottom pump to furnace at the very end.
10 Full range naphtha to be routed to naphtha tank bypassing NSU. (Directly from stabilizer)
11 Keep heavy naphtha caustic wash / water wash on line to wash full range naphtha.
B VDU SHUTDOWN
1 After through put reduction in CDU to 350 M3 / hour, start reducing vac. furnace COT @ 30°c/hr to 300°c.
2 At VDU COT 300°c, stop velocity steam injection in vacuum furnace coils and stripping steam to column.
3 Stop slop recycle at this temperature.
4 Cut off fires to vacuum heater. Leave only pilots on. Depressurize FG ring header after closing SDV 2301
through one of the lighted burner.
5 Route VR to specified tank. VR cannot go as Bitumen. It will be too light.
175 | P a g e
6 When ID fan inlet temp falls below 170°c, bypass APH.

7 Change over to light flushing oil in heavy flushing oil drums.
8 Introduce stripping steam to kero stripper since HVGO will not be available for reboiling.
9 Cut off ejectors one by one.
10 Stop side stream withdrawal and increase internal refluxes to make the VR more and more light.
11 Continue closed circulation of slop quench and VR quench.
12 Route hot well off gas to atmosphere PV 1513 and cut off hot well gas to CDU heater burners by closing
SDV 1504
13 Isolate hot well water seal gooseneck by blinding the flange next to Hot well. Close off gas vent valve to
atmosphere heater (close PV 1513). When we break vacuum, we do not want FG to spread in the open.
Contain the FG within the hot well.
14 Break the vacuum in the system by backing gas with FG to around 1000mm Hg.
15 Stop chemical injection to vac. column.
16 Take light flushing oil to pump suction and activate all CR pumps to cool down the tower and also to lighten
the vac. bed contents. Watch VDU top temp. Do not allow Hot well slop generation
17 Take the fuel oil ring header bypass in VDU heater. Close the IFO supply / return SDVs. Do not worry about
IFO congealing. Keep FD running
18 Let FD fan continue to run to cool down the furnace.
19 Route hot well slop oil to 7002D. /Hy.slop (sour HSD tank) This alone will go to 2D. (HGO+LGO) are going
to GOHDS/7005 series
20 CDU-2 is still running. VDU FD is running
C STABILIZER SHUTDOWN
1 Control system of stabilizer column shall be changed from total condensation to partial condensation. LPG
Merox to be informed.
2 Cut off LPG to merox. Isolate LPG rundown to amine absorber.
3 Reduce feed to stabilizer. De-cascade atm. Column reflux drum level controller from stabilizer feed flow
controller.
4 Decascade stabilizer column top temperature controller TIC 1920 from reflux flow controller FIC 1902.
5 Bring the stabilizer column to total reflux.
6 Reduce the column top pressure very gradually by operating PIC 1901. Care must be taken to reduce
pressure very slowly to avoid lifting of heavy ends to top and sudden release of heavy components to FG
system. Watch FG K.O. POT levels.
7 Reduce heating medium to stabilizer reboiler. (HGO CR)
8 Pump out stabilizer top reflux drum liquid till stabilizer reflux pump looses suction. LPG make has become
Zero.
9 By utilizing the available pressure, empty out the stabilizer to naphtha pool to R/D but maintain stabilizer
bottom level. Do not allow LPG to go to Naphtha tank.
10 Stop heavy naphtha caustic wash only after CDU is shutdown.
D CDU SHUTDOWN
1 CDU is running with 350 M3 / hour rate.
2 RCO is still going to VDU.
3 Start reducing atm furnace COT @ 30°C/hr. All controls will be taken on manual.
4 As temperature of crude oil drops, there will be less of distillate production and column pressure will tend to
fall. Admit FG to reflux drum if required.
5 Cut off atm Off gas to CDU furnace burners and close SDV 1603. Cut off FG back up to atm. Off gas
header by closing PV 1517. Depressurize the atm. Off gas header to one of the lighted burners. See that
PSLL 1518 activities. Close SDV 1501.
6 As column top temp drops, quality of products will suffer. Route the products to slop only if needed. Inform
to related units. Naphtha quality to be watched. After stabilizer s/d, Naphtha RVP will be high.
7 Cut off stripping steam to strippers LGO/HGO.
176 | P a g e
8 Cut off heating media to HN stripper and kero stripper.

9 Cut off stripping steam to atm Column at 300°c CDU COT.
10 Cut off feed to stabilizer and put the atm Column on total reflux. Stop heavy naphtha caustic wash.
11 Liquid in reflux drum will be emptied out into crude column.
12 Stop products withdrawal and stop product pumps.
13 Stop overhead chemicals.
14 Stop water and chemical injection to desalter. Switch off transformer.
15 Cut off fires to heater leaving pilot alone. When FO firing is cut off, keep open purge steam to F.O gun.
Close IFO supply/ return SDVs. Do not worry about IFO congealing.
16 Reduce the CR rates slowly and as and when pump looses suction, stop CR pumps.
17 With lowering of heater COT, RCO yield will increase and its viscosity will come down.
18 Establish closed circulation. Have you routed Hot well slops to 7002D (sour HSD TANK).
19 Once the closed circulation is on, cut off pilots in all heaters.
20 Once the ID fan suction temp drops below 170°c bypass APH. Continue to run FD fan.
21 Once the CDU COT reaches 100°c, stop closed circulation.
22 Ensure all the battery limit product rundown valves are closed.
23 Keep a close watch on column pressure.
24 Allow product rundown lines to breathe
25 Finally after all fires are off, worry about IFO lines to each furnace. Flush and keep ready for a long s/d.
E SHUTDOWN OF FUEL GAS AMINE UNIT
NOTE: If entire phase2 is shut down then FG amine unit has to be shut down, but if CCR,GOHDS,ISOM or
HCU is running then unit cannot be shutdown.
1 Inform RSM and all above stated units about the shutdown
2 Isolate sour FG inlet valve.
3 Drain sour and sweet fuel gas filter to CBD.
4 Isolate lean amine flow to unit.
5 Reduce column bottom level and isolate rich amine to ATU
F SHUTDOWN OF LPG AMINE UNIT
NOTE: If entire phase2 is shut down then LPG amine unit has to be shut down, but if CCR & HCU is running
then unit cannot be shutdown.
1 Inform RSM and all above stated units about the shutdown
2 Stop LPG booster pump.
3 Isolate sour LPG inlet valve.
4 Isolate LPG product rundown to merox and to Vaporizer.
5 Isolate lean amine flow to unit.
6 Reduce column bottom level and isolate rich amine to ATU
XI CRUDE BLOCK PROCEDURES RELATED TO ASPECT MANAGEMENT.

INDEX
OCP:S
PROCEDURES PAGE
R No
1 Hydrocarbon leak / black oil leak / fire. 2
2 Safe handling and disposal of coke in VBU. 2
3 SOx / NOx emission control from heaters. 2
4 Chemical transfer from barrels. 3
177 | P a g e
5 Handling of chemical / oil / HC flange leaks. 3

6 Safeguard personnel working in high noise areas like ejectors. 3-4
7 Safe disposal of waste generated from cleaning of fired 4
heaters/APH.
8 Reduction of effluent generation during kero reactor hot water wash. 4-5
9 Reducing noise level in NSU-1 overhead. 5-6
10 Draining of Kero Merox-2 wash water to ETP. 6
11 Routing of Merox-1 Disulphide separator off gas when BA1001 is not 6
able to take off gas.
12 Routing disulphide off gas from Merox –2 to VBU-2 heater when 6
GOHDS trips
13 Prevention of recurring leaks in caustic line to APH neutralizing pit 7
in CDU-2.
14 Disposal of waste generated from equipment maintenance activity. 7
15 Acidic water leak during APH wash in CDU1 and CDU-2. 7
16 Safe disposal of spent activated charcoal from Merox-1 & 2. 7-8
17 Safe disposal of spent Attapulgus clay from Kero Merox-1 & 2. 8
18 Safe disposal of Spent / Damaged Carbon Rasching Rings from 9
LPG Merox-1 & 2.
19 Safe disposal of spent Anthracite coal from LPG Merox-1 & 2. 9
20 Safe disposal of Spent Quartz Sand from LPG sand filter and 10
disulphide oil filter in LPG Merox-1 & 2.
21 Work execution procedure during revamp jobs in plant. 10
22 Safety precaution precautions to be followed during radiography jobs 11
in plant.
23 Procedure for general plant House keeping in plant. 11
24 Handling of Sour FG filter or Amine absorber flange leaks. 11-12
25 Handling of Gas leak from line or flange leak from fin fans/ Vessels. 12-13
26 Exchanger tube bundle cleaning. 14

27 Exchanger cleaning at BBU yard. 14
28 Sour water draining to OWS. 14
29 Draining of hydrocarbon in CDU1&2 CBD headers which are leaking 14
30 Draining of hydrocarbons to CRWS in CDU-2
31 Tube rupture in Fired heaters.
1) Purpose: Hydrocarbon leak / black oil leak / fire.

Procedure
Sl.No Activity
01 Inform control room immediately up on noticing the leak/fire.

02 Mobilize DCP fire extinguisher, steam hoses etc and attack fire/leak.
03 Locate the source of the leak/fire, and cut off the source if possible.
04 If the leak is small diffuse the HC concentration with steam.
05 Isolate and depressurize the equipment.
06 Control the leak/fire as quickly as possible taking all precautions.
178 | P a g e
07 Take steps to prevent leaking HC/fire from spreading.

08 After putting of the fire, attend to the leak and normalize the system.
2) Purpose: Safe handling and disposal of coke in VBU.

Procedure
Coke is generated normally in VBU vessels; filters and black oil pump strainers. All heater coils black oil
circuits are also vulnerable for coking. It is removed periodically and handled / disposed off as per the
procedure given below
Sl.No Activity
01 Isolate the equipment for removal of coke.

02 Allow the equipment to cool.
03 After sufficient cooling, flush and cool further with flushing oil and
depressurize.
04 Drain out HC liquid completely and flush the equipment with water. Steam out
in case of vessel entry.
05 Open the equipment and remove the coke.
06 Collect the coke in bags / barrels, close, tag. DAN is prepared and sent to
environment cell and shift them to area designated by environment cell.
07 Flush the equipment with water. Wash effluents should always be routed to
OWS and not to the storm water sewer.
08 Box up the equipment and normalize the system.
3) Purpose: SOx / NOx emission control from heaters.

Procedure
Sl. No. Activity
1 The alarm limits are incorporated in the DCS for the CDU/VDU/ NSU/VBU
heater stack. SOx– 595 ppm, NOx– 220 ppm, CO– 160 ppm.
2 This is achieved by control of combustion operation and controlling the sulphur
level in the fuel, i.e. for Fuel gas by Amine absorption and for FO by using
LSHS.
3 If the emissions exceed the alarm limit in the DCS, immediately check the
heater for any abnormality and takes corrective actions like increasing amine
circulation rate to reduce the sulphur level in the Fuel gas or reduce FO firing.
4 If the alarm in case of SOx emission is due to high sulphur in the fuel, alert
RSM and HOD and wait for further instruction as reducing IFO sulphur is not
in the scope of the unit.
4) Purpose: Chemical transfer from barrels.

Procedure
Considerable quantity of chemical is left over in the barrels while transferring into the day tank. It is
wastage of resource and a hazard being a toxic chemical. This procedure is to ensure effective transfer of
chemical and tackle hazard
Ref: MSDS
Sl. No. Activity
01 MSDS of chemicals should be referred before handling
179 | P a g e
02 Transfer the chemical using hand pump keeping the barrel vertical to start
with.
03 Once the hand pump loses suction, Keep the barrel inclined and pump again
until it losses suction and a negligible quantity of chemical left over in the
barrel
04 Water wash empty barrels thoroughly and discard effluent into CRWS/OWS.
Ensure effluent is not going to storm sewer.
5) Purpose: Handling of chemical / oil / HC flange leaks.

Procedure
Sl.No Activity
01 Inform control room immediately up on noticing the leak. Refer MSDS before
handling any leak of chemicals. Check for proper selection of PPE.
02 Mobilise maintenance personnel and house keeping personnel. DCP fire
extinguisher, steam / water hoses etc to the location.
03 If the leak is minor and controllable, get it arrested by tightening the flange. If
leak is major, isolate the source and attend.
04 If oil is fuming, diffuse it with steam.
05 After attending the leak, recover the oil in to empty barrel if it is heavy oil.
Wash the floor with oil dispersing followed by water. Keep the collected oil
barrel in covered condition in a marked place. Shift the covered and collected
oil barrels to designated place. If it is light oil, clean the floor with water and
ensure effluent is going to CRWS/OWS. Alert ETP before washing. Use hot
water / soda ash, if oil is sticky.
06 Normalize the system.
07 For chemical spillage, wash it with copious amount water into the
CRWS/OWS.
08 Ensure cleaning personnel uses necessary personnel protective equipment.
09 If caustic is leaking, cordon the area, isolate source, if leak is heavy arrange
water hose at the location. Water wash thoroughly and attend to the leak.
6) Purpose: Safeguard personnel working in high noise areas like ejectors.

Procedure
Ejectors are provided with acoustic insulation to reduce the noise level. Minimum and maximum noise
levels are recorded as 92 dB (outside platform) and 105 dB (over the platform). Maximum permissible
time for continuous exposure to 95dB s 4hrs and to 105dB is 1hr. The OCP is made for safeguarding the
personnel working in those areas.
Sl.No Activity
01 Persons working outside ejector platform area should wear earplugs during the
period they are exposed.
02 Persons working over the platform should wear earmuffs for additional safety
and restrict their exposure to less than four hours.
03 Acoustic insulation to be periodically checked for any damage and rectified, if
any.
7) Purpose: Safe disposal of waste generated from cleaning of fired heaters/APH.

Procedure
180 | P a g e
Sl.No Activity
01 Persons working inside heater to collect dust should wear dust mask, hand gloves
and other PPEs required.
02 Dust should be collected in the empty barrels and covered.
03 Once all the dust is collected, the barrels should be shifted to CDU-1 neutralising
pit.
04 Neutralise the dust applying the same procedure adapted to neutralise APH wash
effluent.
05 After neutralizing the dust, empty out the pit effluent. Analyze the neutralized dust
for pH, phenols and sulfides and if it is within limits collect the material in barrels.
06 Prepare DAN and dispose to area designated by environment cell.
07 Cover all bags with Tarpaulin to avoid spillage. After getting clearance from
environment cell shift the material to designated area.
8) Purpose: Reduction of effluent generation during kero reactor hot water wash.
Procedure
Kero merox reactor will be taken for hot water washing during Reactor catalyst activity failure and
higher-pressure drop across the reactor. This is monitored by the Delta P across the reactor, Reducing
RSH conversion between feed and product and reducing flow through reactor. During hot water
washing effluent from reactor normally routed to ETP /OWS. This effluent having higher concentration
of phenols, Sulphides and Mercantile of Sodium. Since the effluent at the outlet is at 80 –100 C
firewater is used to quench the effluent. This further increases the effluent generation rate. For
reducing the effluent generation rates the following procedure being followed.
1. Inform RSM, OM&S, CPP, HYDROGEN (for BFW) and Lab in advance about the hot water wash of
Reactor/ Caustic settler.
2. Ensure ETP to keep one spent caustic tank empty for receiving wash water.
3. Take shutdown of Kero Merox if it is on ATF run.
4. Bypass Kero Merox and isolate the system.
5. Isolate Kero reactor inlet and caustic settler outlet to water wash.
6. Check the strength of caustic available in caustic settler and inform ETP.
7. Connect a Nitrogen hose on the Kero caustic settler system. Pump out the hydrocarbon material
from the reactor to slop under Nitrogen pressure.
8. Send spent caustic from the caustic settler to ETP through spent caustic line under nitrogen
pressure.
9. Once all spent caustic is drained, isolate spent caustic line and pump out hydrocarbon material
to slop header under nitrogen pressure.
Once reactor and caustic settler hydrocarbon is pumped out, introduce cold DM water to reactor
inlet and collect effluent material in the caustic settler.
10. Send wash water sample for ph, phenols, sulphides, and sodium napthenates.
Stop water injection once settler level reaches 50% in LG. Start caustic circulation pump
GA41602A/B. Maintain circulation rate around >75 m3/hr. Circulate it for one hour. During
circulation maintain settler level at 50%.Stop circulation. Collect all the material in caustic settler
and send it to ETP through spent caustic line under nitrogen pressure.
11. Now introduce boiler feed water (BFW) to reactor and maintain water inlet to reactor
temperature at 80-90°C by mixing with DMW. Collect the contents in caustic settler. Once
caustic settler level reaches 50%, start circulation pump and circulate it for 2hrs @ >75 m3/hr.
Stop circulation and allow the material to settle in the settler and send it to ETP through spent
caustic line.
12. Repeat the same once more.
13. Every time collect the sample of effluent for checking ph, phenols, sulphides and napthenates.
Repeat the same till the effluent becomes clear. Cut off nitrogen to system.
181 | P a g e
14. Now caustic settler from the reactor and fill the reactor with hot water (BFW). Maintain reactor
inlet water temperature at around 80°C by quenching with DM Water.
15. Once hot water is coming from reactor vent, open reactor drain to OWS. Quench the effluent
with firewater to maintain effluent temperature at 35-40°C.
Ensure continuous flow of hot water through reactor vent.
16. Maintain hot water flow through the reactor at around 130 m3/hr
17. Continue washing till the reactor effluent is clear. Check for ph.
18. Once reactor effluent is clear again take settler to the circulation loop. Fill the settler with reactor
(reactor outlet material) up to 50%, taking care not to exceed 60°C.
19. Start circulation pump and circulate it for 2hrs. Bleed effluent from the reactor at a rate of 10
m3/hr with continuous makeup.
20. Once the effluent is clear stop circulation. Drain the water from system completely. Purge the
reactor with N2 for 2hrs for removing moisture and the take fresh 20% caustic into settler.
21. Alkalinize the bed with 20% caustic by circulation.
Note:
1. Clean the caustic suction strainer of circulation pump before starting circulation.
9) Purpose: Reducing noise level in NSU-1 overhead.

Procedure
The NSU-1 column is operated nowadays at 0.6kg/cm2 against the earlier operating pressure of
0.9kg/cm2. Since the column operating pressure itself is less now and the reflux drum pressure is
maintained at 0.2 to 0.3kg/cm2 the differential across PDC10903 is not as high as it was earlier. Hence
due to reduced differential pressure operating range (0.3 to 0.45kg/cm2 against an earlier range of 0.6
to 0.7) and reduced column operating pressure variance seen in the noise level due to variation in PDC
value is from 83db to 93db respectively. The revised OCP is as follows.
S No Activity
1 Follow the naphtha start-up procedure and bring column to normal operation.
2 Maintain column top pressure at 0.6 kg/cm2g and top temperature based on LN
FBP requirement& LN make.
3 Maintain column differential pressure (PDC10903) less than 0.3 with minimum
fans running.
4 Check noise levels (<90 dB) at spillter top reflux control valve area and
Splitter bottom area every 3 months. In extraordinary cases as in the case of Nile
crude (where LN make is less) or due to reduced LN cut operation column
overhead dp is 0.45 with even one fan running. In such cases were the noise level is
above 90db earplugs have to be used.
10) Purpose: Draining of Kero Merox-2 wash water to ETP.

Procedure
Wash water was initially drained to OWS for water replacement. This could not be done as draining to
OWS caused odour and air pollution problems. An EMP was generated and implemented for routing
water wash vessel water to spent caustic tank at ETP. This procedure is for ensuring that the scheme is
implemented.
Sl No Activity
1 Note the initial interphase level in water wash vessel before draining.
182 | P a g e
2 Open the drain valve, to spent caustic line to ETP, slowly.
3 Keep a watch on the interphase level at all times. When the interphase level is at a
substantially low level of the level gauge stop draining.
11) Purpose: Routing of Merox-1 Disulphide separator off gas when BA1001 is not able to take off
gas.
Procedure
Sl.No Activity
01 Once BA1001 trips, route HCU-1 and CDU-1 LPG to Merox-2.

02 If Merox-2 is unable to take entire feed then reduce CDU-1 throughput till unit
is stabilized and heater is able to take off gas.
03 Stop GA1502
04 Stop and close caustic circulation
05 Cut off air to regeneration
06 Isolate steam to EA1501.
12)Purpose: Routing disulphide off gas from Merox –2 to VBU-2 heater when GOHDS trips
Procedure
Sl.No Activity
01 As soon as GOHDS Heater trips, SDV towards GOHDS heater will close.
02 FG makeup SDV will close.
03 OFFGAS to atmosphere SDV will open
04 HS415002 to be switched over towards BA41201 and Route off gas to BA41201
05 Minimise venting time and when sufficient pressure is achieved, divert off gas to
BA41201 heater and close atmosphere vent.
13)Purpose: Prevention of recurring leaks in caustic line to APH neutralizing pit in CDU-2.
Procedure-: Recurring failure of APH pit caustic line was found to be due to stagnant caustic in the
line. Hence an EMP was executed to provide wash facility so that the caustic line could be kept flushed
when not in use.
Sl.No Activity
01 Ensure that APH neutralization activity is completed.

02 Now isolate upstream gate valve provided on newly fabricated U loop in caustic
line (opposite GA41009).
03 Connect water hose to bleeder provided at the downstream of the 1st isolation
valve in the caustic line U loop.
04 Water flush the caustic line of its contents into the APH neutralization pit.
183 | P a g e
05 After thorough flushing cut off water flushing.

06 Now the line has been made caustic free.
14)Purpose: Disposal of waste generated from equipment maintenance activity.

Procedure:
Sl. Work Instruction
No
01 Generally after any maintenance activity metallic, non-metallic and
hydrocarbon waste will be generated.
02 Once maintenance activity is completed and before closing work permit
maintenance Dept will clear the area of all waste items produced due to
maintenance activity as per Maint ISO14001 procedure EP/MM/02.
03 Metallic, non-metallic and hydrocarbon waste to be properly segregated
and put in drums provided for such material and covered.
04 After maintenance has cleared the area final cleaning and area washing
will to be done by operations.
05 Oily waste / hydrocarbon must be shifted to sludge pit by mech
maintenance.
15)Purpose: Acidic water leak during APH wash in CDU1 and CDU-2.
Procedure:
Sl.No Work Instruction
01 As normally there will be some leaks in APH and acidic water is bound to
fall down, barricade the area around CAPH & GAPH.
02 Provide firewater hoses on east west and south side of APH so that water
going to the storm water is well diluted.
03 Remove soot debris from APH bottom chute before starting washing so that
outlet line does not get choked.
04 After cleaning is over put water to see if water is freely coming at APH
neutralizing pit.
05 Check availability of caustic for neutralization at pit.
06 Start APH washing and keep checking Storm water PH and if found acidic
use more water to dilute it.
16)Purpose: Safe disposal of spent activated charcoal from Merox-1 & 2.

Procedure: Activated charcoal is being used in Kero Merox in Phase-2 and LN Merox in Phase-1
reactors. Once charcoal activity comes down we have to replace this. This charcoal has to be washed
before unloading for safe handling and disposal. Following procedure need to be followed.
Sl.N Work Instruction

o
01 Bypass Kero/LN Merox system.

02 Isolate the reactor inlet.
03 Pump out the hydrocarbon material under nitrogen pressure as per
Operating procedure and then close outlet valve.
04 Open the bottom drain and drain the residual hydrocarbon material to
184 | P a g e
CBD/OWS.
05 Water wash the charcoal bed as per procedure mentioned in Merox
operating manual.
06 Dry the bed with plant air.
07 Open the bottom man way and arrange a chute at the man way.
08 Remove the stopper plate.
09 Wear the dust masks, Goggles and slowly remove the charcoal from the
reactor with shovel through chute and collect it in bags. Check bags for any
damage before filling.
10 Arrange the bags in order and tag it. Prepare the DAN and send it to
environment cell.
17) Purpose: Safe disposal of spent Attapulgus clay from Kero Merox-1 & 2.
Procedure: Attapulgus clay is being used in Kero Merox Phase 1 & 2 clay filters. Once Clay activity
comes down it has to be replaced. This clay has to be safely handled and disposed as its crystalline
particles will soften and form an amorphous mass if it comes in contact with water. Following procedure
need to be followed.

o
01 Bypass Kero Merox system.

02 Isolate the Clay filter inlet.
03 Keep the outlet open and pressurize the vessel with Nitrogen to empty out
the vessel and then close outlet valve.
04 Open the bottom drain to OWS till entire kerosene in the bed is drained out.
Then purge out bed with nitrogen until hydrocarbon stops coming out from
bottom drain.
05 Open the vessel top man way and check condition of the clay.
06 Open the bottom man way and arrange a chute at the man way.
07 Remove the stopper.
08 Wear the dust masks, Goggles and slowly remove the clay from the vessel
with shovel through chute and collect it in bags. Check bags for any damage
before filling.
environment cell.
10 After getting clearance from environment cell shift the material to
designated area.
18) Purpose: Safe disposal of Spent / Damaged Carbon Rasching Rings from LPG Merox-1 &
2.
Procedure: Carbon Rasching rings are used in Oxidizer for caustic regeneration in LPG
Merox Phase-1 & 2. Once charcoal activity comes down or gets damaged it has to be
replaced. Following procedure need to be followed for unloading of carbon Rasching
rings.
o
01 Bypass LPG regeneration section and positively isolate it from LPG

Extractor.
185 | P a g e
02 Empty out caustic from the regeneration system as per procedure.

03 Drain all holdup water to OWS from low points.
04 Open the vessel top man way and carbon ring unloading flange and start
unloading.
05 Wear the dust masks, Goggles, gloves and slowly remove the charcoal rings
from the reactor by hand and collect it in bags. Check bags for any damage
before filling.
environment cell.
07 After getting clearance from environment cell shift the material to area
designated.
19)Purpose: Safe disposal of spent Anthracite coal from LPG Merox-1 & 2.
Procedure: Anthracite coal is being used in LPG Merox of Phase-1&2. Once charcoal activity comes
down it loses it efficiency to coalesce oil and has to be replaced. This charcoal has to be safely handled
and disposed as it may contain Phenols and sulphides. For safe handling and disposal the following
procedure need to be followed.

o
01 Bypass LPG regeneration section and positively isolate it from LPG

Extractor.
02 Empty out caustic from the regeneration system as per procedure.
03 Wash the system with water to remove all traces of caustic.
04 Drain all holdup water to OWS from low points.
05 Carryout water washing till all traces of caustic is removed and water PH is
neutral.
06 Then wash Disulphide separator with hot water so that it is odor free while
opening.
07 Then Open the Disulphide separator vessel top man way and charcoal
unloading bottom flange. Arrange drums and keep it just below the flange so
that the coal directly falls into the drum. Then start unloading.
08 Wear the dust masks, Goggles, gloves and slowly remove the charcoal from
the vessel by specially designed spade from bottom and tater by pushing
from top man way.
09 Arrange the drums in order and label it. Prepare the DAN and send it to
environment cell.
10 Cover all drums with Tarpaulin to avoid spillage. After getting clearance
from environment cell shift the material to designated area.
20) Purpose: Safe disposal of Spent Quartz Sand from LPG sand filter and disulphide oil filter
in LPG Merox-1 & 2.
Procedure: Quartz Sand is being used in LPG Merox in Phase-1&2. When sand has got
decolorized we have to replace this. For safe handling and disposal the following
procedure need to be followed.
o
01 Isolate LPG merox inlet and push holdup LPG in unit by using water.
186 | P a g e
02 Once water comes at B/L stop water and isolate at B/L.

03 Isolate sand filter and open vent valve to depressurise the unit.
04 Make backwashing arrangements and carryout back washing till clear water
starts coming out.
05 Isolate Disulphide oil sand filter and pump out holdup.
06 Make arrangements for backwashing and carryout washing till clear water
comes out of filter.
07 Carryout mild air scoring for both LPG sand filter and Disulphide sand filter
while backwashing to facilitate proper agitation during backwash.
08 Drain all water from vessels and open man way for unloading.
09 Collect all sand in drums.
10 Wear dust masks, Goggles, gloves and slowly remove the sand from the
vessel by spade from bottom man way.
11 Arrange the drums in order and label it. Prepare DAN and send it to
environment cell.
12 Cover all drums with Tarpaulin to avoid spillage. After getting clearance
from environment cell shift the material to designated area.
21)Purpose: Work execution procedure during revamp jobs in plant.

Procedure: Revamp activity is carried out in an already existing running plant. Most of
the activity except tie-up that requires shutdown is done when the plant is running and
therefore extra care must be administered while carrying out revamp in plant .
o
01 Plan the job to be undertaken one day prior to execution and

make sure all resources are available for execution of job.
02 Prepare the area and see to it that area is made safe for carrying
out the job.
03 Check LEL and see to it that required safety precautions have been taken and
safety gazettes are available at site prior to issue of permit.
04 Ensure adequate supervision is available while performing job.
05 Ensure proper PPE / tools and tackles are being used while
carrying out any job.
06 Debris generated should be cleared from site as and when generated or at
least at the end of the day before calling off the day.
07 Ensure that the job is being done at the designated location for which permit
is issued.
08 Proper valid permit must be available at site with clearance from all related
depts. (In case of excavation)
09 Ensure that the installation of scaffolding and other temporary structure
does not effect normal operation or does not hinder normal operation.
10 Ensure proper barricading wherever jobs are being done.
11 Stop all activity in case of plant emergency.
22) Purpose: Safety precaution precautions to be followed during radiography jobs in plant.
Procedure: As radioactive material is used for carrying out radiography extreme care to be
administered while carrying out this activity, as it is a major health hazard.
o
187 | P a g e
01 Ensure that the job is planned well in advance.

02 Inform all persons working in plant about the job to be undertaken.
Complete routine jobs in that area.
03 Ensure that area is prepared and barricaded depending on the strength of
the source used for radiography and proper signboards have been put in
place.
04 Ensure that the contractor has proper PPE and radiation meter and then
Issue work permit.
05 Inform field personnel’s about the job and that the permit has
been issued. Inform RSM also.
06 Note down job supervisor’s emergency contact number and location if
required in case of emergency.
07 Once job is completed again inform all concerned persons about the
completion of job.
08 In case if any person unknowingly is exposed to radiation immediately shift
him to OHC for necessary treatment.
23) Purpose: To ensure cleanliness inside the plant and avoid oil spills into storm water
trenches.
Procedure:
o
01 Pick up all solid waste in plant and segregate it to metal, plastic and
cotton/paper waste.
02 Put segregated waste in specific waste drums provided around the unit. Black
drum for metal waste, yellow drum for plastic and cotton/paper etc.
03 Oil spills if any to be scraped and removed or washed into nearby OWS pit.
04 Ensure that minimum water is used for floor washing, also care should be
taken to see that oily water does not go to storm water trench.
05 If by any chance oil enters Storm water trench then it has to be
blocked on the down stream side with sand bags and hay booms.
Then spilled oil to be removed using gully sucker.
24)Purpose: Handling of Sour FG filter or Amine absorber flange leaks.

Procedure:
Sl. No. Activity
188 | P a g e
1. Suitable alarms are located in the access area of the plant to indicate the presence of H2S. The use of
all safety equipment (BA set, escape set) is known to the plant operating personnel. The H2S
detectors are set at an alarm limit of 10 PPM.
2. If leak is noticed by any operating personnel or detected by gas detector, the field operator
immediately informs the control room/ fire control room/ Shift In charge/ Production
Superintendent.
3. Run towards direction perpendicular to wind.
4. Shift In charge/Production Superintendent informs DGM/Refinery Shift Manager about the
emergency and the action being taken. Refinery Shift Manager informs GGM(O)/GM(O)
accordingly
5. Meanwhile water curtain to be maintained to dilute the H2S to envelop the gas from spreading into
nearby area.
6. Shift In charge/Production Superintendent instruct to isolation of equipment/system for stopping
the gaseous H2S leak by using breathing apparatus.
7. If leak is out of control, Shift In charge/Production Superintendent in consultation with fire chief
will declare emergency. Shift In charge in consultation with Refinery Shift Manager and concerned
DGM / GM/GGM, orders shutdown of the amine system.
8. Fire & Safety crew on reaching the leak spot would immediately organize and dilute the leak. They
would also help in isolating valves/lines etc.
9. Refinery Shift Manager arranges stand-by teams with safety equipment to replace the operating
crew sent earlier for tackling with the gas leak in the particular plant area. He arranges for fire
cover, mobilizes engineering service help for repairs etc., as needed.
10. Information should be passed from the central control room on to other plants to be on the alert for
any help.
11. Once the situation comes under control, Shift In charge orders the back up teams, fire crew etc, to
return to normal places.
12. Fire chief declares for all clear siren.
13. Affected part of the unit is to be handed over to maintenance after carrying out the hand over
procedure.
Minor leak:
1. In case of minor leak, inform Panel operator, Production superintendent / Refinery Shift
manager & fire control room.
2. Shift In charge/ Production Superintendent with operators of the plant will rush to the location
of leak after wearing BA set and attempt to dilute the gas leak, by providing water curtain etc.
Wind direction has to be taken into consideration in while approaching towards affected area.
3. Mechanical / Instrument maintenance personnel arrest the leak after wearing BA set.
Sl.No Activity
1. Inform control room immediately up on noticing the leak.
2. Mobilise maintenance personnel and housekeeping personnel. DCP fire extinguisher, steam / water
hoses etc to the location.
3. If the leak is minor and controllable, get it arrested by tightening the flange.
189 | P a g e
If leak is major, follow the below procedure.

1.Shift In charge/Production Superintendent informs DGM/Refinery Shift Manager about the
emergency and the action being taken. Refinery Shift Manager informs GGM(O)/GM(O)
accordingly
2.Meanwhile water curtain to be maintained to dilute the gas from spreading into nearby area.
3.Shift In charge/Production Superintendent instruct to isolation of equipment/system for stopping the
gaseous leak, if requires use breathing apparatus.
4.If leak is out of control, Shift In charge/Production Superintendent in consultation with fire chief will
declare emergency. Shift In charge in consultation with Refinery Shift Manager and concerned DGM
/ GM/GGM, orders shutdown of the system.
5.Fire & Safety crew on reaching the leak spot would immediately organize and dilute the leak. They
would also help in isolating valves/lines etc.
6.Refinery Shift Manager arranges stand-by teams with safety equipment to replace the operating crew
sent earlier for tackling with the gas leak in the particular plant area. He arranges for fire cover,
mobilizes engineering service help for repairs etc., as needed.
7.Information should be passed from the central control room on to other plants to be on the alert for
any help.
8.Once the situation comes under control, Shift In charge orders the back up teams, fire crew etc, to
return to normal places.
9.Fire chief declares for all clear siren.
10.Affected part of the unit is to be handed over to maintenance after carrying out the hand over
procedure.
26)Purpose: Exchanger tube bundle cleaning.

Procedure:
SL. NO. Activity
1. Isolate the exchangers meant for bundle cleaning.

2. Flush the exchangers with flushing oil if the material is heavy.
3. Drain the exchangers to CBD.
4. Handover to maintenance for blinding.
5. Release the exchangers for bundle removing after confirming blinding.
6. Shift the bundle to designated location for cleaning.
7. Field personnel Ensures oily-water will go to OWS.
8. PS instructs maintenance to ensure oily-water has to go OWS
25)Purpose: Handling of Gas leak from line or flange leak from fin fans/ Vessels.
27)Purpose: Exchanger cleaning at BBU yard.

Procedure:
190 | P a g e
SL. NO. Activity
1.
Isolate the exchangers meant for bundle cleaning.
2.
Flush the exchangers with flushing oil if the material is heavy.
3.
Drain the exchangers to CBD.
4.
Handover to maintenance for blinding.
5.
Release the exchangers for bundle removing after confirming blinding.
6.
Shift the bundle to BBU yard for cleaning where entire area has been paved with bund wall and
outlet routed to OWS.
7. Field personnel Ensures oily-water will go to OWS.
8. PS instructs maintenance to ensure oily-water has to go OWS
28)Purpose: Sour water draining to OWS.
Procedure:
SL. NO. Activity
1. Drain the line hold up to OWS before sampling.

2. Use water for diluting sour water during hold up draining.
3. Monitor for H2S content using H2S meter during draining.
4. Collect the sour water sample using closed sample point.
5. Use proper PPE during draining to OWS.
29)Purpose: Draining of hydrocarbon in CDU1&2 CBD headers which are leaking
Procedure
Sl.No Activity
1. Inform control room before starting draining any hydrocarbon to CBD.
2. Start draining hydrocarbon material at slow rate.

3. Watch/ confirm increase in CBD level. Monitor surrounding area for any leak.
4. If found leak stop draining and inform control room and PS.
5. Flush the line content material to CBD.
6. Handover maintenance for attending leak.
30)Draining of hydrocarbons to CRWS in CDU-2.

Procedure:
Sl.No Activity
1. Use Close loop sample point for sampling.

2. If any problem in close sample point use other alternate points.
3. Inform control room before starting draining any hydrocarbon to CRWS.
4. Confirm CRWS is not lined up to storm canal.
5. Start draining hydrocarbon material at slow rate.
6. After taking samples, flush the CRWS trench thoroughly with water and confirm sample
point is closed condition.
7. While heavy monsoon during CRWS rout up to Storm canal, do not drain any
hydrocarbon to CRWS.
31) Tube rupture in Fired heaters.

If tube leak is very small say pinhole leak, then it doesn’t require an emergency shutdown. The unit can be
brought down normally as per procedure.
191 | P a g e
However in case of severe tube leak the following actions to be taken up.
1. Cutoff heater firing.
2. Isolate all individual burners including pilots and isolate main FG and FO C/V.
3. Close feed control valves and isolate at field.
4. Open snuffing steam and purge the heater box.
5. Open stack damper and Bypass APH.
6. Introduce emergency steam to coils and push the coil hold up material to column. Pump
out the column material to slop..
7. After thorough steam out, allow heater box to cool down.
8. Stop FD fan and handover heater for blinding and maintenance.
AUTHENTICATION
Particulars Designation Signature
Reviewed & approved by HOD
Prepared by Task force member
192 | P a g e

CDU-2 Operating Manual For Updation

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CDU-2 OPERATING MANUAL

DISTILLATION UNIT AND NAPHTHA SPLITTER UNIT OF MANGALORE REFINERY AND

AND EMERGENCY HANDLING OF THE UNITS.

MAY BE NECESSARY IN DUE COURSE OF TIME AS A RESULT OF EXPERIENCE GAINED IN

ACTUAL OPERATION OF THE UNITS.

3.1 PREHEAT-1 AND CRUDE DESALTING 14

3.2 CRUDE PREHEAT-2/ CRUDE PREFLASHING/PREHEAT-3 21

3.3 CRUDE HEATER/CRUDE COLUMN 23

3.4 NAPHTHA STABLIZER 34

3.5 KERO/NAPHTHA SPLITTER(KSU/NSU)/ CAUSTIC/WATER WASH 36

3.6 VACUUM DISTILLATION UNIT 53

3.7 TEMPERED WATER SYSTEM/ STEAM GENERATION SYSTEM 66

3.8 CHEMICAL INJECTION 69

3.9 UTILITIES/ FLUSHING OIL SYSTEM/ EFFLUENT SYSTEM 72

3.10 FLARE SYSTEM 85

4 FUEAL GAS/LPG AMINE SYSTEM 87

6 NORMAL OPERATION 126

7 SHUTDOWN PROCEDURE 132

8 EMERGENCY PROCEDURES 138

9 EQUIPMENT OPERATING PROCEDURES 147

9.1 PUMP 147

9.2 HEAT EXCHANGER 150

9.3 FURNACE 151

10 SECTION WISE STARTUP AND SHUTDOWN PROCEDURE 158

11 CDU ENVIRONMENT ASPECT RELATED OPERATING PROCEDURES 171

Issue No. Issue Date Particulars

- - Previous issues were not controlled with Issue Number.

1.0 15-07-2017 Inclusion of recent Modifications. KSU/NSU revamp changes included.

1.1 30-07-2018 Inclusion of Desalter revamp

mentioned separately. Changes has

changes included. MN and HN to OMPL

mentioned separately. Changes has

Products Arab Mix Arab Mix Bombay Bombay High

1.2 Products and their Specification

(Corresponds to min 95 % vol. vaporization at 760 mm Hg and 2 ° Celsius)

(ii) Stabilized Naphtha

(iv) Light Gas Oil Arab Mix Bombay High

(iv) Heavy Gas Oil

(v) Vacuum Gas Oil

1.3 Battery Limit Conditions:

Feed Stock Pressure Temperature Source

Product Pressure Temperature Destination

Fuel Gas 6.0 45 - 60 Amine absorber (in CDU)

1.4 Utilities and their Specifications (at unit B/L)

Minimum Normal Maximum Mech.

Fuel Gas Composition (%Vol.) With HCU/CDU / VBU

1.5 KSU/ NSU Feed Stocks Characteristics:

Cut point, °C TBP

Case I Case II Case III Case IV

C5 - 150 C5 - 150 C5 - 150 C5 - 150

Light ends analysis (%wt)

iC4 0.02 0.02 0.05 0.05

Composition of Crude Oil:

does not exceed 5%.

CDU/VDU/NSU is an integrated unit having no battery limit segregation.

Crude Distillation Unit

Crude Distillation Unit (CDU)

Crude Feeding to Unit:

3.1 Crude preheats train –1 & Desalting:

 Transformer module : Steps up the input voltage to secondary level.

emulsion/rag layer to CBD .

LIC1204 interface level controller.

suction OF GA41022A/B to inject chemical .