117 solvent replacement

SD August 2021
GENERAL

Objective Exchange of Amine Solution in Unit 117

Shut-down Activities  Reclaimer 117D008 internal inspection.

Covered  Charcoal filter 117F002 carbon replacement.
 Loading new amine to 117T001
 Unloading waste amine.
 Washing system using DM water & caustic soda.
 Neutralization of U117 after washing
 Loading new amine into system.
 117E001 frames replacement.
 Cleaning of slope drum 117D003

Scope of work
Department Responsibilities

PDH  Optimize plant parameters to comply with unit 117 outage

 Solvent replacement associated activities
 Prepare 117D008 for internal inspection
 Change charcoal filter 117F002
Mechanical  117E001 frames replacement
 Positive isolation of 117D008
Inspection  Inspection activities of 117D008

Safety  Ensure safety precautions to do all necessary jobs

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01)Reclaimer internal inspection
Requirements
 MISCELLANEOUS

Requirements Department
1- Proper PPEs for personnel Warehouse department
2- 25 empty barrels and wooden pallets Warehouse/safety department
3- Forklift standby Bagging/warehouse department
4- Powder for cleaning work area Safety department
5- Air Blower Electrical department
6- 2 Electrical lighting Electrical department
7- Inspection tools Inspection department

 Blind list

Size Rating Tag number (marked PID) Quantity

Blinds
1’’ 150 B1 1
2’’ 150 B2, B3, B10, B11 4
2’’ 600 B4 1
3’’ 300 B5, B6 2
3’’ 150 B7, B8 2
20’’ 300 B9 1
Spectacle blind
2’’ 150 B12 1

 End flange removal

Size Rating Tag number (marked PID) quantity

1’’ 300 E1, E4, E5 3
1’’ 150 E2, E3 2

 Gaskets

Size Rating Tag number (marked PID) quantity

1’’ 300 E1, E4, E5 3
1’’ 150 E2, E3 2
1’’ 150 B1 1
2’’ 150 B2, B3, B10, B11 2
2’’ 600 B4 1
3’’ 300 B5, B6 2
3’’ 150 B7, B8 2
20’’ 300 B9 1
2’’ 150 B12 1

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24’’ - M1 1

Procedure:

Reclaimer drainage Duration Notes

 Cut feed to reclaimer (FV117401) and its manual valves
 Cut MP steam heating (FV117403) and its manual valves
 Stop 117P013A and 117P014 and close XV117431
 Open N2 to reclaimer through 2’’ valve
 As soon as pressure is increased inside reclaimer to 2 kg/cm2g
open HV117401 and its 2’’ manual valve
 Start draining reclaimer slurry into barrels (FV117402 d/s should
be drained and washed)
01.01  Maintain positive pressure inside reclaimer through N2 at 2 kg/cm2 12 hrs
 Once reclaimer has been drained completely, Close HV117401
and introduce BFW to the reclaimer up to 80%.
 Open HV117401 and drain the flushing water.
 Repeat steps 7,8 while opening LP steam sparger (line warm up is
required) to clean unremoved HSS until water is drained clear.
 Depressurize reclaimer to atmospheric pressure through 2’’ vent
 Start positive isolation procedure

Reclaimer positive isolation Duration Notes

01.02  Manual isolation 6 hrs
o Ensure manual isolation of FV117401 (double block and
bypass) and open bleed.
o Ensure manual isolation of FV117403 (double block and
bypass) and open bleed.
o Ensure manual isolation of FV117402 (double block and
bypass) and open bleed.
o Ensure manual isolation of MP steam line d/s reclaimer
(double block and bypass) and open bleed.
o Ensure manual isolation of BFW line to reclaimer (double
block)
o Ensure manual isolation of antifoam line.
o Ensure manual isolation of N2 line to reclaimer (double
block) and open bleed
o Ensure manual isolation of 117P013A discharge and plant
water to 117P013A
 Install all blinds except for N2 line and reclaimer outlet
 Purge reclaimer with N2 (continuous purge) and vent through V1,
V2
 Close N2 to reclaimer and install Blinds B12, B9

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 Open manhole M1

Reclaimer internal inspection Duration Notes

 Install air blower at M1 and open vents of reclaimer V1, V3 for 4
hours
 Take O2 samples until O2 content 20%
01.03  Install Electrical lighting inside reclaimer 12 hrs
 Issue confined space permit and handle equipment to inspection
team.

Reclaimer related activities Duration Notes

1- Mechanical checks
- Reclaimer demister checking and cleaning
- 117P013A check valve cleaning, 117P013A water cooler
cleaning
- 117P013A checking
- Strainer of 117P014A cleaning
- 117P014A checking
2- Instrument checks
01.04 12 hrs
- FT117401 calibration
- LT117403 & LI117401 cleaning
- TT117402 thermowell checking
3- Electrical checks
- Heat tracing checking (LI117401&LT117403&HV117401)
4- Technical services department
- Implementation of new TT inside reclaimer slurry (MOC issued)

Putting reclaimer into service Duration Notes

 Remove blower and electrical lighting inside reclaimer
 Close manhole M1
 Remove Blind at N2 line
 Purge reclaimer with N2 (Continuous – Piston) and vent
through V1
01.05  Take samples till O2 content is below 2% 12 hrs
 Depressurize reclaimer through V1
 Remove all blinds as attached marked PID
 Install End flanges as attached marked PID
 Put reclaimer back in service.

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02) Loading new amine to 117T001
Requirements
 MISCELLANEOUS

Requirements Department
1- 60 tons fresh MDEA Warehouse department
2- 3’’ Hose Warehouse department
3- Propper PPEs Warehouse department
4- Forklift Bagging department
5- 3’’ hose Warehouse department

 Blind list

Size Rating Tag number (marked PID) Quantity

Blinds
3’’ 150 B13 1
4’’ 150 B14 1

 End flange removal

Size Rating Tag number (marked PID) quantity

3’’ 150 E6 1

 Gaskets

Size Rating Tag number (marked PID) quantity

3’’ 150 B13, E6 2
4’’ 150 B14 1

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Procedure:
Steps Checked Notes
Close XV117301 and force close it from DCS engineer.
02.01
((PID11712))
02.02 Install blind 4’’ downstream XV117301 to the tank.
Close 3’’ (2 MVs from 117P004 to stripper 117C002) (line
02.03
11712003).
Install blind 3’’ downstream 117P004 to stripper upstream
02.04
3’’ manual valve (line 11712003).
Close 3’’ (2 MVs from Demin water line to tank (line
02.05
18201025).
Close all tank drains to slop system (4’’ MV line 11712004,
02.06
2’’ (5 MVs line 11712005)).
Change 2’’ (3 spectacle blinds) from tank to slop system to
02.07
close position.
02.08 Remove end flange from filling station
02.09 Close 4’’ MV from tank to 117P004 (line11712004)
Open 4’’ MV suction of 117P004 and 3’’ MV min. flow of
02.10
117P004.
Connect 3’’ hose from outsource tank to 117T001 filling
02.11
station.
Connect LP N2 blanket on outsource tank and open vent on
02.12
it.
02.13 Open outsource tank MV.
Open 4’’ MV at filling station & ensure 117P004 is in
02.14
service (min. flow condition)
02.15 Start 117P004 to fill fresh MDEA to 117T001
Monitor PI117303 and pump current; if they start to
02.16 fluctuate then pump is running near cavitation condition and
outsource tank is almost empty.
02.17 Stop 117P004 as soon as cavitation noise is heard.
02.18 Close outsource tank MV, filling station MV
02.19 Repeat steps 02.11 to 02.18 with other tanks
02.20 Disconnect the 3’’ hose from both sides.
Connect one side to DM water station and the other side to
02.21
the nearest pit
02.22 Clean the hose with DM water.
02.23 Remove previously installed 3’’ blind after new MDEA

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charged to unit 117.

03) Unloading waste MDEA to trucks (Part I – 117P002)

Requirements
 MISCELLANEOUS

Requirements Department
1- 2’’ hose Warehouse department
2- Pressure gauge Instrument department
3- 4 trucks (each 40 m3) General relations/ environment
4- Scaffolding for unloading hose Workshop

 Blind list

Size Rating Tag number (marked PID) Quantity

Spectacle Blinds
2’’ 150 B15 1
4’’ 150 B16 1

 End flange removal

Size Rating Tag number (marked PID) quantity

2’’ 150 E7 1

 Gaskets

Size Rating Tag number (marked PID) quantity

2’’ 150 B15, E7 2
4’’ 150 B16 1

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Procedure:
Steps Checked Notes
Make sure the procedures for unit isolation have been
03.01
executed correctively
All spectacle blinds must be @ open position except for
03.02
MDEA tank for unloading and drainage purpose.
N2 line to stripper must be opened 2’’ (2 MVs) (line
03.03
11706012).
Install PI on 1’’ drain of absorber bottom to slop drum.
03.04
(line11714017).
Remove end flange of 2’’ (line 11712008) and connect 2’’
03.05
hose to the loading truck. ((PID11712)).
Ensure filtration unit 117F001, 117F002, 117F003 is on
03.06
bypass mode according to marked PID, FV117091 100%
Close XV117301 and make it force closed (inlet of the
03.07
tank). Blind is installed ((PID11712))
Open 4’’ (2 MVs) (line11704008) downstream filters.
03.08
((PID11704)), Ensure SB 16 is on open position
Open 2’’ (2 MVs) (line 11712008) to loading truck.
03.09
((PID11712)), Ensure SB 15 is on open position
Start system drainage to truck accordingly while transferring
03.10
all level accumulation towards 117C002.
Start depressurizing of absorber through SV117007 bypass
03.11 till reaching 10 kg/cm2 or the lowest pressure to keep
circulation running
Keep 5% of absorber level and flash drum level in order to
03.12
prevent HC from escaping to stripper
Reduce circulation rate to 100 m3/hr and open XV117122 to
03.13
consume stripper level till reaching 5%
When truck is full close 2’’ MVs of unloading station and
03.14
switch to the other truck then open 2’’ MVs again
03.15 Keep unloading condition till level trip point of 117P002A.
Stop system drainage and close 2’’ (2 MVs) (line 11712008)
03.16
to loading truck. ((PID11712))

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4) Unloading waste MDEA to trucks (Part II – 117P005)

Requirements
 MISCELLANEOUS

Requirements Department
1- ¾’’ hose PDH
2- Two hoses 1’’ PDH
3- 2/1 reducer Workshop

 Blind list

Size Rating Tag number (marked PID) Quantity

Spectacle Blinds
1’’ 150 1-41 41
Blinds
4’’ 150 B15 1

 End flange removal

Size Rating Tag number (marked PID) quantity

1’’ 150 E14 1
2’’ 150 E13 1

 Gaskets

Size Rating Tag number (marked PID) quantity

1’’ 150 1-41, E14 42
2’’ 150 E13 1

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Procedure:
Steps Checked Notes
Close 3’’ MV inlet of 117F001 (line 11704009) and 3’’ MV
04.01
from 117P002 to 117F001
04.02 Close 3’’ MV outlet of 117F001 (line 11704003).
Open 2’’ (2 MVs bypass of 117F001), 3’’ MV
04.03
(line11704011).
04.04 Close FV117091
04.05 Close 1’’ MV antifoam to 117P003A/B ((11710015))
04.06 Close 8’’ MVs of 117P003A/B suction lines
Open 4’’ (2 MVs) (line11704008) downstream filters to
04.07
unloading station. ((PID11704))
Connect ¾’’ hose to 117P005 discharge drain to 117pit.
04.08
(open if needed)
04.09 Open 2’’ (2 MVs discharge of 117P005) and its ¾’’ bypass.
04.10 Open 2’’ (2 MVs) (line 11712008) to loading truck.
Open all drains of the system to slop drum (one by one)
04.11 except slope tag points 1, 2, 9, 20, 21, 29, 30 and start
117P005.
During slope drain, connect 1’’ hoses to vent and drain of
04.12 117E002 shell side and connect them to demin water and
sewer respectively
04.13 Close MVs of 117P002A/B suction
After all slope points except 1, 2, 9, 29, 30 are drained, Start
04.14 draining slope tag point 20, 21 and open demin water to
117E002
Check drain to sewer periodically, when clear water is
noticed reduce demin water flow to 117E002 to minimum
04.15
and open same opening to sewer drain to keep shell side of
117E002 full of demin water
04.16 Keep eye on PI117332 (slop drum pressure).
04.17 Avoid high slope drum level during drainage.
04.18 Close all drains to slope after drainage finish
Close 2’’ MVs of unloading station, 4’’ MVs d/s filters to
04.19
unloading station and disconnect hose

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04.20 De-blind B15

5) Depressurizing and HC exchange with N2 (117C003, 117D001)

Requirements
 MISCELLANEOUS

Requirements Department
1- Four 1’’ hoses Warehouse department
2- HP N2 manifold Workshop
3- 2’’ hose PDH
4- HP & LP N2 O&U

 Blind list

Size Rating Tag number (marked PID) Quantity

Spectacle Blinds
1’’ 150 S36, S39, S29, S30 4

 End flange removal

Size Rating Tag number (marked PID) quantity

1’’ 150 E8, E9, E10, E11 4

 Gaskets

Size Rating Tag number (marked PID) quantity

1’’ 150 S36, S39, E8, E9, E10, E11 6

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Procedure:
Steps Checked Notes
Depressurize absorber 117C003 through (SV117007
05.01
bypass)2’’ MV till absorber pressure reaches 0.5 kg/cm2.
Depressurize flash drum 117D001 through (SV117002
05.02
bypass)1’’ MV till pressure reaches 0.5 kg/cm2.
Close 2’’ MV U/S of FV117001 (discharge of 118P014) and
05.03
its bypass line. Drain the line to 117C003 to sewer
Connect 1’’ hose of HP N2 to 1’’ drain upstream of
05.04
FV117001 and open 2’’ MV downstream FV117001.
Close 4’’ MV (line 11715001) upstream
05.05 FV117371(minimum flow line of pump around). Open slope
tag point 36 till drain is complete
Connect 1’’ hose of HP N2 to 1’’ drain upstream of
05.06
FV117371 and open 4’’ MV downstream FV117371.
Close 4’’ MV (line 11716001) upstream
05.07 FV117381(minimum flow line of pump around). Open slope
tag point 39 till drain is complete
Connect 1’’ hose of HP N2 to 1’’ drain upstream of
05.08
FV117381 and open 4’’ MV downstream FV117381.
Connect all above 3 (1’’ hoses) through manifold to HP N2
05.09
header (located beside 118P001).
05.10 Connect LP N2 to 1’’ drain of slope tag point (1)
Start absorber purging with HP N2 using (FV117001,
FV117371, FV117381) to flare through bypass SV117007
05.11
and flash drum purging with LP N2 using slope tag point (1)
through SV117002
05.12 Clean check valve 118P014 discharge (WR 5376)
05.13 Pressurize absorber and flash drum to 2 kg/cm2
05.14 Open slope tag points 1, 2, 9, 29, 30 till drain is complete

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6) Flushing system with demin water

Requirements
 MISCELLANEOUS

Requirements Department
1- Two 2’’ hose PDH
2- Manifold of HP N2 Workshop
3- Four 1’’ hoses PDH
4- 120 m3 DM water O&U
5- HP & LP N2 O&U

 Blind list

Size Rating Tag number (marked PID) Quantity

Spectacle Blinds

 End flange removal

Size Rating Tag number (marked PID) quantity

2’’ 150 E12 1

 Gaskets

Size Rating Tag number (marked PID) quantity

2’’ 150 E12, spool FO117003 2

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Procedure:
Steps Checked Notes
Make sure all procedures for system drainage have done
06.01
correctively.
06.02 Make sure all drains to slope drum have been closed.
Put 117F001 in service and ensure 117F002,117F003 are
06.03 fully isolated before job start and till new MDEA loaded to
the system.
Start pressurizing 117C003 with HP N2 to 10 kg/cm2 and
06.04 117D001 with LP N2 to 3 kg/cm2 as mentioned in steps 05.03
to 05.12
Remove spool of FO117003 (min flow of 117P005) and
06.05 connect 2’’ hose on it and the other side to be connected on
117C002 bottom 2’’ drain
Connect 2’’ hose from drain of Demin water (filters
06.06
connection) to 117D002 top 2’’ vent,
06.07 Make sure that 117P005 is on min flow condition only
06.08 open Demin water fully for above 2’’ hoses in step 5.
Run 117P001 to transfer demin water level in 117D002 to
06.09
117C002
Open 2’’ MV of Demin water fully to slop drum and start
06.10
117P005.
Start 117P002,117P003 and increase circulation rate
06.11
gradually.
Target level of all the system to be maintained on 50%,
06.12
Then close all Demin water sources to the system.
Adjust reboiler flow to stripper to keep 70OC water
06.13
temperature.
Keep system circulation till reaching low concentration
06.14
values of MDEA in the solution.
Start unloading of washing water from system to trucks
06.15
according to MDEA drainage procedures

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7) Unloading solvent from 117T001 to system

Requirements
 MISCELLANEOUS

Requirements Department
1- 2’’ hose PDH
2- 80 m3 DM water O&U
3- HP & LP N2 O&U

 Blind list

Size Rating Tag number (marked PID) Quantity

Spectacle Blinds
1’’ 150 1-41 41

 End flange removal

Size Rating Tag number (marked PID) quantity

 Gaskets

Size Rating Tag number (marked PID) quantity

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Procedure:
Steps Checked Notes
07.01 Ensure all slop lines of the system are fully isolated.
If system pressure is low, apply pressurizing step with HP
07.02
N2 according to step 06.04
07.03 Maintain positive pressure of 117C002 by opening N2.
Ensure filling station and unloading station valves are fully
07.04
closed
07.05 Open 4’’ (2 MVs) from 117T001 to 117P004.
Ensure 117P004 is in service (unloading tank condition) by
07.06 opening 3’’ (2 MVs discharge of 117P004) and closing 3’’
MV and its bypass (minimum flow of 117P004 to the tank.
07.07 Start 117P004 in order to unload 117T001 to 117C002.
07.08 Fill 117C002 with fresh MDEA till reaching 30%
07.09 Stop 117P004.
Ensure 117P002A is in service (min flow condition) through
07.10
XV117031 to the stripper.
Start 117P002A and open DM water to 117C002 bottom 2’’
07.11
drain till reaching 80% level at stripper.
07.12 Stop 117P002A.
Ensure that condition of all MVs of normal circulation
07.13
condition is applied
07.14 Ensure 117P002A is in service (normal operation condition)
Monitor 117P002A discharge pressure & current while
07.15
adjusting 8’’ discharge MV to prevent pump trip
Start circulation to transfer solvent solution to rest of unit till
07.16
reaching level trip point of 117P002A
Repeat steps 07.07 to 07.16 till 117P004 reach level trip
07.17
point
Open 2’’ MV of 117T001 bottom & 117P004 suction line to
07.18
slope drum.

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Start slop drum pump 117P005 to transfer residual of fresh
07.19
MDEA to system
Take samples from 117C002 and 117D001 to monitor
07.20
solvent concentration
If amine concentration is around 40%, putting 117 unit in
07.21
service is applicable

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