Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist

Doc. No. Date OP-511-11014 1-NOV 2009 Rev. Page 1

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A-100 Start-Up Check List

Reference Revision Date Prepared By Reviewed By Approved By 0 26-10-2009 Al-Hamadani.Aziz Abdullah Al-Farsi Abdullah Al-Farsi Signature . Procedure 5. No. Page 1 2 of 17 CONTENTS 1. Responsibility 4. A. Purpose 2. Records 6.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. Date OP-511-11014 1-NOV 2009 Rev. Scope 3.

The purpose of this procedure is to provide a detailed steps in carrying out safely and at shortest time possible for CDU normal start-up 2. 3.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc.1. The CDU Area Manager and/or CDU Process Engineer are responsible for updating or revising this procedure.3. 3. Appropriate actions are done to correct any deviation from the prescribed activities when this event occurs 3. Adequately trained operator coverage is provided The procedures outlined are understood by all concerned and carried out to completion. Purpose 1. 3. The Lead Operator in charge shall be responsible for ensuring that the procedure outlined in this instruction is performed properly in coordination with the Shift Foreman and the Panel Operator.1. Scope 2.1. No. 3. Be responsible for the periodical review of this work instruction or when process modifications warrant the review. and for recommending appropriate changes.4. and to ensure that all related documents/checklists are accomplished by the operators concerned after the units have been secured. Date OP-511-11014 1-NOV 2009 Rev. A copy of this procedure will be placed in the control room and ensure the time is indicated as each step was carried out. All safety regulations are observed at all times. The Foreman shall be responsible for ensuring that: 3. 3.7. .1. 3.6.1. The Shift Supervisor on duty is responsible for coordinating all activities of and interrelated with each Operating Section within the Refinery.2.1. Page 1 3 of 17 1. Responsibility 3. 3.5.1. 3. The Control Operator and Field Operator are responsible for carrying out their prescribed activities within the safest and shortest time period possible. Accurate blind listing is maintained. 3.4.1.2.1.1. This procedure covers the Normal Start-up of CDU unit from cold circulation until the products are all on-specification 3.1.5.3.

drains and sample connection. Check pump freeness. xv. The line up for start-up has been completed vi. Date OP-511-11014 1-NOV 2009 Rev. Housekeeping of the plant is must before any startup.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. x. PSV auditing is completed. Leak checked all the equipments.ESD check completed. Procedures a. Make sure that all valves are open to level glasses and pressure gauge. xiv. iv. iii. All pumps are ready. v. chemicals and effluents are properly lined up and are ready to supply and receive materials. Commissioned steam tracing. Date/Time Sign . viii. products. is ready for use. Ensure that the Flare is lined up and operable. No. Preliminary Start-up checks and activities i. Control valve stroke check is completed. xi. xiii. ii.utility connections and oil condition . xii. etc. xvi. ix. vii. All blinds or spectacle blinds have been placed in their respective operating positions. Ensure all feeds. All utilities are available for all the equipment.electrical equipments. Close all vents. Page 1 4 of 17 4. All equipment including instruments. Make sure that all instruments are ready for operation.

xx. 4. xix. electrical power. 5. Offsite operators must keep a constant watch on the tank level in order not to overfill the tank and flare system is ready and operating. 2. Date OP-511-11014 1-NOV 2009 Rev. 6. No. All portable fire fighting equipments are in place. The fire hydrant system is in service. xviii. Page 1 5 of 17 xvii. Check that: 1.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc.1. Offsite – Ensure use of required slop tanks. Necessary warning signs are posted.1.. Advice Offsite personnel to line up mixed crude oil .1. The area is reasonably free from obstructions. Inform all other concerned units . Miscellaneous safety equipments are available.3. 4. cooling water and potable water have been informed.1. 4. 4.Area Manager.Shift supervisors about the crude unit start up.1.offspec tanks and product tanks are ready and can be linedup as and when required. Ensure that the Crude Oil circulation line up is ready to receive crude oil. Preparation for Cold Oil Circulation Before starting cold oil circulation the following preparations to be done. All safety equipment required for hydrocarbon entry to the unit must be on site and operable. Ensure that all preliminary start-up activities/checks have been completed. Utilities – use of instrument/plant air. 3. Readiness of ignitor for lighting the furnace. Emergency shower and eye wash are ready and operable. 4.2.

Line up tankage and heavy slop line for all products. 4.6. No.4.2.5. 4. 4. 4.2. Line up Crude Oil Charge line at the battery limit in preparation for Crude Oil receiving and line filling.2.2.1.7. 4.4. 4. . PC-004 at 2. start P-1109 A or B going to the Heavy Slop Tank via FV-31 and FV-32.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. Preflash Drum Level Control should be in MANUAL position at this stage.2. Ask Offsite personnel to start the one Crude Charge Pump (P-6101 A/B or C) Open FC-001 and FC-002 gradually by keeping a watch on Desalter Pressure and keep the crude oil flow rate at 60% of design (460 m3/hr). Page 1 6 of 17 tank (T-6101A-C) to the crude distillation unit. Keep Desalters on-line with the power in OFF position Close atmospheric residue line block valves at battery limit to RFCC Unit (V-2101) and to storage (T-6102). Set FC-051 to FC-058 with initial opening of 40% and put in CASCADE with 11-LC-008. Establish or maintain flow rate for a once through operation for 1 hour and drain condensate from low 4.2. Maintain equal flow rate on E-1102 A/B and E-1103. Cold Oil Circulation 4. Date OP-511-11014 1-NOV 2009 Rev.1. When C-1101 bottom level reached 60%.5. 4.2. 4.2. start P-1101 A or B. 4.2.3.8. Continue filling the system including Desalter A/B (V1101 A / B) to the Pre-Flash Drum (V-1102). Set Pre-Flash Drum pressure controller.1.1.6.5 BarG When the level in the Pre-Flash Drum reached 60%.9. 4.2. 4.2.

4. Maintain Crude Column Overhead Drum (V-1103) pressure approximately 0. See attached Furnace Start-up Procedure and Checklist 4.10.4. 4.3.385 barg using the over head pressure control valve (11-V-007A). The circulation will be as follows.3. Start closed loop circulation by opening the isolation valve of the jump over line and closing the slop line isolation valve and the crude charge isolation valve at the Battery Limit simultaneously. 4. hold for 30 minutes and drain water from all the lowest points including equipment pump casing other than Cold oil circulation loop. NOTE: Start overhead fin fan coolers (E-1116) as required. Purge the furnace with steam and Lightup burners in furnace as per procedure. Date OP-511-11014 1-NOV 2009 Rev. 4. Page 1 7 of 17 points.1. E-1101A/B(S) E1102A/B (S)  E1103 A/B(S)  1104A/B (S)  E1105A/B (S)  (V-1101A/B)  E1106(T)  E-1107 (T)  E1108A/B (T)  V1102  P1101A/B E1109A/B(S)  F1101  C1101  P1109A/B  E1109 (T)  E1108 (S)  E1105 (T)  E1116  Start up bypass line  E1101A/B (S). 11-PCwith 11-PC007 B fully closed on ‘Manual” and 11-PC-007A on “AUTO” control. Hot Oil Circulation 4.2. stop the circulation.2. 4.2. Increase the crude heater F-1101 out let temperature at .3.2. Continue to check and drain water condense at all low points as the unit comes on line.3.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. 4.3.12. After the circulation has continued for 2 hours. No.11.3.

Open the Mixed Crude Charge valve. a small amount of stripping steam can be introduced in to the column.2. 4.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc.4. Open the AR line to slop and Open fully the crude charge valve at battery limit. Close the circulation line isolation valve.4.5. Kerosene Stripper (C-1102) and Gas Oil Stripper .7.1. NOTE: Before admitting stripping steam.3.4. Open all products. Naphtha. Continue increasing the heater outlet temperature to 200oC. 4. and Gas Oil rundown line at the battery limit to HSL. Introduce LLP Steam to F-1101 steam coil when 11-TI100 reached 185 oC. Page 1 8 of 17 around 28oC /hr. o Continue increasing the Coil Outlet temperature to 340 C at the same 30 oC/hr rate.7.4. 4.4.4.3. Date OP-511-11014 1-NOV 2009 Rev.6.3. Kerosene.6. make sure the steam is free from condensate At 300°C Hot bolting to be done. No. When the crude column bottoms temperature reaches 235oC. Monitor the Crude Column Overhead Receiver (V1103). and the Heavy Slop Tank at Battery Limit while closing the jump over line for a once-through operation.4. 4. and open vent to atmosphere At 235 oC. 4. Crude Column Section Start-up 4.4. 4. 4.Ensure Hot bolting is done. 4. 4. The level on the C-1101 bottom will drop due to vaporization while heating up the system.3.5. Open Flushing Oil line at P-1108 A/B discharge to establish Bottom Pump Around (BPA) circulation 4. Continue gradual increasing of Coil Outlet temperature to 250oC at 30 oC/hr rate.4.

4.8. No.13.10. Drain all low point bleeds of free water. 4. Date OP-511-11014 1-NOV 2009 Rev.4.4. Line up the top pumparound pumps P-1104A/B through all exchangers and control valves back to the crude column. Page 1 9 of 17 (C-1103) level.11.9. 4. start cold reflux to C-1101 by starting P-1102A/B NOTE: All water must be drained from the pump casing before starting the overhead reflux pump. Line up from the discharge of the bottom pump around pumps P-1108A/B.4. start the gas oil/kerosene product pumps and route rundown to Heavy Slop Tankage. 4. 4.4. 4. 4. When level appears in gas oil and kerosene side strippers.4.4. Monitor the water boot level of crude column overhead receiver (V-1103) and maintain the level at maximum 50%.4. P-1107A/B through the crude/gas oil heat exchangers with bypass closed. Line up the gas oil product rundown from the discharge of the gas oil pumps. When hydrocarbon begins to accumulate in the crude column overhead receiver. NOTE: Drain all low point bleeders and pump casing before starting the pump. through all exchangers and control valve back to the crude column. 4. As the atmospheric residue product rate from C-1101 begins to decrease due to lowering of C-1101 bottom level. 4.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. the gas oil rundown cooler E-1115 and through the flow control valve 11-FV-030A/B to the heavy slop header.12. Line up middle pumparound pumps P-1106A/B through all exchangers and control valves back to the crude column. start stripping steam. the crude charge can be increased to maintain the level of Pre-Flash Drum V-1102 and C-1101 bottom.15.14. Drain all low point bleeds of free water .

As the crude heater transfer temperature increased.5. commission the Desalting water injection and put the power on the Desalter transformer.19.4. the crude outlet temperatures should be increased as required.4. When gas oil meets the specifications. 4.4. The unstabilized naphtha is routed to Stabilizer (C-1121). [Stabilizer  Stabilized naphtha to storage ] NOTE: Never route unstabilized naphtha alone to heavy slop.21. Start all the required chemical injections to the crude column and desalters such as: 4. 4. 4. Page 1 10 of 17 4. 4. Date OP-511-11014 1-NOV 2009 Rev.2.20.1.Corrosion inhibitor 4. 4.1.16. When atmospheric residue meets specifications divert atmospheric residue to RFCC unit or RFCC Intermediate tank. No.22.3. When the Desalter inlet temperature reached 120oC.22.4. start P-1121 A/B and circulate the bottoms using 11-FC-018 and establish minimum flow rate of 90 m3/hr .5. 4. 4. Continue to make needed adjustments on the side-cut stripper draw off rates and stripping steam injections to produce the desired products with the required unit charge rate.4. When V-1121 level reached 30%.18.4.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc.22. increase the crude charge to maintain approximately 60% of design atmospheric residue flow rate.4. divert gas oil to DHDS unit or storage tank.17.4.4.Ammonia 4. After establishing reflux streams. When kerosene meets the specifications divert kerosene to kerosene Merox unit or to intermediate storage tank.4.Demulsifier.22. The crude column overhead liquid sent to the stabilizer feed surge drum (V1121). Start water injection to both Desalter at 5% of the Crude Charge rate. Stabilizer Section Start-Up 4.

Place 11-FC-026 on “CASCADE” control with LC-020 set at 50% When C-1121 level at 30%. gradually commission Stabilizer reboiler by opening 11-FC-036 NOTE: Ensure V-MOV-004 is fully opened 4.3. Ensure 11-PC-011 B isolation valve is opened and lined up to Off Gas system and 11-HC-021 is lined up to Flare Increase gradually the Reboiler temperature 11-TI-088 up to 210 oC by increasing 11-FC-036 flow rate. When Deethanizer pressure starts to rise. 4.5.5. Start heating up Deethanizer reboiler (E-1129) gradually by increasing the LLP steam flow. start P-1122 A/B and establish reflux flow rate to C1121.5. when LCV-024 reached 30%.7 BarG and increase Reeboiler temperature. increase it gradually up to 30. maintaining top temperature of 70 oC.5. when 11-LC-027 level is at 40%.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. 4.4.6. Page 1 11 of 17 4. Heat up the system and build up pressure via 11-PC011 on Auto with a setting of at 12. place 11-FC-035 on “CASCADE” control with the 11-LC024 set at 60%. Naphtha rundown will be on HSL or Off specification tank and routed to ON specification tank (T-6217 A/B/C when the required specifications was met 4.10. NOTE: Ensure 11-MOV-005 is fully open 4. 11-TI097 gradually When level appears in the Deethanizer Overhead Receiver (V-1123) .8.5. No. V-1122 excess level will go to C-1122 via P-1124 A/B 4.5.9 BarG. 4.5. Watch V-1122 level. Deethanizer Section Start-Up Establish level in Deethanizer and route LPG to off spec tank. 4. Reset 11-UC-009.7.5. 4.5.9.6. Date OP-511-11014 1-NOV 2009 Rev.2.5.

1.1. No. 4. maintaining C-1122 top temperature of 45 oC. Records 5. Start-Up Checklist 6.7.3. Reference 6. Special Precautions The special precautions at the start-up are as follows: 4. When the specification of LPG is met bottom product can be sent to CDU LPG Merox Unit.7. 5. Date OP-511-11014 1-NOV 2009 Rev.1. P&ID See attached drawing for proper line-up . Circulation Loop Mark-Up Drawing 6.7. 4.2.7.2.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. And the firebox atmosphere is also checked by manual sampling with using portable vacuum pump through sampling points periodically. 4.4. Check no leakage of any fluid periodically during heating up Excess air normal conditions An online oxygen analyzer AI-001 is provided on the heater to check the fire-box atmosphere. by starting P-1123 A/B. All start-up operation of heater should be performed by means of manual control until the heater is in normal and stable operation.7. Page 1 12 of 17 start top reflux. 4.

Date OP-511-11014 1-NOV 2009 Rev.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. Page 1 13 of 17 Cold Oil Circulation . No.

Page 1 14 of 17 Hot Oil Circulation . No.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. Date OP-511-11014 1-NOV 2009 Rev.

Date OP-511-11014 1-NOV 2009 Rev. Page 1 15 of 17 Crude Column Section Start-up .Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.

Page 1 16 of 17 Stabilizer Start-up line-up . Date OP-511-11014 1-NOV 2009 Rev. No.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc.

Date OP-511-11014 1-NOV 2009 Rev.Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. Page 1 17 of 17 Deethanizer Line-up . No.