Trouble Shooting Compendium 2022-23

COMPENDIUM
OF
TROUBLESHOOTING EXPRIENCES
2022-2023
Indian Oil Corporation Limited
Refineries Headquarters
New Delhi
Trouble s hooting Compe ndium 2022-23
Index
BARAUNI REFINERY
S.No. Description Page
No.
1. Improvement in CCRU recycle gas HCl content and decrease of 7
Chloride leaching from catalyst
2. Issue of debutanizer overhead condenser outlet high temperature 9
and slippage of heavier hydrocarbons to Fuel Gas
3. NSU (CRU) feed limitation 10
4. High CO2 slippage from N2 plant APU Bed-B 12
5. Improvement in Isomerate RON due to Optimization in DIH column 14
sensitive tray temperature
6. Reduction in RON drop across Prime G during higher feed sulfur 16
processing
7. Identification of Coker MRN passing into MS blend 18
8. Improvement in RFCCU Deaerator performance through 19
operational changes
GUJARAT REFINERY
No.
1. KHT CFE leak (2061-E-01(2)) leak identification, rectification and 22
running
2. Use of LAB product for stabilization of LAB column and Finishing 26
column thereby saving 4 startup days
3. Troubleshooting of high Catalyst Loss in JR FCCU 28
4. Troubleshooting of high-pressure drop-in FCC MAB discharge to 30
Regenerator
Page | 2
GUWAHATI REFINERY
S.No Description Page
No.
1 CDU main fractionators high flash zone pressure 33
2 High Sulphur content in NHT recycle gas and NHT rundown to ISOM 35
3 High nitrogen consumption in INDAdeptG during activation cycle 36
4 High-pressure drop-in Reactor-02B bed-1 during regeneration in 37
INDAdeptG
5 High pressure drop across reactor-1 bed-1 of HDT 38
6 High fuel gas consumption in HDT reactor furnace 49-F-01 39
7 Changing of TPS Air compressor cooling media 40
8 High H2S in Sweet gas & FG header 41
9 High TMT & higher DP of reformer leading to limitation of HGU T’put 42
10 DCU/LRU cooling water supply flow restriction 43
PANIPAT REFINERY
No.
1. ATF merox Throughput restriction during High TAN crude run 46
2. Inability to monitor brine quality going to ETP 47
3. Indigenization of the ZSM Loader system 48
4. Change of insulation in RGC Turbine 49
5. High DP across Packinox inlet effluent strainer 50
6. High RPM fluctuations in RGC of CCRU 51
7. Off spec PTA product 52
8. Off spec PTA product 53
9. Reformate unloading from wagons at PMC and dispatch to PR 54
10 Maintaining ATF product Silver rating 55
11 Routing of sour flare KOD pump discharge to U-53/54 interconnection 56
line
12 Sustenance of CCRU unit operation with RSU operation as CCRU 57
stabilizer
13 Troubleshooting of Vibration of NDHDT wash water pump (Sundyne 58
Make)
14 Troubleshooting of Vibration of MUG Compressor along with 61
Hydrocom
15 High vibration problem of the CDU ID fan resolved by in-situ balancing 63
16 PTA Decanter Centrifuge spring loaded vibration isolation pads 65
adjustment to reduce vibrations
17 Mismatching of floating head parting plate profile of STRIPPER FEED / 67
BOTTOM EXCHANGER
Page | 3
18 Troubleshooting of intermittent increase in HCU RGC Drive Turbine JB 68

vibrations
19 Troubleshooting of Decoking control valve 70
20 Troubleshooting of HC leakage 72
21 Overhauling of HP valve assembly 73
22 Resolving cavitation issue in stripper recirculation pump P1-512 by 75
providing Titanium orifice
23 Resolving throughput restriction of PTA by shutdown opportunity 77
utilization for replacement of exchanger 1211A/B and dissolver
reactor 1301
24 PTA Decanter Centrifuge rotor axial adjustment to arrest case seal 83
leakage
25 Resolving High pedestal vibration problem in STG-1 84
PARADIP REFINERY
No.
1. Flooding in the Naphtha-Kerosene zone of CDU Column 87
2. High Skin temperature across various section of Riser and Reactor 89
3. Provision of LP steam in Dilution & Quench steam in INDMAX Riser 91
4. Increase in back pressure of reaction furnace of SRU-I & II 92
5. Increase in back pressure of SRU-I & II 93
6. Improve performance of Deaerator 94
7. Packinox Chemical Cleaning 96
8. Catalyst circulation issue in CCR Regeneration Section 98
9. Replacement of steam tracing with electrical heat tracing and 100
provision of skin thermocouples on CTPs
HALDIA REFINERY
No.
1. CO boiler waterwall tube leak rectification by reducing RFCCU t’put 102
from 90 m3/h to 65 m3/h and stopping CO incinerator firing on
28.09.2022
2. Improvement in Debutanizer overhead LPG condensation by putting 106
additional existing coolers in HR-RFCC into operation
3. Reduction in sulphide, cyanide and TSS in Belco effluent to ETP 107
4. Online cleaning of Fuel Naphtha KOD 108
Page | 4
MATHURA REFINERY
No.
1. Unstable VDU operation 111
2. DHDS successful LS ATF run 116
3. Dechoking of Static Mixer in CCRU Regen gas circuit 118
4. Eliminating the cause to increasing DP in CRU-NHT reactor 119
5. Increase in Load of NHGU 120
6. Provision of Bypass duct to SAPH (302-E-58) 121
7. FCC Economizer pressure fluctuation and frequent PSV popping issue 123
8. Octamax reactor basket collector failure and thermo well bending 125
issue
DIGBOI REFINERY
No.
1. CRU NHDT reactor high Delta. Pressure issue 128
2. Pinhole leakage of MIBK line from elbows 129
BONGAIGAON REFINERY
No.
1. INDMAX unit shutdown observation report 132
2. Taking out Riser Top plug without damaging 134
3. Giraffe neck pattern in reformer tubes 136
4. Choking in quench column of TGT section 138
5. Hammering of pipeline at New TTL bay 139
Page | 5
BARAUNI
REFINERY
Page | 6
Case Study -1
Summary Sheet
Unit category Secondary Unit
Refinery Barauni
Unit CCRU
Problem Type Operational
Solve Method Operating parameter change
Report No. P/CCRU/2022-23/1
Year / Month 2022/06
Title of the report Improvement in CCRU recycle gas HCl content and decrease of
Chloride leaching from catalyst
Problem High HCl content in CCRU recycle gas
Solution Operating parameter change
Problem:
High HCl content 4 – 6 ppm in CCRU recycle gas and increase of leaching of Chloride from
CCRU catalyst.
Duration of Problem:
Apr’22 – May’22. Solved in Jun’22
Observation:
Increase of HCl content from normal 1 – 2 ppm to 4 – 6 ppm in CCRU recycle gas
Methodology:
Checking of operating parameters for NHT, CCRU air dryers, reduction zone and reactor-01
dp and decrease of differential pressure across reduction zone and R-01
Analysis:
1. Recycle gas HCl using detector tube was found increase to 4 – 6 ppm with catalyst
chloride content lower than design %.
2. Increase in leaching of chloride from CCRU catalyst observed.
3. Probability of increase of moisture content in reactors loop checked – CCR

regeneration section air dryer was working satisfactory, performance of NHT stripper
was satisfactory, increase in differential pressure across Reduction zone and reactor-
1 observed from earlier 1.3 kg/cm2 to 1.6 kg/cm2. This was increased due to earlier
lifting issue.
4. There are two nos. of source for increase of moisture content from CCRU regeneration
section to CCRU platforming section: a) From reduction purge gas to catalyst collector.
b) From Gas flow from reduction zone to reactor-1 along with catalyst.
Page | 7
5. Reduction zone have high amount of moisture due to reduction reaction, with
increase of differential pressure across RDZ and R-1, there will be increase of gas flow
along with catalyst, causes increase of moisture content in reactor section.
6. As per advisory from unit licensor, this DP decreased to 1.1 kg/cm2.
7. With the same, decrease in recycle gas HCl content observed to 2 – 3 ppm.
8. Trend for DP across RDZ and R-1:
Corrected action:
Decrease of DP across RDZ and R-1 to 1.1 kg/cm2g.
Benefits realized:
Decrease in recycle gas HCl content observed to 2 – 3 ppm and leaching of Catalyst Chloride
content reduced.
Page | 8
Case Study -2
Summary Sheet
Refinery Barauni
Unit CCRU
Solve Method Backwashing of debutanizer OVHD condenser 903-E-12
Report No. P/CCRU/2022-23/2
Title of the report Issue of debutanizer overhead condenser outlet high
temperature and slippage of heavier hydrocarbons to Fuel Gas
Problem High debutanizer top temperature, slippage of heavier
hydrocarbons to Fuel Gas, Bed DP increase in vapor dryer DR-02
due to heavier hydrocarbon to DR-2/increased DR-02 inlet flow
Solution Backwashing of debutanizer OVHD condenser 903-E-12
Problem:
High debutanizer top temperature, slippage of heavier hydrocarbons to Fuel Gas, bed DP
increase in vapor dryer DR-02 due to heavier hydrocarbon to DR-2/increased DR-02 inlet flow
Condenser outlet temperature increase observed gradually from Aug’22
Observation and Analysis:

Trends and observations are below
Methodology:
Checking of operating parameters and condenser tubes CW backwashing.
Corrected action:
Condenser tubes CW backwashing was done.
Page | 9
Benefits realized:
Before condenser tubes After condenser

Description
backwash tubes backwash
CCRU T'put 49 TPH 49 TPH
Debutaniser Top Temp 71 °C 65 °C
Debut tray temp for top temperature
114 °C 114 °C
control
Debutanizer reflux flow 3.6 TPH 2.8 TPH
Condenser E-12 outlet Temp 47 °C 32 °C
Condenser CW return temperature 33.8 °C 30 °C
Debut off gas flow 690 kg/hr 300 kg/hr
Dryer-02 Bed DP 0.5 kg/cm2 0.1 kg/cm2
Benefit in saving from loss of heavier HCs to Fuel Gas. Decrease of DR-2 Bed differential
pressure.
Case Study -3
Summary Sheet
Refinery Barauni
Unit CRU
Solve Method Pressure survey and exchanger cleaning
Report No. P/CRU/2022-23/1
Title of the report NSU-I (CRU) feed limitation
Problem NSU-I feed restriction to 65 m3/hr against design of 80 m3/hr
(achieved t’put> 90 m3/hr)
Solution Pressure survey and NSU-I feed bottom exchanger cleaning
Problem:
After start of CRU in Apr’21, NSU was running at low throughput of 50-60% as per feed
availability. Later in the month of Nov’22, there came requirement for increase of CRU
throughput; however, CRU t’put could not increase due to NSU-I (CRU) feed increase
limitation.
NSU feed increase limitation observed in Nov’22.
Page | 10
Observation:
For NSU-I (CRU) and NSU-II (CCRU), there are three nos. of feed pumps, two running and one
in idle condition. Earlier, it was found out that, two nos of NSU feed pumps are not adequate
for feed provision for both NSU-I and NSU-II. Hence, new impeller of increased size in one no
of pump was installed. With running of pump with increased impeller size or with running of
all three nos of NSU feed pumps, it was observed that NSU-I feed is unable to increase beyond
65 m3/hr that is around 80% of NSU feed. Earlier, NSU-I feed achieved > 125%. No feed
limitation observed with NSU-II.
Methodology:
Pressure survey was done for done for both NSU-I and NSU-II line from NSU feed pump. Based
on this, NSU feed bottom exchanger cleaning was done.
Analysis:
NSU-II (CCRU) NSU-I (CRU)
NSU Feed Pressure, Pressure, kg/cm2g
kg/cm2g
NSU Feed Pressure at 7.1 8.5-9
battery limit
Feed-Bottom exchanger 2.85 7.4
inlet, after feed control (FCV OP: 49 %) (FCV OP: 100%, bypass also open)
valve
Feed-Bottom exchanger 1.55 NSU Column inlet: 2.45
outlet (Pressure drop in feed-bottom
exchanger outlet and column inlet ~
1.5 kg/cm2 based, hence exchanger
outlet Pressure: 3.95 kg/cm2g.
DP across feed bottom 1.3 3.45 (design: max 1 kg/cm2)
exchanger
Corrected action:
NSU-I feed bottom exchanger was opened and found high quantity of semi-solid hydrocarbon
(may be due to long time idling of unit) in shell side(feed) of exchanger. Cleaning of NSU-I
feed bottom exchanger was done.
Benefits realized:
NSU Feed bottom exchanger 01-EE-001 cleaning

NSU Feed Before exchanger cleaning After exchanger cleaning
NSU feed restriction to ~ 65 NSU feed achieved > 90 m3/hr
m3/hr at FCV op < 35 %
NSU Feed Pressure
8.5 – 9 kg/cm2g 8.5 – 9 kg/cm2g
at battery limit
Feed-Bottom 4 kg/cm2g
7.4 kg/cm2g
exchanger inlet, (Feed CV OP: 32 – 35 %)
Page | 11
after feed control (Feed CV OP: 100%, bypass also

valve open)
Feed-Bottom
NSU Column inlet: 2.45 kg/cm2g
exchanger outlet
Pressure drop across 3.45 kg/cm2
0.3 – 0.4 kg/cm2
01-EE-01 (Design: max 1 kg/cm2)
Increase in NSU-I feed achieved > 90 m3/hr, no feed limitation; with running of two nos. of
NSU feed pumps.
Case Study – 4
Summary Sheet
Unit category Secondary unit
Refinery Barauni
Unit CRU N2 Plant
Solve Method Replacement of APU (Air Purification unit) Bed-B adsorbents and
strengthening of screen support
Report No. P/CRU N2/2022-23/02
Title of the report High CO2 slippage from N2 plant APU Bed-B
Problem High CO2 slippage from N2 plant APU Bed-B
Solution Replacement of APU Bed-B adsorbents and strengthening of
screen support to avoid mixing of Alumina and Molecular Sieve.
Problem:
High CO2 slippage from N2 plant APU Bed-B
Jan’23- Feb’23
Observation:
High peak of CO2 in air purification bed-B observed. Cold box DP also increased causing
restriction in N2 generation. Frequent requirement of derimming observed.
Methodology:
1. Opening and checking of Bed-B adsorbents for screen checking between Alumina and
Molecular Sieve.
2. Checking of adsorbents mixing. Replacement of mixed adsorbents.
3. Strengthening of screen between Alumina and Molecular Sieve.
Analysis:
1. Intermittent high CO2 in APU Bed-B outlet observed, within expiry time of alumina
and molecular sieve.
Page | 12
2. Previously also, high CO2 in APU Bed-B outlet was observed before expiry of alumina
and molecular sieve life. APU Bed-A was performing normal, Bed-B adsorbent was
replaced and screen was also replaced. Same issue was being observed again.
3. Hence, passing of NRVs/cyclomatic valves either in main line or regeneration was also
suspected of Bed-B leading to damage of Bed-B only and mixing of Alumina and
Molecular Sieve.
4. Cyclomatic valves were found normal. Slight passing in NRV was found.
5. Screen was found damage; some bolts were also found open and mixing of alumina
and molecular sieve observed.
Corrected action:
1. NRV passing was rectified.
2. Adsorbents were replaced for Bed-B.
3. Proper strengthening of screen between Alumina and Molecular Sieve was done with
additional support.
4. Screen before additional support:
5. Screen after additional support:
Benefits realized:
No CO2 slippage from APU Bed-B after correction.
Page | 13
Case Study -5
Summary Sheet
Refinery Barauni
Unit ISOM
Problem Type Product quality issue
Report No. P/MSQ-ISOM/2022-23/1
Title of the report Improvement in Isomerate RON due to Optimization in DIH
column sensitive tray temperature
Problem Lower Recycling of 2methyl pentane, 3 Methyl pentane & N-
Hexane
Problem:
Isomerate Product RON being received 82-83.
Apr’22 – Jun’22. Solved in Jul’22
Observation:
Increase in sensitive tray temperature due to higher reboiler steam and lower reflux.
Methodology:
Checking of operating parameters for DIH column and lab analysis (Detailed Hydrocarbon
Analysis) of Feed, product and recycle streams.
Analysis:
In Isomerization process following reactions are intended to be maximized giving higher RON
improvement i.e.
➢ Conversion of Normal pentane (NC5) into iso pentane (IC5) - RON improvement from
62 to 93
➢ Conversion of normal Hexane (NC6) into 2 Methyl Pentane (2 MP) and 3 methyl
Pentane (3 MP) and subsequently into 2,2 DMB and 2,3 DMB (RON improved from
30 to range of 92-104).
Undesired reactions occurring inside ISOM reactors are cracking of C7+ into LPG
component giving higher exotherm and Hydrogen consumption.
1. In ISOM unit, part of product stream is recycled from DIH column side draw to
maximize product RON. As per Detailed Hydrocarbon analysis, it was observed that
Page | 14
recycle from DIH having higher tail end i.e., C6+. Ideally, DIH recycle shall have
predominantly 2MP, 3MP and NC6 which will further isomerize to produce higher RON
2,2 DMB and 2,3 DMB component.
2. Critical operating parameters were reviewed in conjunction with lab data and
following were observations:
➢ DIH recycle draw tray Temp was running high i.e., 115 DegC against design of
102 DegC
➢ DIH sensitive tray (61st tray) temperature was also running high i.e., 121 DegC
against design of 110 Deg C
➢ Feed X factor is slightly on higher side i.e., 26% against 18% design requiring
higher temperature in isomerization reactor
➢ Iso ratios at reactor outlet are low indicating catalyst performance not optimal,
warranting need to be increase reactor severity after adjusting DIH column
condition.
Description Design PGTR 01.01.2022 June’22 Remarks

Fresh Feed Rate, 15 15 18.5 19.6 Fresh Feed on higher side
TPH
Recycle to Feed, 13.2 14 12.2 11.2 Recycle flow on lower
TPH side
R-01 inlet Temp, 153 122 155 153.9
DegC
R-01 Exotherm, 29 27.3 13 11 Low exotherm as RSU
DegC benzene rich stream is
routed to SRN tankages
R-02 Inlet Temp 155 135 120 122 Presently in Lag position
R-02 Exotherm 8 25.7 14 13
R-03 Inlet Temp 140 120 145 156 Presently in Lead position
with catalyst deactivated
R-03 Exotherm 8 10.8 7 3 Lower activity, need to
increase inlet
temperature to improve
some activity (Licensor to
be consulted)
DIH recycle draw 102 105.4 105 115 Temp. to be decreased by
tray Temp slight adjustment with
reboiler steam flow and
increasing pump back
flow
DIH sensitive Tray 115 110 121 Temp. to be decreased by
Temp (61st Tray) slight adjustment with
reboiler steam flow
Steam Flow to 8.5 8.2 7.99 8.3
Reboiler
Page | 15
DIH pumpback 13.5 12.5 11 Flow to be increased to

flow increase internal reflux
flow and limit tail end
with DIH recycle to feed
RON of Mixed 87 87 84.2 82
Isomerate
Corrected action:
• Feed FBP was controlled below 95°C to reduce Feed X factor
• Temperature of lag reactor was increased by 2°C to improve iso ratios
• Column conditions were optimized with respect to sensitive tray temperature as
per the simulation results and close to design value of 2 Deg C
Benefits realized:
Increase in Isomerate RON by 1.5-2 unit i.e., 84.5-85. With increased isomerate RON MS pool
quantity is expected to increase by appox 1-1.5 TPH leading to economic benefit of Rs 9.5
Crore/annum.
Case Study -6
Summary Sheet
Refinery Barauni
Unit New Prime G
Report No. P/New Prime G/2022-23/1
Title of the report Reduction in RON drop across Prime G during higher feed sulfur
processing
Problem Higher olefin saturation across HDS-1 1st Bed leading to higher
exotherm and higher RON loss
Problem:
RON drop across Prime G during higher feed sulfur processing was 3-3.5.
Apr’22 – Dec’22. Solved in Dec’22
Observation:
Page | 16
Higher exotherm in HDS-1 1st bed and increase in LCN withdrawal from splitter column leading
to lower olefinic feed in HDS section and lower saturation of olefin in HDS section.
Methodology:
Checking of operating parameters for SHU splitter and HDS section and lab analysis (sulfur
and olefin content) of Feed & product streams.
Analysis:
Prime G unit objective is to desulfurize gasoline generated from FCC without much loss of
olefin (Delta RON). To maximize olefin retention (RON rich stream), LCN is withdrawn in
splitter column before undergoing hydrodesulfurization. Olefin rich LCN stream is blended n
MS pool having individual RON of 95-98.
1. During HS crude processing FCC gasoline sulfur increases due to which to maintain
product sulfur, HDS-1 and HDS-2 reactor inlet temperatures are increased. Due to
increase in reactor severity olefin saturation also increases leading to higher RON loss.
2. With review of data, it was observed that HDS-1 Bed-1 exotherm increases to 25 DegC
against typical value of 10-12 DegC during higher feed sulfur processing, while other beds
of HDS-1 and HDS-2 reactor exotherm was only slightly increased.
3. By lab analysis of 1st stage sulfur analysis, it was observed that higher fraction of
desulfurization is taking place in stage-1 while lower fraction in downstream stage. As per
Licensor, equal fraction of desulfurization shall take place across each stage.
4. Keeping in view of licensor recommendation, HDS-1 Bed-1 severity was decreased to
reduce HDS reaction and shift it to second stage.
Corrective actions taken:

➢ Restriction in HDS-1 Bed-1 RIT to not more than 240 Deg C to maintain Bed-1 exotherm
approx 60% of total reactor exotherm.
➢ Total bed exotherm of HDS-1 & HDS-2 reactor has reduced to 60-70% of earlier level
due to maintaining equal percentage of desulfurization across each HDS section (inline
with licensor recommendation). Bed-1 exotherm restricted to less than 15 DegC even
during high sulfur feed processing (earlier used to be 20-25 DegC during high sulfur
feed processing causing high Ron loss)
➢ Improved separation in splitter column. Better olefin retention in LCN stream
(minimizing slippage to HCN stream. LCN draw increased from 20 m3/hr to 24 m3/hr.
Benefits realized:
Decrease in RON dropped from 3-3.5 unit to 2.0-2.5 unit. With increased in recombined
product RON, MS pool quantity is expected to increase by appox 5.5 TPH leading to economic
benefit of Rs 40 Crore/annum.
Page | 17
Case Study -7
Summary Sheet
Refinery Barauni
Unit NHDT ISOM
Problem Type Product quality issue
Solve Method Field visit with line tracing
Report No. P/NHDT ISOM/2022-23/1
Title of the report Identification of coker MRN passing into MS blend
Problem Higher Sulfur of MS blend leading to product quality failure
Solution Site visit identification
Problem:
Higher Sulfur in MS blend during FCC shutdown with MS component being only DSN,
Reformate and Isomerate
Dec’22. Solved in Dec’22
Observation:
Higher sulfur in MS blend even with all MS component stream analysis showing sulfur result
of less than 0.5 ppm
Methodology:
Checking of P&ID and line tracing on field for possible contamination
Analysis:
During FCC shutdown in Dec’22, BR was producing MS using Isomerate, Reformate and DSN.
None of these streams were having sulfur higher than 0.5 ppm. Due to FCC shutdown, coker
MRN was routed to NHDT-ISOM unit. Normally, coker MRN is routed to FCC riser.
Coker MRN at NHDT –ISOM battery limit has provision of routing it either towards FCC unit
or towards NHDT feed surge drum. Prime G splitter heart cut earlier used to be routed directly
to MS pool during BS-IV scenario as sulfur content in heart cut used to be less than 150 ppm.
However, post BS-VI scenario heart cut withdrawal is stopped and existing heart cut line to
MS blend is used for NHDT heavy naptha routing.
During coker MRN line –up to NHDT, it was observed that MS blend sulfur increased.
During line tracing and P&ID check it was observed that Heart cut has one routing back to
FCC riser which was connected to coker MRN. As coker MRN was charged, with a valve in
between passing coker MRN through heart cut line was getting its way to MS blend.
Page | 18
Corrective actions taken:

Line was positively isolated with blind in between.
Benefits realized:
BR could sustain production of MS during FCC shutdown in Dec’22 with coker MRN processing
in NHDT and without any product quality failure.
Case Study -8
Summary Sheet
Refinery Barauni
Unit RFCCU
Solve Method Lab testing
Report No. P/RFCCU/2022-23/1
Title of the report Improvement in RFCCU Deaerator performance through operational
changes
Problem Condensate loss of 1-2 m3/hr (overflowing from top vent) of Deaerator
Problem:
Higher LP steam consumption and condensate loss from top vent of Deaerator was reported
Apr’22- July’22. Solved in Aug’22
Observation:
Deaerator with operating pressure at 0.4 kg/cm2g, LP steam consumption was 5000-6000
Kg/hr and overflow of condensate from top vent was observed.
Methodology:
Lab analysis of Dissolved oxygen at different operating condition was carried out for assessing
performance
Analysis:
➢ Stripping steam to Deaerator reduced stepwise along with Deaerator pressure and
Dissolved oxygen was tested at each condition. Following are the observations:
Deaerator Stripping steam, Dissolved oxygen in Condensate

pressure, Kg/hr Deaerator bottom, overflow
Kg/cm2g ppm
0.4 5000-6000 1.2 Yes
Page | 19
0.2 4000-4500 0.93 reduced

0.1 3200-3500 0.8 No
Benefits realized:
Reduction in Deaerator pressure and maintaining DM water inlet temp close to 100°C helped
in reduction of LP steam consumption by 1.5-2 T/hr which corresponds to SRFT saving of 1252
per year.
Page | 20
GUJARAT
REFINERY
Page | 21
Case Study -1
Summary Sheet
Unit category LAB COMPLEX (PETROCHEMICAL)
Refinery Gujarat Refinery
Unit Linear Alkyl Benzene
Solve Method Simulation
Report No.
Year / Month Aug’22
Title of the report KHT CFE leak (2061-E-01(2)) leak identification, rectification and
running
Problem High Sulphur in KHT stripper bottom
Solution Bypassing One shell of KHT and maintaining the LAB revamp Tput
Problem: During the LAB revamp, KHT catalyst changeover was done. The catalyst sulfiding of
the KHT Reactor was performed from the 15th to 17th of Aug’22 with HT sulfiding completed @
4:00 hrs. on 17.08.2022. RIT reduced to 296°C from 318°C.Rundown Sulphur was coming around
4 ppm whereas the requirement was S <1 ppm.
Duration of Problem: 18 Aug’22-20 Aug’22
Observation:
The catalyst sulfiding of the KHT Reactor was performed from the 15th to 17th of Aug’22 with
HT sulfiding completed @ 4:00 hrs. on 17.08.2022. RIT reduced to 296°C from 318°C. KHT
rundown sample was sent for analysis.
Initially, the condition of the system:
Tput 50 m3/hr
RGC flow 48000 Nm3/hr
Separator pressure 84 Kg
RIT 296°C
As even after many samples, Sulphur in the rundown was consistently high with same RIT. Action
taken: Reactor Bypass isolation valve both closed. CFE drain line were checked and found
normal. Purge increased to improve the RGC purity
At 16:00 hrs. RIT increment started (initial RIT 296°C) on 17.08.2022
At 20:00 hrs. RIT was set @ 300°C which was hold till 3:00 hrs. on 18.08.2022
At 3:00 hrs. on 18.08.2022, RIT was increased to 303°C
Even after increasing the RIT there was no significant change in rundown Sulphur. The
exotherm across reactor are in normal range with WABT in bed 1: 317°C and WABT in bed 2:
316°C
Page | 22
KHT Rundown Sulphur

5.8 5.6
5 5.3 4.9 4.8 4.5 4.5 4.6 4.6 4.6 4.6 4.6
3.9 4.2 4.1 4.3 3.9
3.8 3.8 3.6 3.8
17.08.2022
18.08.2022
17.08.2022
17.08.2022
17.08.2022
17.08.2022
17.08.2022
17.08.2022
17.08.2022
17.08.2022
17.08.2022
17.08.2022
18.08.2022
18.08.2022
18.08.2022
18.08.2022
18.08.2022
18.08.2022
18.08.2022
18.08.2022
18.08.2022
18.08.2022
8:30 10:1512:1514:4515:1517:0017:30 19.3 21 22 23.5 0.4 1.3 2.5 3.4 4.4 5.4 7.3 10 11.3 15 16
Methodology: Elimination method, So the causes were identified which can lead to high
rundown Sulphur
1. Reactor bypass valve passing –
Action taken: Reactor Bypass isolation valve both closed. CFE drain line were checked
and found normal. So, change in rundown Sulphur, hence eliminated
2. Catalyst performance,
Action taken RIT increased and WABT was in normal range, hence eliminated
3. CFE Leak – Probable cause (detail provided in analysis)
Analysis:
At 10:30 hrs. on 18.08.2022 feed CFE bypass was opened to 50%. Which resulted in decrease
of Sulphur in rundown from 4.6 to 3.6 ppm
At 13:00 hrs. on 18.08.2022 both KHT feed and rundown sample were collected to check Sulphur
in different distillation cut. The lighter cut of KHT rundown has high Sulphur content which
indicate mixing of reactor effluent with feed (Suspected CFE leak)
Sample Name: KHT Stripper Bottom on 18.08.2022

Distillation Volume (vol %) Distillation Temperature (deg Sulphur in Distillate Cuts (ppm)
C)
10 189 3.2
20 190 3.3
30 198 3.4
40 200 3.5
50 203 3.6
60 205 3.7
70 210 3.9
80 215 4
90 222 4.3
Page | 23
100 227 4.6

Organic Sulphur 4.4
Inorganic Sulphur 0.2
Sample Name: Heart cut (KHT FEED) on 18.08.2022

Distillation Volume (vol %) Distillation Temperature(°C) Sulphur in Distillate Cuts (ppm)
15 195 1111
30 198 1107
45 202 1207
60 206 1255
75 211 1256
90 218 1284
100 226 1288
Organic Sulphur 980
At 20:00 hrs. to check the performance of the reactor, one sample was taken directly from
reactor outlet. After caustic and water wash, the resultant Sulphur was 1.1 ppm
Same exercise was done for 2061-E-01 (1/2) & 2061-E-11
SN Reactor effluent Sulphur, ppm

1 UF reactor O/L 1.1
2 61 E-11 O/L 3.4/3.3/3.3
3 61-E-1 1/2 14.1/13.16/13.19
At 10:50 hrs. on 19.08.2022, RGC load was reduced from 100 % to 47% for increasing the feed
to CFE bypass. Not much change observed in rundown Sulphur
Based on the result: Sulphur in different distillation cuts, it was certain that there is leak in
CFE and no catalyst performance issue
Corrected action: On 20.08.2022 @ 20:00 hrs. KHT shutdown was taken.
Once water filling started in exchanger shell, leakage observed from tubes of 2061-E-01(2)
2061-E-01(2) – KHT combined feed

exchanger
Page | 24
Total 11 U tubes were plugged, but as so many tubes plugging was done it was decided to
remove the tubes for inspection.
As per the tube’s conditions, it was prone to further leak and better to bypass this exchanger.
Simulation study for feasibility of running KHT with three shells instead of 4 in view of leak
observed in 2061-E-01(2)
Channel cover partition plate was cut, and plate was installed in place of tube sheet, thereby
exchanger got bypassed without creating external bypass
Page | 25
Benefits realized: Early identification of leak help in completing the LAB revamp
start up within schedule. The 2061-E-01 (2) was bypassed as same exchanger was prone to
leakage without compromising the unit T’put.
Case Study -2
Summary Sheet
Unit category LAB COMPLEX (PETROCHEMICAL)
Refinery GUJARAT REFINERY
Unit Linear Alkyl Benzene
Problem Type Unavailability of LAB off spec material for early start up
Solve Method Innovation
Report No.
Title of the report Use of LAB product for stabilization of LAB column and Finishing
column thereby saving 4 startup days
Problem High Sulphur in LAB off spec product
Solution Use LAB product instead for Off-spec material for early stabilization
Problem: To reduce the LAB unit start up day, it was decided to use the LAB off-spec material
(which was generated during shutdown and having 10 % LAB) but the LAB off spec material was
having high sulfur ( 30 PPM) so was unfit to use in LAB back end
Duration of Problem: 1-4 Aug ‘22
Observation: LAB off spec material cannot be used as having high Sulphur.
Results of off-spec tank Tk-001A dated 1.8.2022.
Page | 26
Parameters UOM Result

Density g/cm3 0.7993
Sulphur ppm 10.35
Nitrogen ppm 0.31
Composition
C4+ wt % 0.09
iC5 wt % 0.32
nC5 wt % 2.37
Benzene wt % 39.59
C6+ wt % 0.88
C7+ wt % 0.19
iC8 wt % 0.44
C10 wt % 10.65
C11 wt % 10.56
C12 wt % 10.53
C13 wt % 9.61
LAB wt % 10.36
HAB wt % 4.05
Methodology:
Innovation (Use of LAB product (92% LAB) for stabilization instead of LAB Off spec material
Corrected action:
• Unloading facility was created for unloading of LAB from TTs
• LAB off-spec Pump (2073-P-16) utilized for unloading operation
• 2 LAB TTs were arranged from Marketing
• TTs were filled with LAB from LAB main tank and unloaded directly to LAB unit via off-
spec pump
Page | 27
Benefits realized: The stabilization of LAB and finishing column took 4 days using LAB product
and stabilized before pacol feed cut in thereby saving complete 4 startup days. With this LAB
start up timeline was achieved
Case Study -3
Summary Sheet
Unit category Process unit
Unit FCCU
Problem Type Operational Improvement
Solve Method Catalyst Reformulation
Report No.
Year / Month Nov’22
Title of the report Troubleshooting of high Catalyst Loss in JR FCCU
Problem high Catalyst Loss in JR FCCU
Solution Catalyst reformulation
Problem:
Operational Improvement: - Catalyst Loss in JR FCC was decreased from 3 MT/day to 1-
1.5MT/day.
Page | 28
Jan’22 to Oct’22
Observation:
Catalyst loss in FCC unit is higher side i.e., 2.5-2.7 MT/day against normal loss of 1.5-1.7MT/day
since Jan’22.
The catalyst loss from the unit started gradually after fresh catalyst changeover (from JGC to
ISCPC in Jan’22).
Historically, JR FCC used fresh catalyst which has lower attrition index (in the range of 1-2).
However, the fresh catalyst by M/s ISCPC used after Jan 22 has relatively higher attrition index
(in the range of ~5-6).
0-40 microns content in E-Cat decreased and 0-80 microns content in E-Cat increased gradually
post fresh catalyst changeover
Methodology:
Reformulation of FCC Fresh catalyst
Analysis:
In view of consistent high catalyst loss in FCCU, FCC catalyst was reformulated to reduce the
fresh catalyst attrition index (Typical Range 1- 2) against supplied lot attrition index of 4-5 after
consultation with IOCL R&D catalyst vendor.
Reformulated catalyst had arrived at JR in Nov’22 & started using in unit on 10th Nov’22.
It was observed that catalyst loss has been decreased from 2.7-3MT/day to 1-1.5MT/day i.e.,
Dec’22-Jan’23-month average cat loss.
FCC t'put Catalyst loss 6.0
5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4
5.0
4.0
2.7 2.8 3.0

2.53 2.5 2.45 2.56
2.4 2.4 2.34
1.96
2.0
1.25
1.05
1.0
0.0
(1st (13th (28th 12th 17 Jul'22 4th 8th 29th 22nd 13th 10th 10th
May'22 May’22 May'22 Jun'22 to to 1st Aug'22 to Sep'22 to Sep'22 to oct'22 to Nov'22 to Dec'22 to Jan'23 to
to 10th to 24th to 8th 30th Aug'22 2nd 26th 19th 9th 30th 9th 17th
May'22) May'22) Jun'22) Jun'22 Sep'22 Sep'22 oct'22 Nov'22 Nov'22 Jan'23 Jan'23
Page | 29
Corrected action:
FCC catalyst was reformulated to reduce the fresh catalyst attrition index (Typical Range 1- 2)
against supplied lot attrition index of 4-5 after consultation with IOCL R&D catalyst vendor
Benefits realized:
Catalyst loss in JR FCC has been decreased from 2.7-3MT/day to 1-1.5MT/day.
Case Study -4
Summary Sheet
Unit FCCU
Problem Type Operational Improvement
Solve Method FCC Unit shutdown
Report No.
Year / Month Sep’21 to Aug’22
Title of the report Troubleshooting of high-pressure drop-in FCC MAB discharge to
Regenerator
Problem Less air flow to regenerator results to t’put limitation
Solution Changes in operating parameters
Problem:
Troubleshooting of high-pressure drop-in FCC MAB discharge to Regenerator
Page | 30
Sep’21 to Aug’22
Observation:
• MAB discharge pressure was increased from 3.52 kg/cm2 (t’put of 250 m3/hr) to 3.66
kg/cm2 (t’put of 240m3/hr).
• Delta pressure across MAB discharge to air grid inlet has increased from 0.1kg/cm2 to
0.35kg/cm2. Further governor opening has also increased from 37.8% to 45% indicating
restriction in air flow path to regenerator. This is also led to increase in steam consumption
from 72T/hr to 80T/hr.
• Even at high RPM of MAB (6080 against earlier value of 5950), air flow to regenerator is in
the range of 78000-79000Nm3/hr against earlier value 87000-88000 nm3/hr at same t’put.
MAB RPM has increased to supply air to regenerator.
• As per pressure survey data, delta pressure across MAB discharge to air grid inlet has
decreased from 0.31 kg/cm2 to 0.15 kg/cm2 against normal pressure drop of 0.11
kg/cm2(Before Sept’21) in recent FCC shutdown.
Analysis:
• Pressure drop across NRV discharge to air grid inlet was high i.e., suspecting restriction in
air flow path in DFAH.
Corrected action:
• During start up activity, DFAH damper was adjusted for igniting DFAH. it is observed that
during startup of DFAH, stucked damper has broken inside the DFAH while adjusting it &
DFAH has become inoperable from outside after that. Hence it can be concluded damper
was restricting the path of air. It was rectified in shutdown.
Benefits realized:
• MAB discharge pressure was decreased from 3.7kg/cm2g to 3.47kg/cm2g due to

less/minimum restriction in downstream section.
• MAB air flow to regenerator was increased from 76504 nm3/hr to 82850 Nm3/hr even at
less RPM of 6027 against earlier RPM of 6047 resulting to good regeneration at
regenerated catalyst.
• Fluctuation in MAB deviation has also improved from 0.09-0.13 to 0.11-0.12 & MAB blow
off opening was reduced from 8.2% to 7.2%.
• MAB vacuum was improved from (-)0.47kg/cm2to (-)0.52kg/cm2, however current value
is much higher than normal value i.e. (-)0.72kg/cm2 in Sep’21 due to possible CW leakage
to resulting less CW flow in FCC area.
Page | 31
GUWAHATI
REFINERY
Page | 32
Case Study - 1
Summary Sheet
Refinery Guwahati Refinery
Unit CDU
Solve Method Root cause analysis
Report No.
Year / Month 2023/September
Title of the report CDU main fractionator high flash zone pressure
Problem Increase in flash zone pressure varying from 0.50 to 0.67 kg/cm2g.
Solution BFW injection in 01-S-2G/H (overhead condensers) by reverse BFW
washing from 01-S-2E/F.
Problem:
➢ Increase in flash zone pressure varying from 0.55 to 0.67 kg/cm2g.
➢ Limitation in CDU throughput (max 145 m3/hr against the normal t’put of 155
m3/hr).
Duration of Problem: From 04.09.2022 to 14.11.2022
Observation: Restricted flow of vapours from the column overhead thereby causing back
pressure and subsequently increase in flash zone pressure.
Methodology:
S.no. Action taken Observation

1. Flash zone pressure controller bypass was No change in flash zone
fully opened. pressure
2. New Pressure transmitter installed for No change in flash zone
correct indication pressure
3. Stripping steam to main fractionating Increase in flash zone pressure
column was reduced.
4. Stripping steam to main fractionating Significant increase in flash
column was increased. zone till 0.71 kg/cm2g.
5. SRGO CR flow increased Gradual decrease in flash zone
pressure.
6. SRGO CR flow increased along with charging Significant decrease in flash
stripping steam (30kg/hr) to Kero side zone pressure observed
stripper. temporarily, but it was again
increased to 0.65 kg/cm2g after
reducing steam.
Page | 33
Corrected action:
Deposition of salts suspected in the overhead line which might be causing hindrance to flow
of overhead vapors to condensers. So, it was decided to inject BFW in S-2G/H. But since, BFW
injection valve to S-2 G/H stem was in broken condition, direct injection could not be carried
out (refer Fig 1 below).
Valve broken
CL-2
S-2 C/D S-2 E/F S-2 G/H
BFW from TPS
OPEN
CLOSE
DAMAGE
Figure 1: Schematic of BFW injection in overhead condensers
Hence, it was decided to inject BFW in 01-S2-G/H indirectly by keeping the exchangers 01-S-
2E/F inlet line in isolated condition and opening the BFW injection valve (refer Figure 1
above).
Benefits realized:
Post injection of BFW and all other activities as been mentioned, flash zone pressure has been
brought down and normalized from 0.67 to 0.50 kg/cm2g. Thereafter throughput has been
increased from 145 to 155 m3/hr.
Flash zone pressure trend

0.8
0.6
0.670.670.660.660.670.660.650.660.630.610.610.620.630.630.640.640.640.64
0.4 0.550.51
0.2
flash zone
0
11:30:00
07:00:00
07:30:00
08:00:00
08:30:00
09:00:00
09:30:00
10:00:00
10:30:00
11:00:00
12:00:00
12:30:00
13:00:00
13:30:00
14:00:00
14:30:00
15:00:00
15:30:00
16:00:00
16:30:00
Page | 34
Case Study -2
Summary Sheet
Unit NHT- MSQU
Problem Type Process upset
Report No.
Year / Month 2023/February
Title of the report High H2S content in NHT recycle gas and NHT rundown to ISOM
Problem High H2S in recycle gas and increase in ‘S’ content of NHT rundown to
ISOM
Solution Caustic make-up and caustic wash of LN ex NSF-CDU
Problem: High H2S (~1200ppm) in NHT recycle gas was found even without DMDS dosing. This
posed risk of sulphur slippage in NHT rundown that could consequently poison ISOM catalyst.
Observation: ‘S’ content in NSU top was found high (~230ppm) against design maximum of
120ppm.
Methodology:
• Purging ex NHT separator started immediately with increased make up hydrogen.
• NHT reactor and stripper bottom temperature increased to cater high Sulphur in feed.
• Lead acetate test of stripper bottom done frequently and check samples of NHT rundown
sent to QC lab to ensure ‘S’ in ISOM feed is within limit of 0.5 ppmw.
Analysis:
• High H2S in recycle gas was due to increased ‘S’ in NSU top naphtha to NHT.
• ‘S’ in crude was within normal range i.e., 0.29%.
• Caustic strength for caustic wash of LN ex NSF-CDU reduced to <1% that resulted in
increased H2S of NSU top to NHT
Corrected action:
• Fresh Caustic make-up done in CDU.
Benefits realized:
• H2S in recycle gas and Sulphur in NHT rundown reduced to normal range.
• Sulphur poisoning of ISOM catalyst averted.
Page | 35
Case Study-3
Summary Sheet
Unit category Process Unit
Refinery Guwahati refinery
Unit INDAdeptG
Problem Type Operational /High nitrogen consumption
Report No.
Year / Month 2023/March
Title of the report High nitrogen consumption in INDAdeptG
Problem High nitrogen consumption during activation cycle
Solution Identification of leak point and leak rectification
Problem: High nitrogen consumption in unit leading to depletion in nitrogen stock of Refinery
Duration of Problem: Feb’23
Observation: Increased nitrogen consumption was observed during activation cycle.
Methodology: Pressure drop across loop checked and leak test done
Analysis:
• Pressure hold test of activation loop was done and pressure drop of approx. 0.25 kg/cm2
/hr observed across loop.
• No valve was found passing and no flanges were found leaking.
• Trim cooler (E-07) isolated and pressure survey was done again. After isolation of trim
cooler, no drop in pressure was observed confirming tube leak in cooler.
Corrected action:
• Activation trim cooler (E-07) isolated and handed over to M/M for leak rectification
Benefits realized:
• Nitrogen loss at the rate of ~50kg/hr arrested.
Page | 36
Case Study -4
Summary Sheet
Unit INDAdeptG
Report No.
Year / Month 2022/Nov-Dec
Title of the report High pressure drop across reactor-2B bed-1during regeneration
Problem High-pressure drop-in reactor-02B bed-1 during regeneration in
INDAdeptG
Solution Skimming the reactor top bed
Problem: INDAdeptG Reactor-2B bed-1 pressure drop increased to 4.8kg/cm2g against normal
pressure drop of 1.5 kg/cm2g at regeneration gas flow of 5500 kg/h (design 7550 kg/h).
Observation: Pressure drop was increasing and affecting reactor regeneration.
Methodology:
• Unit taken under shutdown in Nov’22.
• Reactor-2B bed -1 top layer skimmed.
Analysis:
• After analyzing the spent adsorbent unloaded, root cause for pressure drop found to be
due to high amount of corrosion depositions.
Corrected action:
• Combustion Compressor suction and discharge KODs and volume bottles cleaned.
• Combustion compressor suction and interstage KODs MOC will be changed from CS to SS
(MOC for the same was under approval).
Benefits realized:
• Post Shutdown, reactor-2B bed -1 pressure drop reduced to 0.5 kg/cm2g at design
flow of 7550 kg/h.
Page | 37
Case Study -5
Summary Sheet
Unit HDT
Report No.
Title of the report High pressure drop across reactor-1 bed-1
Problem High-pressure drop-in reactor-01 bed-1 of HDT limiting T`put
Solution Skimming the reactor top bed
Problem: HDT reactor-1 bed-1 pressure drop running high at 4.8 kg/cm2g against process design
of 2.2 kg/cm2g and mechanical design of 5.05 kg/cm2g at low T`put of 105 m3/h (design 120
m3/h).
Observation: Pressure drop was increasing and further limiting HDT T`put
Methodology:
• Unit taken under shutdown in Nov’22.
• Reactor-1 bed -1 guard beds (metal guard, Silica guard) arranged from other refineries
contingency catalyst.
• Reactor-1 bed -1 CATTRAP, metal guard and some portion of silica guard replaced with
contingency catalyst from other refineries.
Analysis: After analyzing the spent catalyst unloaded form the unit, root cause for pressure drop
was found to be due to high sodium content in feed and due to corrosion depositions.
Corrected action:
• CDU de-salter operation continuously monitored to avoid salt carryover to secondary
units.
• Recycle gas compressor changeover SOP reviewed and modified to avoid any sudden
shock in the reactor.
• Corrosion in recycle gas compressor circuit continuously monitored to avoid carryover of
corrosion particles.
Benefits realized:
• Post Shutdown, reactor-1 bed-1 pressure drop reduced to 1.0 kg/cm2g at design
T`put of 120 m3/h.
Page | 38
Case Study -6
Summary Sheet
Unit HDT
Problem Type Problem in control valve
Report No.
Title of the report High fuel gas consumption in HDT reactor furnace 49-F-01
Problem Feed vs reactor effluent exchanger (BLE) bypass control valve stuck
Solution Control valve opened in shutdown, root cause for problem identified &
solved
Problem: HDT Feed vs reactor effluent exchanger 49-E-03 bypass control valve 49-TV-1401
found stuck up at 40%. Due to this, furnace inlet temperature dropped to 278 ℃ against design
of 290 ℃ and fuel gas consumption in furnace increased.
Observation: Low furnace inlet temperature and high fuel gas consumption in furnace. Control
valve in bypass line of feed effluent exchanger 49-E-03 found to be stuck at 40%.
Methodology: Control valve opened to analyze the problem during Nov-Dec`22.
Analysis: Metallic piece found at control valve seat and not allowing the valve to close fully.
Corrected action:
• Metallic piece removed and valve internals checked for damage.

• Valve operation checked from 0 to 100 % before installing at position.
Benefits realized:
• Furnace inlet temperature increased by 5-7 ℃ and fuel gas consumption in furnace
reduced by ~ 200 kg/hr.
Page | 39
Case Study- 7
Summary Sheet
Unit category Thermal Power Plant
Unit TPS
Problem Type Equipment Reliability
Solve Method Root Cause Analysis
Report No.
Year / Month For 6 months after commissioning
Title of the report Changing of Air compressor cooling media
Problem Leakage of inter cooler Tubes of air compressor
Solution Changing Cooling media from CW to Fresh Water
Problem: Corrosion deposits and leakage problems in Inter cooler tubes of TPS air compressor
used during Black start.
Duration of Problem: For 6 months after commissioning.
Observation:
• TPS CT air compressors were supplied with TPS Cooling water whose header pressure
was 2.2kg/cm2 as normal. Also, pressure at inlet of TPS CT air compressor coolers was
even lower at 2.0kg/cm2.
• As per design data, to maintain sufficient flow across the coolers minimum DP of 1
kg/cm2 or more is required. However, this DP was achieved only after throttling of outlet
flow which means insufficient cooling water flow is achieved.
• Insufficient flow and low velocity due to reduced header pressure, deposits were
observed in water jackets of both primary and secondary stage of compressors and in
interstage and after coolers, leading to inefficient cooling of the inside chamber. This also
led to frequent seal failures and leaks.
• Repetitive maintenance occurred because of the same.
• Running two compressors with drier in service was difficult since inlet pressure was
further getting reduced.
Methodology:
• Changing of cooling media from Cooling water to Fresh water which was available at high
pressure of 3kg/cm2.
Analysis:
• Insufficient cooling water flow was achieved with current TPS cooling water use due to
its already reduced header pressure.
Corrected action:
• Low pressure TPS CW was replaced with Fresh water which was already available at
higher pressure at 3kg/cm2.
Page | 40
Benefits realized:
• This helped in increasing cooling water flow for TPSCT compressors and problem of
deposition was eliminated. Leaks also have not been observed since changing of cooling
water media.
• Avoidance of repetitive maintenance have considerably reduced maintenance costs.
• Parallel running of compressors without throttling the isolation valves could be done.
Case Study- 8
Summary Sheet
Refinery Guwahati
Unit ATU/ARU
Problem Type Process abnormality
Solve Method Process parameter adjustment and Gas diversion
Report No. GR/ATU/2023/01
Year / Month 2023/March
Title of the report High H2S in Sweet gas & FG header
Problem DCU ATU column High DP
Solution Partial diversion of DCU offgas to HDT ATU
Problem:
ATU unit was running normal. Suddenly sweet gas H2S increased from nil to > 2000 ppmw
leading to high H2S in common FG header.
Duration of Problem: From 07.03.2023 to 08.03.2023.
Observation: Sweet gas H2S was found higher than design.
Methodology:
• Process variables adjusted to check impact sweet gas H2S.
• Column related instruments checked.
• MDEA strength checked.
Analysis:
• ATU column DP was higher 0.3 kg/cm2 against 0.13 kg/cm2.
• Column bottom level was faulty.
• HC carryover from DCU. No level in DCU ATU inlet KOD due to faulty level.
• This was causing unstable column operation.
• Lean amine strength was re-checked and found to be 25.1wt% against required 30-
35wt%.
Page | 41
Corrective action:
• Level Control valve 51BLC_0202 tuning was done.
• Column bottom LT span was changed.
• DCU ATU off gas partially diverted to HDT ATU.
Benefits realized:
• Sweet gas & common FG H2S came under limit of less than 200 ppmw.
• Stable ATU column operation.
Case Study- 9
Summary Sheet
Unit HGU
Problem Type Operational / High TMT & High DP of Reformer
Solve Method Route Cause Analysis
Report No.
Title of the report High TMT of HGU Reformer
Problem High TMT & higher DP of reformer leading to HGU T’put limiting
Solution Catalyst Replacement
Problem: Post start-up in Sept’21, unit started to experience hot spot in 5 numbers of reformer
tubes (A2/A3/A10/B8/B9) and hot bands in most of tubes (at top portion). The DP was also in
higher side i.e., 2.7 kg/cm2g against the design of 3.3 kg/cm2g at 75% t’put.
Observation: At 75% of T’put, TMT observed to be 936 deg C against the design limit of 950 deg
C. This put a limitation on unit T’put.
Corrected action to Sustain unit operation:

• S/c ratio of the reformer increased from 2.60 to 3.2-3.3 mol/mol.
• Reformer COT maintained at 815-818 deg C against the normal operating of 870 deg C.
Methodology:
• Unit taken to shutdown in Nov’22.
• Catalyst of all tubes replaced with fresh catalyst.
Page | 42
Analysis:
• Unit experienced emergency shutdown on Sep’21 due to sudden de-pressurization of
Process System caused by malfunction of Cold Separator pressure controller at
upstream of PSA section. This resulted into violent de-pressurization of the system and
led to crushing of reformer catalyst.
Benefits realized:
• Post Shutdown and replacement of reformer catalyst, reformer DP normalized, and
TMT came under limit. At 83% T’put max TMT observed 904-906 deg C against 950
deg C.
Case Study -10
Summary Sheet
Unit DELAYED COKER UNIT
Report No.
Year / Month Dec 2022
Title of the report DCU/LRU cooling water supply flow restriction
Problem Inadequate cooling in downstream cooler/condensers
Solution Hot tapping in existing cooling water supply line
Problem:
DCU was taken under SAD shutdown on 22.11.22. Post completion of SAD, it was observed that
cooling water flow to compressor interstage cooler in LRU section was very low due to which
level could not be build up in interstage KOD’s. As a result, stabilizer column could not be
stabilized leading to LPG flaring. And due to high RCO stock unit shutdown was not possible. To
operate LRU section smoothly, proper cooling water supply was required.
From 06.12.2022 to 18.12.2022.
Observation:
Valve seat of CW header isolation valve got detached resulting in low water pressure/flow of
cooling water which was causing LPG flaring and unstable LRU operation. Adequate cooling could
not be achieved in the product rundown coolers.
Methodology:
Hot tapping from main cooling water header to downstream of defective valve of LRU cooling
water supply header provided for proper flow/pressure of cooling water in DCU-LRU units.
Page | 43
Fig: Hot tapping on 18” Cooling water supply line
Corrected action:
As isolation of cooling water supply header was not possible without DCU shutdown, hot tapping
was taken on the existing line.
Benefits realized:
• Troubleshooting carried out without unit shutdown.

• Timely identification and rectification of the problem lead to minimization of flare loss.
Page | 44
PANIPAT
REFINERY
Page | 45
Case Study-1
Summary Sheet
Refinery Panipat refinery
Unit ATF Merox unit
Problem Type ATF Quality issue during High TAN processing
Solve Method Installation of additional facility
Report No.
Year / Month 2022
Title of the report ATF Merox Throughput restriction during High TAN crude run
Problem Inability of producing ATF during high TAN crude run
Solution Installation, commissioning & test run of Electrostatic Coalescer
precipitator (ECP)
Problem: Panipat refinery had limitation in producing on-spec ATF during High TAN crude run
due to presence of naphthenic acid which causes froth formation and loss of efficiency of Pre-
wash vessel due to formation of Sodium naphthenate. Also, naphthenic acid is a poison to Merox
reactor as it blocks its pores. During high TAN run, kero from AVU-II used to be routed to DHDT
feed. This caused loss of ATF production and subsequent buildup of DHDT feed.
Duration of Problem: Since unit commissioning.
Corrected action: Electrostatic Coalescer precipitator (ECP) was commissioned in Dec’21 but due
to unavailability of high TAN crude, its test run could not be performed then.
PR received batch of High TAN crude from 11.02.2023 to 15.02.2023 & the test run of ECP was
conducted during this timeline. As per Lab analysis, TAN in kero was reported as high as 0.33 mg
KOH/g on 12.02.2023. The ECP outlet TAN against aforementioned inlet TAN was 0.025 mg
KOH/g i.e., 92% TAN removal efficiency. ECP was followed by Prewash to further cater to the
treatment of naphthenic acids below design TAN specification of catalyst in the downstream.
Lab Analysis:
Date Time ECP inlet TAN ECP outlet TAN
12.02.23 11:00PM 0.293 0.022
12.02.23 11:00AM 0.33 0.025
12.02.23 05:00AM 0.192 0.018
13.02.23 05:00AM 0.3281 0.017
13.02.23 10:00PM 0.2892 0.038
13.02.23 02:00PM 0.2 0.017
14.02.23 05:00AM 0.29 0.04
15.02.23 05:00AM 0.229 0.016
15.02.23 10:00PM 0.106 0.008
Page | 46
Benefits realized:
• Increased ATF production
• With the commissioning of ECP, limited ATF production during HIGH TAN run should not
be an issue in frequent processing of HIGH TAN crude by Panipat refinery.
Case Study-2
Summary Sheet
Unit AVU-I
Problem Type ETP Effluent quality issue
Solve Method Process Scheme
Report No.
Year / Month Nov 2022
Title of the report Inability to monitor brine quality going to ETP
Problem Inability to monitor brine quality going to ETP
Solution Extension of common line of AVU-I Brine and stripped sour water in ETP-1
Problem: 1) Effluent streams (AVU-I Brine and Stripped Sour water purging) are routed to ETP-1
through a common line. This line terminates at OWS manhole at OSBL of ETP-1 near Wet Slop
Oil tanks (61-T-29 A) and routed to OWS sump through OWS network. There is no flow meter
installed in this line and no provision of sampling. This creates problem in monitoring Effluent
quality as Desalter Brine is one of the main sources of Oil carryover to ETP other than tank farm
drain.
Duration of Problem: Since unit commissioning.
Corrected action: Common line from OSBL of ETP-1 is further extended from OWS manhole
to OWS Sump and to Grit Chamber d/s of OWS Sump. Instruments like magnetic type flow
meter, PG and TG have been provided. Sampling provision is given.
Date of Execution: The proposed job was executed during AVU-I shutdown – Nov’22.
Benefits obtained:
Extending line to grit chamber by passing OWS sump has following advantages.
1) Saved pumping energy of ~11 kW of pumping effluent from OWS sump to grit
channel and TPI.
2) OWS sump (compartment wise) could be handed over easily for cleaning i.e,
sludge/debris removal
3) ETP operating personnel could better monitor effluent quality visually on regular
basis and sampling could be carried out for Lab analysis.
Page | 47
Case Study-3
Summary Sheet
Refinery Panipat
Unit RFCCU
Problem Type Outage of ZSM Loader
Solve Method Through In House Expertise
Report No. PR/FCCU/2022
Year / Month Dec/2022
Title of the report Indigenization of the ZSM Loader system
Problem Outage of ZSM Loader system and non-support from the OEM
Solution The system was revived using in house expertise and implemented the
entire system in DCS.
Problem: ZSM catalyst is Zeolite catalyst which breaks Gasoline (heavier) into LPG C3-C4
hence increases LPG yield.
Operator Inputs the Total weight to be loaded from field with help of Local HMI. Starts the
injection manually. Auto loader loads the Catalyst according to the weight set points. Weight
of ZSM loader Catalyst shot pot is measured by Load cells, output of load cell comes into
weight controller. Controller compares the weight set point with Current weight and executes
the sequence of Loader by operating Fill/pressurization/discharge valves. Weight set-points
measured parameters and cycle running timer were displayed in HMI locally.
ZSM HMI display was reported non-working. OEM for the system, M/S Pneumix was
contacted, and they refused to supply the card saying that the complete system is obsolete.
Duration of Problem: Nov’22-Dec’22
Observation: Upon investigating it was found weight controller was not powering on. On
further checking it was found main controller card was not working.
Methodology: Weight controller was not reading the weight as it was not able to provide
Excitation voltage to existing Load cells and was not further able to display parameters in HMI.
The controller is the main heart of the system as it was operating the Valves according to the
weight and measuring Load signals as well.
Hence it was envisaged to move the system to DCS in place of existing set-up. For Execution
of Logic in DCS, the Actual weight of the Shot pot was to be transmitted as a 4-20ma signal to
DCS. The Load cells don’t provide a signal of 4-20ma corresponding to weight as the output
of the load cells was in milliVolts and the functionality of Load cells can be achieved only when
excitation voltage is provided to the same .For functioning of Load cells and getting their
output as a 4-20ma signal, P&F make Barrier KFD2-WAC2-EX1.D was tested and was found
working satisfactorily upon calibrating and checking by standard weights . Then 4-20ma
Page | 48
output of the barrier was wired into existing DCS and Digital outputs for all Valves were also
wired into DCS.
Logical sequential operation of complete catalyst loader was then made into DCS (in-house)
and operational checks were done and were found working satisfactorily
Benefits realized:
Saving of approximately 100 Lacs, Indigenization of the system and availability of all the ZSM
Loader data in DCS for continuous monitoring and historization.
Case Study- 4
Summary Sheet
Unit category Process Unit (PRE)
Refinery Panipat
Unit Hydrocracker (HCU)
Problem Type Design issue
Solve Method Change of Design
Report No. PN/HCU/2022
Year / Month Dec/2022
Title of the report Change of insulation in RGC Turbine
Problem Frequent smoke detection in glass wool insulation due to oil-soaked
insulation
Solution Insulation type changed from Glass wool to calcium silicate
Problem: HCU RGC Turbine runs in HP steam having temperature above 400°C. Due to
leakage/spillages the insulation of the turbine gets soaked with lube oil. Since the glass wool
type insulation provides large surface area for oil to get absorbed, slow oxidation starts due
to higher voidage available for air to ingress freely and high Temperature of HP steam
producing smoke
Duration of Problem: Since Commissioning to Dec’22
Modification Done:
Glass wool was replaced with calcium Silicate. Since calcium silicate is relatively more compact
compared to glass wool and hence chances of oil absorption and air ingress is lower thus
preventing smoke formation
Benefits realized: No instances of smoke were observed from turbine post replacement of
insulation material
Page | 49
Case Study 5
Summary Sheet
Refinery Panipat
Unit CCRU (08)
Problem Type CCRU Packinox effluent inlet strainer high DP
Solve Method Reactor RB-203 centre grid repair and alignment job
Report No. PR/CCRU/2023/1
Year / Month January 2023
Title of the report High DP across Packinox inlet effluent strainer
Problem High DP across Packinox inlet effluent strainer
Solution Reactor RB-203 centre grid repair and alignment job
Problem:
High DP across CCRU Packinox inlet effluent strainer
14.12.2022 to 8.01.2023
Observation:
The unit was running smoothly with reactors and packinox suction strainer DP in normal
ranges till 14th December 2022. Since 14th December 2022, Packinox suction strainer DP
had increasing trend and increased sharply. It increased from 0.10 Kg/cm2 to 0.46Kg/cm2
in 48 hours period against maximum allowable DP of 1.0 kg/cm2.
Methodology:
It was suspected that some leak has developed in the center pipe of reactor RB-203 and
catalyst is reaching packinox inlet effluent strainer and causing chockage in the strainer.
Analysis:
It was observed that Packinox strainer DP was constant if the catalyst circulation was
stopped (established by stopping and starting catalyst circulation). The regeneration rate
of the catalyst kept 12 batches per day against normal 24 batches per day. The DP was
holding up at 0.36kg/cm2 but the CCRU throughput had been dropped to 65m3/hr from
the normal 90m3/hr in order to keep the packinox DP from increasing any further.
DP was showing increasing trend if CCRU thru’put is increased beyond 65 m3/hr. CCRU
emergency shutdown was taken to restore thru’put to more than 100 m3/hr. shutdown
was taken for cleaning of packinox inlet strainer, unloading of catalyst from CCRU reactors
and regenerator, rectification of center pipe of RB-203, screening and loading of catalyst
in reactors and regenerator.
Page | 50
Corrected action:
CCRU shutdown was taken on 08.01.2023 for cleaning of the packinox inlet effluent
strainer and inspection/repair of the RB-203 centre grid. It was found that reactor RB-203
had gaps more than recommended 0.8 mm at four locations. Gaps were rectified at three
locations and one location was patched to rectify the gap. Packinox strainer found
chocked with broken catalyst. It was cleaned. Centre grid also found misaligned from its
location. It was lifted and aligned properly. Ceramic rope gaskets were found damaged
and replaced with the new rope gaskets.
Benefits realized:
Packinox inlet effluent strainer DP came to normal ranges post startup. It decreased from
0.5 Kg/cm2 to 0.07 Kg/cm2. It is stable at 0.07 Kg/cm2.
Case Study-6
Summary Sheet
Refinery Panipat
Unit CCRU (08)
Problem Type High RPM fluctuations ( + 400) in recycle gas compressor (RGC)
of CCRU
Solve Method CCRU RGC turbine Servo motor was removed & a new servo
motor was installed.
Report No. PR/CCRU/02
Year / Month February 2022
Title of the report High RPM fluctuations in RGC of CCRU
Problem High RPM fluctuations in recycle gas compressor of CCRU
Solution CCRU RGC turbine Servo motor was removed & a new servo
motor was installed.
Problem:
High RPM fluctuations in recycle gas compressor of CCRU
Oct. 2021 to Feb 2022.
Observation:
High RPM fluctuations were being observed in RGC causing operational issues. Due to
these fluctuations, there was big fluctuation in recycle gas flow to the reactors.
Page | 51
Methodology:
It was suspected that Servo Motor of the control oil system of turbine was faulty. RGC
vendor (BHEL) was consulted & vendor recommended changing servo motor. Shutdown
was taken & this Servo motor was removed & a new servo motor was installed
Analysis:
RGC vendor (BHEL) was consulted & vendor recommended replacing servo motor.
Corrected action:
Servo Motor of Control oil system of RGC turbine was replaced with a new motor.
Benefits realized:
After replacement of servo motor, no abnormal fluctuations in RPM of RGC were
observed.
Case Study 7
Summary Sheet
Unit category Petrochemical unit
Refinery Panipat
Unit PTA
Problem Type Product Quality issue
Report No. PR/PTA/01
Title of the report Off spec PTA product
Problem Low b* value (<0.4) and High p-Toulic acid (>170 ppm)
Solution Oxidation reactor parameters got adjusted
Problem: Low b* value (<0.4) and High p-Toulic acid (>170 ppm) of PTA product.
06.05.2022 to 13.05.2022
Observation:
M/s. BASF supplied Palladium (Pd) catalyst loaded in M&I April 2022 for the first time.
Pd Catalyst is used to convert oxidation impurity 4 CBA (Carboxy benzaldehyde) in crude
terephthalic acid (CTA) to p-Toulic acid through hydrogenation for easier separation in
centrifuges and to produce pure terephthalic acid (PTA).
Purification feed in done on 05/05/22 with new reactor catalyst. Initially due to recycle
product in CTA hopper, P-toulic acid in the product was within the range.
But once recycle product is over, P-toulic acid increased to 200 ppm with low 4-CBA values.
For controlling the P-toulic acid Reactor pressure has been decreased to 72 Kg/cm2g still we
Page | 52
are getting the P-toulic acid in the range of 170 ppm ,4-CBA in the range of 1-3 ppm and b*
value in the range of 0.2-0.30.
For 8 days approx. 3000 MT off spec material (Low b*value) generated.
Methodology:
o Oxidation severity increased to reduce 4CBA input to Purification Unit
o Reaction oxygen optimized to increase DCMY color (to raise b* value)
o Hydrogen partial pressure to reactor optimized to control conversion of 4 CBA and to
increase b*.
o Slurry density and flow adjusted to keep p-Toulic acid under limit (170 ppm) and to
avoid reprocessing.
o Washing of cake increased in centrifuges to remove more p-Toulic acid
Analysis:
Low b* value of PTA product generated continuously even after reducing the reactor
pressure up to 72 Kg/cm2g due to high activity of the new catalyst.
Corrected action:
o Reaction oxygen optimized to increase DCMY color from 20 to 32.
o Hydrogen partial pressure to reactor optimized to control conversion of 4 CBA and to
increase b*.
Benefits realized:
PTA product b* value got increased above 0.4 and p-toulic acid got decreased below 170 ppm.
Offspec product generation of PTA product is resolved.
Case Study 8
Summary Sheet
Unit category Petrochemical unit
Refinery Panipat
Unit PTA
Problem Type Product Quality issue
Solve Method Checking of Mixing streams in Feed
Title of the report Offspec PTA product quality
Problem Increase in b* value and Decrease in Millipore value
Solution Change in DM water quality
Problem: Increase of b* value and Millipore value of PTA product on 26.02.2021. Nearly
1500 MT offspec product generated and recycled. Due to this problem oxidation section
load decreased from 42 T/hr to 26 T/hr.
Page | 53
25.02.2023 to 26.02.2023
Observation: On 25.02.2023 at 2300hrs, there was increase of b* value from 0.7 to 1.0 and
Millipore value of product also decreased from 0.96 to 0.93. At 0300 hrs sample, b*value
further increase to 1.25 leading to off spec product. All parameters like Reactor pressure,
Slurry density, and Reactor inlet temperature checked found normal.
Methodology: CTA (Crude terephthalic acid) powder and V-1615 metals checked & found
within the limits. CTA 4 CBA quality checked found within the range. DM water quality
checked which was having low Millipore. (0.83)
Analysis: Normally, DM water Millipore will be in the range of 0.97-0.99. However, at that
time it was found 0.75, 0.65. DM water will mix with CTA in the feed slurry drum and will be
further processed in downstream of unit. Low value of DM water Millipore value contributes
in increase of b* value and decrease in Millipore value of PTA product.
Corrected action: Feeding of DM water tank to PTA unit at TPS, changeover done. Morpholine
dosing to DM water reduced. After changeover of DM water tank, decrease in b* value and
increase in Millipore of PTA product.
Benefits realized: PTA product quality b* value and Millipore of Product improved. Off spec
product generation of PTA product is resolved.
Case Study 9
Summary Sheet
Unit OMS
Problem Type Product dry out prevention
Solve Method Product receiving with existing facility
Report No.
Year / Month Jan’2023
Title of the report Reformate unloading from wagons at PMC and dispatch to PR
Problem unavailability of Reformate at refinery due to CCRU shutdown
Solution Reformate unloading from wagons at PMC and dispatch to PR
Problem:
Due to CCRU shutdown, reformate was not available in refinery.
Jan’2023
Page | 54
Observation:
MS production from PR is necessary to meet the market demand. Due to requirement of
shutdown of CCRU for maintenance issue, reformate production and hence the MS production
from PR was expected to be nil during the period creating a crisis in the market. MS could
however be produced if reformate was made available. However, there was no facility to
unload/receive reformate at PR
Modification done:
Rack unloading facility was available for Naphtha in marketing terminal. This facility was utilized
to directly unload and pump reformate to PR MS tanks, by doing minor modification in PR offsite
area.
Benefits realized:
By blending available reformate quantity in MS blend, PR was able to produce MS by thus
preventing dry out of MS in the market.
Case Study 10
Summary Sheet
Unit DHDS
Problem Type Product Quality issue related
Solve Method Re-routing of kero product to Merox feed
Report No.
Year / Month Aug’22 onwards
Title of the report Maintaining ATF product silver rating
Problem Intermittent failure of ATF product in silver rating
Solution Routing of Kero through DHDS unit before processing in Merox
Problem:
PR typically produces ATF from Old + New Merox and HCU + OHCU Kero streams. Intermittent
failure of ATF in silver rating from Merox unit resulted in hampering ATF production from
refinery.
Aug’22 onwards
Observation:
The exact cause of this silver rating failure was not known; however, this intermittent failure was
due to suspected crude quality changeover.
Page | 55
Methodology:
It was planned to operate DHDS unit in full kero mode and taking treated kero ex DHDS to
Merox unit, to avoid the intermittent failure of ATF in silver rating.
Production of on spec ATF utilizing DHDS unit, provision was made and implemented within
record 10 days’ time for routing of treated kero ex DHDS to Merox feed.
Benefits realized:
a) Provision was made to produce on spec ATF utilizing DHDS unit.
b) Hydrogen consumption reduced upto one third, which was typically 6500-7500
nm3/hr in LGO mode now 2000-2500 nm3/hr in Kero mode.
c) Value addition- Catalyst Life increased due to low severity feed. Already guaranteed
life is over in January’22 but still catalyst performance is good.
d) Problem solving- Managed on spec ATF production on sustained basis, when Merox
unit was facing operational issues for producing on spec ATF.
Case Study 11
Summary Sheet
Unit category Offsite
Refinery Panipat
Unit S Block
Problem Type Pumping issue of Flare KOD Sour Water
Solve Method Hydraulic adequacy check and proposed alternate routing
Report No. PR/S Block/2022-23/01
Year / Month May’2022
Title of the report Routing of flare KOD pump sour water discharge to U-53/54
interconnection line
Problem Pumping issue of Flare KOD Sour Water
Solution Routing of flare KOD pump sour water discharge to U-53/54
interconnection line
Problem:
Pumping issue of Flare KOD Sour Water
Apr-May’2022
Observation:
In order to route the Flare KOD sour water to SWS unit instead of draining to OWS, one
redundant pump has been provided for routing of sour water to SWS U-20.
It is observed that even with slight increase in back-pressure of sour water header, the existing
pump is not able to deliver the flow.
Page | 56
Methodology:
Line Hydraulics & Pump adequacy checked.
Analysis:
It is observed that operating pressure of U-20 sour water header is ~2.5-3.0 kg/cm2g and for the
2” header size and total length of ~350 meter (2” line size), the pump found to be inadequate at
higher back-pressure (pump can deliver the total head of around 50 meter).
Corrected action:
In order to resolve the issue, as short-term measure, a process scheme is proposed and
commissioned to route the flare KOD pump discharge to U-53/54 interconnection line. With
this scheme, the pump discharge can be routed to U-53/54 instead of U-20 which is being
operated at comparatively lower pressure of ~1-1.5 kg/cm2g against the ~2.5-3.0 kg/cm2g
operating pressure of U-20.
Benefits realized:
After commissioning of the scheme, the sour water from flare KOD is being transferred
through the same pump to SWS.
Case Study 12
Summary Sheet
Refinery Panipat
Unit CCRU (08) / RSU (302)
Problem Type CCRU stabilizer Reflux / LPG pump issue
Solve Method Rectification of Reflux / LPG Pump by bypassing stabilizer section and
sustenance of CCRU unit operation with RSU operation
Report No. PR/CCRU/2023/03
Year / Month Oct’2022
Title of the report Sustenance of CCRU unit operation with RSU operation as CCRU
stabilizer
Problem CCRU stabilizer Reflux / LPG pump issue
Solution Rectification of Reflux / LPG Pump by bypassing stabilizer section
without CCRU shutdown
Problem:
CCRU stabilizer Reflux / LPG pump seal leak issue. Rectification job couldn’t be done as the
isolation valve of pump was found to be heavy passing.
Oct’2022
Page | 57
Observation:
It is observed that the running Stabilizer reflux/LPG pump 08-P-203A/B having seal leak issue.
Handing over of this pump was tried, however due to heavy passing of its suction valve; pump
couldn’t be handed over for rectification job.
Methodology:
Brainstorming was done to handover the pump without taking CCRU into shutdown. It is
suggested to bypass the stabilizer section and carryout the job (pump seal rectification job &
isolation valve replacement).
Analysis:
There were two major challenges for bypassing the stabilizer column and to sustain the CCRU
operation without the stabilizer column.
1. There is no present facility to bypass the stabilizer column
2. Routing of LPG absorber drum bottom stream (V-205) to other designated section as it
contains ~2.5% LPG content in it.
Corrected action:
1. RSU Column adequacy was checked for direct routing of “LPG absorber drum bottom
stream (V-205)” and observed that at lower CCRU unit, RSU is adequate to handle the
load.
2. Process scheme prepared to route LPG absorber drum bottom stream (V-205) to RSU
column.
Benefits realized:
CCRU Stabilizer column was bypassed, and Stabilizer reflux/LPG pump seal rectification job and
its isolation valve replacement job were performed without taking CCRU into shutdown.
Case Study 13
Summary Sheet
Unit category BS-VI units
Refinery Panipat Refinery
Unit DHDT (BS-VI)
Problem Type Vibration of NDHDT wash water pump ( Sundyne Make)
Solve Method • Define the problem.
• Gather PDM data from various trials and compare it with pump
internals observation
• Generate possible root causes.
• Evaluate the solutions and take action
Report No. MN/1
Year / Month 2022/ Apr
Page | 58
Title of the report Troubleshooting of Vibration of NDHDT wash water pump (Sundyne
Make)
Problem Running with increased gearbox Vibration
Solution Implementation of Deep Groove ball bearing instead of Angular contact
bearing.
Problem:
LMV-336N is comparative bigger sized Sundyne model. Hence, these Sundyne gearboxes are
equipped with mono directional MLOP due to size constraint. The gearbox was opened for
inspection of internals for the first time due to suspected reverse rotation (on 21st Sept’ 21) due
to negative phase in motor.
Since Sept 2021, the wash water pump tagged 107P4A has not been healthy for a long time due
to high gearbox vibration.
PUMP DETAILS
Pump Make Sundyne
Model LMV-336N
Pump Type DB200/33
Speed 15370 rpm
Motor Rating 157.3 kW
Head 1005.16 m
Flow 10.2 m3/hr.
Sept 2021- May 2022 (9 months)
Observation:
• During the First Maintenance, gearbox was overhauled using mandatory spares due to
reverse rotation.
• During the 2nd maintenance, Impeller was found loose and minor mark was found on the
flinger sleeve. Flinger sleeve and all roller and ball bearings were changed during this
maintenance.
• During the 3rd maintenance, the impeller was intact this time. Hence, Flinger sleeve and
all roller and ball bearings were changed during this maintenance.
• After each maintenance, the vibration increased over a period of 3-6 days
• Heavy noise from gearbox during operation
Methodology:
Vibration analysis
• Velocity signature generating dominating 1X peak & Acceleration signature generating
high frequency non-synchronous peak which indicates symptoms of flow abnormalities
or gear meshing abnormalities or rotating looseness.
.
Checking of Strainer
• Strainer was checked and found ok.
Page | 59
Checking of pump internals

• During the 4th maintenance, No abnormality was found in impeller, bearings or slinger
sleeve as mentioned in the PDM recommendation.
Analysis:
• Process abnormalities and rotating looseness mentioned in the PDM was ruled out
after inspection of strainer and pump internals
• High noise and PDM gear mesh frequencies pointed out gear meshing abnormality
• Various Sundyne designs were compared and crosschecked. Deviation was found.
Mostly, Sundyne Gearboxes comes with deep groove ball bearing. Deep Groove ball
bearings are better in taking thrust loads than angular contact bearing, thus avoiding
the gear mesh frequencies due to any unwanted axial play.
Corrected action:
• It was concluded to replace the angular contact (7308) bearing to deep grove bearing
(6308).
Benefits realized:
• Reliable operation with reduced vibration.
• Trial was done 04.05.2022. The pump is working satisfactory since May’2022.
Flinger sleeve Impeller Thrust Bearing
Page | 60
Case Study 14
Summary Sheet
Unit category BS-VI units
Unit DHDT (BS-VI)
Problem Type Tripping of MUG motor on high Vibration while starting with Hydrocom
• Gather data from various trials
• Generate possible solutions.
• Evaluate the solutions
• Take trial and observe and implement
Report No.
Year / Month 2022/ Sept
Title of the report Troubleshooting of Vibration of MUG Compressor along with Hydrocom
Problem Running the compressor without hydrocom leading to energy loss
Solution Commissioning of Hydrocom
Problem:
Both the MUG compressors (tagged 107K003A/B) faced a motor vibration tripping issue during
operation with Hydrocom.
Both the compressors were operating satisfactory without Hydrocom
Oct 2020- Sept 2022 (23 months)
Observation:
• The NDE motor bearing vibration starts to increase on initial loading with Hydrocom
leading to tripping level (trip value 7.1mm/s)
• Crosshead, Cylinder, Frame vibration also increased on further loading.
• Eccentric loading on the crankshaft was suspected for the increased vibrations leading
to bending of the crankshaft.
• During trial, uneven hydrocom loading was observed; The Hydrocom loading is 49.1%
and 30 % for 1st and 2nd stage respectively at a flow of 2652 kg/hr (which is 50% of
the compressor design flow)
Methodology:
Checking of Hydrocom
• Logic of the Hydrocom have been verified with similar configuration of IOCL Gujarat
and functionally is found to be same.
• Hydrocom loading checked in simulation mode and found ok.
Page | 61
• 4-20mA signal have been checked for Hydrocom system of both the compressors and
found ok.
• Manual operation of all the PICs used for Hydrocom have been checked and found ok
.
Checking of System
• Logic/ calibration of the 1st & 2nd stage spillback valves were verified by M/s Forbes
Marshall and they were found to be satisfactory.
Checking of Compressor
• OEM also checked the suction and discharge valves and found boxed up in satisfactory
condition.
Trials
• 4 trials were done on both MUG A/B at i) 30 %, ii) 50%, iii) 60% and iv) 55% minimum
loading at a higher set point of 12mm/s for Motor vibration.
Analysis:
• 4 trials were done on both MUG A/B, at i) 30 %, ii) 50%, iii) 60% and iv) 55% minimum
loading at a higher set point of 12mm/s for Motor vibration. The vibration (around 5
to 6) was found to exist in the band of 30% to 55% loading. The parameters were found
to be normal in the 60% trial except motor vibration at 6mm/s against 3mm/s in
spillback control.
• After analyzing the trial data, a need of mass balance had to be done by closing the
2nd stg spillback to eliminate uneven loading as 2nd stg spillback was designed to
control only 10% of flow.
• Crosschecked Hydrocom hydraulic oil pressure v/s system pressure with Panipat Old
DHDT-72 MUG compressor. Deviation was found.
Corrected action:
• 2nd stage spillback to be kept permanently closed during hydrocom operation
• Tripping value of Motor and Compressor vibration increased as per OEM
recommendation.
• Hydrocom oil pressure increased to 84 Kg/cm2 from 64Kg/cm2 (near to system
pressure)
• Tuning of PIC controllers was done (for faster response to Hydrocom for quicker
loading)
Benefits realized:
• Most of the time the compressor was operated at 72%, (3700kg/ 5100 kg = 72%) Max
loading ,
Motor rating is 3.5MW, Hence a saving of 945KWH
Annual saving of 7560000KWH (5.29Cr INR)
Page | 62
• Compressor vibration has reduced with hydrocom in operation along with energy
saving.
• Compressor is running smoothly without maintenance from sept’22 onwards.
Case Study 15
Summary Sheet
Unit category Primary process unit
Unit AVU-1
Problem Type High Vibration in CDU ID Fan
Solve Method Rectification of high vibration issue of CDU ID fan by in-situ balancing
Report No. P/AVU-1/2022-23
Year / Month Mar 23
Title of the report High vibration problem of the CDU ID fan resolved by in-situ balancing
Problem During M&I shutdown of AVU-1 unit, casing and Rotor of the CDU ID
fan was replaced. During trial at operating RPM of 900 RPM vibration
was high. As per PDM recommendations Shaft run out, shaft end play
and bearing clearances were checked again and found under
permissible limits. Because of this, ID fan was unable to run at
operating RPM of 900 RPM
Solution To rectify the vibration issue at operating RPM, in-situ dynamic

balancing was performed. The vibration issue has been resolved and
CDU ID fan is running at its operating RPM.
Problem: High Vibration in CDU ID Fan
Duration of Problem: Problem was resolved after dynamic balancing in Mar 23
Observation: CDU ID fan was having high vibration issue. Vibrations were normal under 650
RPM but vibrations gradually increased once the ID fan reached the operating RPM of 900. As
per initial PDM recommendation Shaft run out, Shaft end play, bearing clearances were
rechecked and found under permissible limit. Realignment was done and foundation bolts were
retightened, which decreased the vibration at low RPM but axial vibrations were still high (14.08
mm/s) at operating RPM.
Methodology: Discussion with PDM agency was held and the agency suggested the in-situ
dynamic balancing.
Analysis:
• Vibration was 5.2 mm/s in fan NDE side axial direction at 650 RPM
Page | 63
• Vibrations increased to 14.08 mm/s in fan NDE side axial direction at 900 RPM
• Vibration analysis was done, and in-situ dynamic balancing was proposed
Corrected action:
Balancing carried out at 900rpm
• Initially, before balancing the maximum vibration value at ID fan NDE bearing in
axial direction is observed as 14.08 mm/s.
• After adding trial weight 550 grams added at 0◦ (1 Blade), and vibration value
at ID fan NDE bearing in axial direction is observed as 26.8 mm/s.
• After adding trial mass, correction weight of 520 grams was added at 190◦
Degree, vibration value at ID fan NDE bearing in axial direction is observed as
4.6 mm/s.
Benefits realized: After balancing, CDU ID is running at operating RPM of 900 RPM with
vibrations under the permissible limits due to which CDU APH is running at normal operating
parameters.
Page | 64
Case Study 16
Summary Sheet
Unit category Petrochemical Unit
Unit PTA
Problem Type Throughput restriction
Solve Method Checking of operational and mechanical parameters
Report No. PTA (01)
Year / Month 2023 / Feb
Title of the report PTA Decanter Centrifuge spring loaded vibration isolation pads
adjustment to reduce vibrations
Problem Increase in vibrations of Decanter Pressure centrifuge A
Solution Online spring preload adjustment of vibration isolation pads carried out
Problem:
Increase in vibration of Gear end of PTA Pressure Centrifuge 21-CN-1411A
26.01.2023 to 03.02.2023
Observation:
Pressure centrifuge 21-CN-1411A was started on 22.02.2023 after rotor replacement. The
centrifuge started with Feed end vibration 13-14 mm/s and Gear end vibration 17-18 mm/s and
stabled at 13-15 mm/s & 16-17 mm/s respectively. But the Gear end vibration started increasing
and reached up to 25 mm/s.
Methodology:
To identify the reason, operational parameters like Slurry feed rate, density, temperature,
pressure were checked for any deviation or abnormality. These parameters were found similar
and normal in all the pressure centrifuges but vibration of Pressure centrifuge 21-CN-1411 B&C
were normal and found increased only in 21-CN-1411A Gear end. Then the vibrations were also
measured by condition monitoring group to check if the probes readings are showing correct or
spurious. The readings were found close to probes readings which mean probes were correct
and not spurious.
After confirming the above points, the vibrations on all six spring loaded vibration isolation pads
were measured to confirm any abnormal vibration reading in any specific vibration isolation pad
or more.
It was found that three vibration isolation pads (01 of Gear end side and 02 of Feed end side)
out of six pads were having high vibration readings. The identified pads were checked and their
gaps were found less than the recommended.
Page | 65
Analysis:
The spring loaded vibration isolation pads are installed to reduce the transmission of noise,
shock, and vibration produced by Centrifuges into the structure and nearby running centrifuges.
Deviations found in gaps of three pads resulted in overall non-uniformity in vibration isolation
due to all the pads thereby increasing the vibration of the machine. The increase in vibration
might have worse further if not rectified and would have increased to trip value of 40 mm/s.
Corrected action:
The gaps of identified pads were then adjusted online by screws located in the pads as per
recommended values in the manual and eventually adjusting the spring preload, making all the
spring loaded vibration isolation pads with gaps uniform as per OEM manual.
Benefits realized:
Gear end side vibration of Pressure centrifuge 21-CN-1411A was reduced from 25 mm/s to 18-
19 mm/s.
Page | 66
Case Study 17
Summary Sheet
Refinery Panipat
Unit CCRU
Problem Type Mismatching of parting plate profile of floating head
Solve Method Changing the parting plate profile
Report No. PR/CCRU/01
Year / Month 2023/Feb
Title of the report Mismatching of floating head parting plate profile of STRIPPER FEED /
BOTTOM EXCHANGER
Problem Floating head parting plate Z-profile was not matching with the new
bundle.
Solution By modifying the parting plate profile with cutting and welding
Problem:
Floating head parting plate Z-profile was not matching with the new bundle.
26 Feb to 1 March’2023
Observation:
During the installation of new bundle of 08E103A/B, it was found that floating head Z- profile
was horizontally inverted with respect to new bundle which led to the problem of assembly of
floating head with new bundle.
Methodology:
By visual inspection, it was observed that a groove for the gasket (Z-profile Type) in new bundle
is not matching with the parting plate of the floating head.
Analysis:
Due to the problem of floating head profile, we could not proceed for the tube test.
Corrected action:
We have inverted the parting plate z profile and aligned with bundle by cutting and welding.
Before After
Page | 67
Benefits realized:
Following benefit has been realized:
1. Assembly of floating head with bundle has been done for the tube test.
2. By making the correct profile of parting plate, we have avoided the intermixing of flow
and the performance of exchanger remained intact.
Case Study 18
Summary Sheet
Unit category PRE unit
Unit Hydrocracker (HCU)
Problem Type Manufacturing defect
• Gather data from uniformance and system one
• Generate possible root causes.
• Evaluate the solutions and take action
Report No. MN/2
Year / Month 2020/ June
Title of the report Troubleshooting of intermittent increase in HCU RGC Drive Turbine JB
vibrations
Problem Intermittent spike in Journal bearing vibration in RGC drive Turbine
Solution Changing the probe fitting location in the housing
Problem:
Post COVID-19 startup in June 2020, it was observed that intermittent spikes were generating in
Journal bearing vibration tag in RGC drive turbine. These spikes were observed in interval of 1-2
days and sometimes in weeks.
Turbine Details
Turbine Make BHEL
Model G300-2
Rated Speed (RPM) 11114
Rated Motor Power (KW) 4893
June 2020- Nov-2022 (29 months)
Observation:
• When the vibration spikes were studied, it was observed that the spike were generating
whenever there was a dip in inlet steam temperature.
Page | 68
• After discussion with TPS, steam inlet temperature was also increased to meet the
minimum requirement of 380⁰C.
• After increasing the temperature, the vibration spike frequency got reduced but still
spikes were observed intermittently.
Methodology:
• During M&I shutdown in Nov-2022, it was observed that the old probes that were
removed from housing were worn out on the sides.
Analysis:
• During boxup of probe, it was observed that the probe was going towards lower half
of the shaft and its sides were rubbing with the shaft due to which proper gap was not
getting maintained.
Corrected action:
• After various trials, it was found that the hole drilled in the housing was not correct, it
was a manufacturing defect, when the probes are being inserted through these holes it
is directing the probe towards lower half of the shaft other than the centerline of the
shaft.
• The same was discussed with BHEL and upon discussion it was decided to drill a new hole
by measuring proper gap with shaft.
Benefits realized:
• Vibration trend from Apr’2022 till Nov’2022. Intermittent spikes can be seen in the
below attached snapshot of vibration trend.
Page | 69
• Vibration trend from Mid Dec’2022 till mid March’2023. No spike has been observed
till date.
Case Study 19
Summary Sheet
Unit DCU
Problem Type Passing control valve issue
Solve Method Cleaning & All gaskets, O-rings & Piston assembly Replacement
Report No. PR/WS/MN/001
Year / Month June/2022
Title of the report Troubleshooting of Decoking control valve
Problem Passing in by-pass mode due to which switching from drilling to cutting
was not possible
Solution Cleaning & O-ring, Gaskets Replacement
Page | 70
Problem: DCV of 78-P-104B was having passing problem as it was passing in by-pass mode due
to which switching from drilling to cutting was not possible. For switching from drilling to cutting
every pump (Two Pump Installed) has to be turned off. In one day approx. 3 times cutting of
coke has to be carried out in DCU which means HT motor driven multistage pump has to be
turned on and off minimum 3 times more than required in normal operation a day which can
damage pump or motor.
DCV of 78-P-108B malfunctioned on 16.06.2022 as it was directly going to cutting mode. Hence,
it was not possible to do cutting.
Duration of Problem: 16th June’22 to 19th June’22
Observation: On opening the valve, it was found that hollow piston was fully choked with hard
coke leading to no flow across it, the reason for switching into cutting mode. Snapshot enclosed
below.
Methodology: Cleaning & All gaskets, O-rings & Piston assembly Replacement
Benefits realized: All gaskets, O rings & piston assembly was replaced with the new one in-house
without help of OEM. This was first time that maintenance of DCV was done in-house without
help of OEM leading to lot of tangible as well as intangible benefits. After maintenance, DCV was
taken in operation & checked it was undergoing all the three By Pass, Prefill & Cutting modes of
operation required for coke cutting.
Benefits were observed mainly in three ways which are as follow-

1. Cost wise:
DCV overhauling service charge which would have been paid to OEM M/s Flowserve
22,32,724.86 INR (ref W.O. 25404746 dated 27.02.2018 including 18% GST and escalation as per
CPI index). Since we have repaired the DCV in house, it has saved the overhauling cost.
The DCU unit would have to be taken under shutdown if both the valves fail to operate.
Petroleum coke generation @ 375 MT/Hr
DCU Profit = Rs.1022/MT
Indirect Saving = (375X24X1022) = Rs 91, 98,000/day
2. Safety wise:
Page | 71
Directly going into cutting mode could have damaged coke cutting system
3. MTBF wise:
DCV overhauling can be done in house without sending it to vendor works it will reduce the
downtime drastically
Case Study 20
Summary Sheet
Unit category Process unit (PRE)
Unit DCU
Problem Type Hydrocarbon leakage at high Temperature
Solve Method Maintenance and Replacement in shutdown
Report No.
Year / Month 2022/Nov
Title of the report Troubleshooting of HC leakage
Problem Hydrocarbon leakage from bottom flange of all coke drum
Solution Insitu machining
Problem: Frequent leakage of VR from bottom flange of all 4-coke drum. Since the VR comes out
at their auto ignition temperature casing fire hazard in the system. This was becoming the major
safety concern at 20-meter platform of reactor section.
Page | 72
Duration of Problem: 2022
Observation:
Leakages of VR were observed from particular area. During checking of faces of flanges, ovality
was found which was not observed visibly.
Thermal deformation was observed in the retaining bolt.
Methodology:
During M&I Shutdown, Bottom flange assembly taken for maintenance.
Analysis:
During checking of bottom flange, ovality were observed in the faces. Also, alignment of bolt
were out due to thermal deformation in the retaining bolts of coke drum bottom flange.
Corrected action:
In situ machining of Bottom flange faces & replacement of retaining bolt were done in Nov-Dec
2022 shutdown.
Benefits realized: Zero Leakage of VR from bottom flanges of coke drum.
Case Study 21
Summary Sheet
Unit category Process unit (PRE)
Refinery PANIPAT REFINERY
Unit DCU
Problem Type Stuck up of HP valve of WGC drive turbine
Solve Method Replacement during shutdown
Report No.
Year / Month NOV/2022
Title of the report Overhauling of HP valve assembly
Problem Stuck up of HP valve of WGC drive turbine
Solution YOKE ASSEMBLY WERE REPLACED DURING m&I SHUTDOWN
Problem: Limiter of HP Valve was 92% open, however Max HP steam flow was restricted to 82
MT/Hr. However as per Turbine datasheet, HP steam flow rate of 95.9 MT/Hr can be achieved
in Turbine rated case 1 D. RPM of turbine was not increasing upon increasing the Gas load. This
was causing abnormal flaring of Gas Leading to production loss.
Duration of Problem: 1.5 years
Page | 73
Observation:
Upon dismantling of Yoke assembly of HP valve, it was found that one of the valves is fallen on
the seat. The same was blocking the steam passage.
DAMAGED YOKE ASSEMBLY
NEW YOKE ASSEMBLY
Methodology:
The machine was taken under maintenance in M&I shutdown.
Analysis:
Avg Steam flow per passage = 95/5 =17 ton/hr approx.
Since out of 5 valves in yoke assembly one passage was blocked. So, there was shortage of
approx 15-17 ton/hr of steam during operation (capacity is 95.9 ton however 80 ton/hr were
actual consumption).
After rectification of the same, steam consumption increases which increases the RPM even at
high gas load.
Corrected action:
During M&I shutdown the HP valve assembly was overhauled. The damaged parts were
replaced.
Benefits realized: RPM of machine reaching its desired value as steam flow increases. This
reduced the abnormal flaring of the gas.
Page | 74
Case Study 22
Summary Sheet
Unit PTA
Solve Method Upgrading metallurgy of orifice from Duplex SS to Titanium
Report No. PTA (03)
Year / Month 2022 / April
Title of the report Resolving cavitation issue in stripper recirculation pump P1-512 by
providing Titanium orifice
Problem Issue of cavitation and high vibration in pump 21-PA-CF-512
Solution Upgraded the metallurgy of orifice plate to Titanium
Problem:
Increase in vibration of Gear end of PTA Pressure Centrifuge 21-CN-1411A
Aprrox. 3 years
Observation:
The Stripper Circulating pump, P-512 was having perennial issue of cavitation and high vibration.
Methodology:
The pump is single line equipment handling hot acid slurry service with capacity of 973 m3/hr at
125 deg C and metallurgy of Duplex Stainless Steel (SS2205). Being a critical and single line
equipment, it could not be handed over for maintenance and troubleshooting in running unit.
So, using the major shutdown opportunity in April’22 M&I shutdown of PTA unit, the pump was
taken for maintenance and troubleshooting. Upon dismantling, it was found that the pump
impeller, casing, wear plate were corroded and eroded
On further analysis, it was observed that the discharge orifice has also totally eroded.
Orifice Bore
totally eroded
Page | 75
Orifice
Pump
P512
Analysis:
The main reason for cavitation and high vibration was found due to heavy erosion of orifice plate.
The increased orifice size failed to restrict the flow and leading the pump to frequent cavitation
and high vibration. The metallurgy of the orifice was Duplex SS 2205 which eroded heavily.
Corrected action:
To resolve the issue, metallurgy of the orifice plate was upgraded. An orifice plate was made
from high metallurgy i.e., Titanium, as Titanium metallurgy is installed in various other sections
of PTA unit handling highly corrosive acid at high temperature, and same was installed in P1-512
discharge line. Also, Refurbishment of impeller was carried out and casing & wear plate were
replaced with new casing & wear plate during the shutdown.
Benefits realized:
Pump is running smooth after the above jobs.
Page | 76
Case Study 23
Summary Sheet
Unit PTA
Problem Type Unit Throughput Restriction
Solve Method Replacement of bottleneck equipment
Title of the report Resolving throughput restriction of PTA by shutdown opportunity
utilization for replacement of exchanger 1211A/B and dissolver reactor
1301
Problem PTA Unit throughput was getting restricted due to repetitive tube
failure of third preheater exchangers E-1211A/B
Solution M&I Shutdown opportunity in Apr’22 was utilized for replacement of
third preheater exchangers E-1211A/B & dissolver reactor 1301
Problem:
Repetitive tube failure was observed in third preheater exchangers E-1211A/B of PTA. First
leakage incident was observed in Mar’17. Subsequently, 3 more failures were observed in
May’17, Jul’18 and Sep’19. Each failure resulted in unit interruption and consequent losses.
In Oct’19, HTRI Vibration analysis was carried out on the exchangers, and it was observed that
exchanger was vibration free with 619 MT/hr hot oil flow but with hot oil flow of 677 MT/hr,
there were fluidelastic vibrations in the exchanger. It was therefore decided to keep the hot oil
flow reduced to 620 MT/hr till resolution of the problem, consequently the unit throughput was
also restricted to about 80% of the design value.
The problem started in Mar’17 and was resolved in Apr’22. Duration of the problem is about 5
years.
Observation:
PTA unit produces 553 TMT per annum PTA (Purified Terephthalic Acid). There are two sections
in the unit — Oxidation and Purification. Oxidation section produces CTA (Crude Terephthalic
Acid) which is further purified in the Purification section. CTA from intermediate hopper is fed
to V1-1206 where 30.0% w/w slurry is prepared in DM water. This slurry is pumped by P1-
1207A/B (LP dissolver pump) to suction of P1-1209 A/B/C/D (HP dissolver pumps) through E1-
1218 (Condensate sub cooler). P1-1209A/ B/ C/ D pump the slurry through a series of heat
exchangers to R1-1301 (Dissolver reactor) where the 4-CBA is converted to Para toluic acid in
presence of hydrogen.
The purpose of preheat train is to dissolve the CTA in water by increasing the temperature of
slurry from 150 °C to 286 °C which is 7-8 °C above the solubility temperature at 30.0% w/w
strength. This reactor solution is further crystallized in downstream 5 crystallizers. The solid,
which is PTA, is separated from liquor in pressure and atmospheric centrifuges and finally dried
in PTA drier to be conveyed to product hoppers.
Page | 77
The third pre-heater (21-E1-1211 A/B) is the second last heat exchanger in the dissolver reactor
(21-R1-1301) feed pre-heat train. The shell side has hot oil (therminol-66) and tube side has
slurry which mainly consists of terephthalic acid (~30%) and DM water (~70%).
This is a four pass, fixed tube sheet, welded tube ends, horizontal shell and tube heat exchanger
with following process and construction details:
Process Details
Process Parameter Shell side(Hot oil) Tube side(slurry)
o
Op. temp (In/out) C 330/285 236/286
o
Design temp C 350 350
2 3.5 75
Op. pressure (Kg/cm )
2
Design pressure (Kg/cm ) 91.8 + FV 122.4 + FV
Design flow (T/hr) 628 (760-790 m3/hr) 262
Construction Details
Shell MOC: ASTM A 516 Gr 70 (Carbon Steel) (50 mm thickness)
Tube Size: 19.05 mm (OD) x 3.05 mm (min. thickness) x 6700 mm (L),
Tube MOC: ASTM B 338 Gr2 (Titanium).
No. of Tubes: 932 nos.
Shell MOC: ASTM A 516 Gr70 (50mm thickness)
Preheat train circuit of PTA unit is as shown in the block diagram below.
Methodology:
Each failure of the exchanger was analyzed through why-why analysis. Process trend study,
Boroscopy, PMI, ECT etc. tools were utilized to find out root cause of the problem.
Page | 78
Analysis:
Following photographs show the nature of failure,
Page | 79
Following are the observations of last failure,

• After opening the covers, oil in tube side was noted in 1211A only.
• No signs of corrosion observed on tube sheet cladding and both side tube ends.
• No crack was seen in the Ti cladding and tube to tube-sheet strength weld.
• Powder accumulation was observed in most of the tubes.
• All tubes were cleaned/de-chocked by hydro-jetting.
Leak Identification
• During water filling itself, heavy tube leak was observed in 1211A.
• The tubes identified were first tube in pass-2 (5th and 7th row).
• In 1211B, no leak was detected in hydro test.
• Both these leaky tubes are the newly re-tubed tubes in Feb-19 s/d.
Boroscopy:
• Boroscopy of the leaky tubes in pass-2 was carried out.
• In tube no 1 of 5th row, complete tube was found perforated in approx. 50% of the
circumference in a portion of around 13 mm width.
• In tube no 1 of 7th row also, a perforation of about 2-3mm was noticed in 1-2 o’clock
position
• Rubbing marks of tube in baffle edge was noticed
• No hole enlargement, out of roundness, erosion noticed in the baffle hole.
Page | 80
• This indicates that tube is vibrating and titanium being soft compared to SS304L baffle,
Ti tube is getting damaged preferentially
• Cut marks in the pulled-out tubes noticed at the failed location (2nd baffle from inlet
side, 4th baffle, 6th baffle, 8th baffle from inlet side).
• The depth of cut marks is in the order of decreasing depth from inlet side baffle onwards.
• However, the width of cut mark is 13mm which is exactly the width of baffle.
• This further confirms that the baffles are intact.
• It may be noted that the subject tube is passing through 2nd, 4th, 6th and 8th baffle as
per the baffle design/configuration.
After above analysis, HTRI Vibration analysis was carried out on the exchangers in Oct’19 and it
was observed that exchanger was vibration free with 619 MT/hr hot oil flow but with Hot oil
flow of 677 MT/hr, there were fluidelastic vibrations in the exchanger. It was therefore decided
to keep the hot oil flow to 620 MT/hr till resolution of the problem, consequently the unit
throughput was also restricted to about 80% of the design value.
Corrective Action:
Exchangers E-1211A/B were required to be replaced with higher size exchangers in PTA Revamp
shutdown which is presently planned in Jul’23. However due to the above problem, the
procurement of 1211A/B was pushed, and the exchangers delivery was expedited to Mar’22 so
that the replacement of the exchangers could be carried out in the Planned M&I shutdown in
Apr’22.
The replacement job was supposed to be carried out by PJ group in the revamp shutdown,
however the job was proactively taken over by Mechanical Maintenance team and all the
preparatory activities were done for replacement of the exchangers in Apr’22 M&I Shutdown.
Page | 81
The opportunity was also used to carry out replacement of dissolver reactor 1301, which was
also a major safety & reliability concern for plant operation.
750T crane was lined up and mobilized for the job. The job involved heaviest erection in PR
mechanical maintenance history considering approx. 240T dissolver reactor weight and 45T
weight of each exchanger.
Photographs below depict the quantum of the job,
The job was completed safely and timely.
Benefits realized:
• Unit throughput restriction of operation below 80% design capacity of PTA was removed
after the replacement which will amount in multibillion of rupees.
• Reliability of the exchangers improved and there has been no failure in last 10 months.
• Replacement of dissolver reactor also improved unit reliability considering 2-unit
interruptions in year 2020 because of the reactor.
Page | 82
Case Study 24
Summary Sheet
Unit PTA
Problem Type Pressure centrifuge case seal (solid/liquid end) leakage
Solve Method Axial adjustment between case seal gland plate and adaptor flange.
Report No. PTA (04)
Year / Month 2022 / Aug
Title of the report PTA Decanter Centrifuge rotor axial adjustment to arrest case seal
leakage
Problem Leakage in case seal of Decanter Pressure centrifuges
Solution Rotor axial adjustment was carried out to reduce case seal leakage
Problem:
A random phenomenon of seal leak in the Decanter Pressure centrifuges (21-CN-1411A/B/C)
was observed since last several years, immediately after seal water line up after major overhaul
of the machine. Sometimes, the seal leak used to stop subsequently and sometimes it kept
leaking till next opportunity.
About 3-4 years.
Observation:
In the latest case in Aug’22, pressure centrifuge 21-CN-1411A was taken into maintenance due
to feed end high vibration. Balanced Rotor and tested case seal replacement was done. Lining
up of seal water inlet/outlet, seal flushing lines of case seal was done, but the case seal of both
(liquid end/solid end) started leaking after lining up the seal lines.
Methodology:
To identify the reason, 2 major points were cross checked:
1) Rotor was dismantled to check the alignment of the plumber block with the help of
straight edge. A huge straight edge of 4m length was procured for the purpose and the
alignment was done. The alignment outage was not observed to be very significant.
2) Case seal was locked in its position to check for any change in the compression of the
case seal. Upper adaptor flange attached to gland plate of case seal was dismantled to
lock the case seal in its initial position and check for any change in compression of the
case seal.
After locking the case seal in its initial position, 6-9 mm of gap was found between the adaptor
flange and the seal gland plate.
Analysis:
1) Both end (solid/ liquid end) Plumber block alignment was checked and found ok.
Page | 83
2) After rotor was placed in its position and the case seal of both ends were in locked
condition. After placing the lower half of the adaptor flange 6-9 mm gap was observed
between the case seal and the adaptor flange.
Weld build up and machining job was carried on the rotor head based on the condition
during overhaul and over the period of time the rotor dimensions got changed slightly,
leading to the gap.
Due to this, rotor gap was originated in between the case seal gland plate and the adaptor
flange of both ends. Thus, installing the rotor in the position disturbs the compression of
the case seal causing the leakage.
Corrected action:
The gap in between the case seal gland plate and the adaptor flange were then adjusted by
placing the nut size sleeve as per the gap found on solid and the liquid end.
Benefits realized:
Case seal leakage due to rotor shifting was arrested and its procedure added to the installation
SMP of pressure centrifuge 21-CN -1411 A/B/C.
Case Study 25
Summary Sheet
Unit category Power Plant
Unit CPP
Problem Type High Vibration
Solve Method Exhaust hood cooling
Report No.
Year / Month Feb2023
Title of the report Resolving High pedestal vibration problem in STG-1
Problem High pedestal vibration problem in STG-1
Solution Exhaust hood cooling by dechocking of spray nozzles installed
Problem: After overhauling of Steam turbine generator-1 (STG-1), machine was tripping on high
pedestal vibration and turbine bearing vibrations were also on higher side (close to tripping
point). Pedestal vibration alarm range is 63 microns and tripping point is 150 microns whereas
alarm range for shaft vibration is 150 and tripping point is 240 microns
Duration of Problem: Jan’23- Feb’23
Observation: OEM, BHEL was requested to send their expert to troubleshoot the problem.
However, they shown their inability to depute expert. Vibration analysis was done to find out
root cause of the vibration. From vibration frequency and trend, it was observed that the cause
of vibration was rubbing due to uneven expansion.
Page | 84
Methodology: Both the glands and bearings of steam turbine were checked no significant
problem was observed except rubbing marks on turbine and generator coupling hub. Hence, the
DE side gland clearance was adjusted. However, still same problem was observed during the
trial. On further analysis it was observed that exhaust hood temperature was abnormally high
i.e around 120 deg C which should remain under 70 deg C. Other machines were having
temperature around 60deg C.
Analysis: For checking the reason behind high exhaust hood temperature 4 spray nozzles
installed in exhaust hood was checked for any hindrance to the condensate which is sprayed in
exhaust to maintain its temperature. All the 4 spray nozzles were found chocked.
Corrected action: All the 4 nozzles were dechocked and then again trial was taken for machine.
After dechocking temperature of the exhaust hood reduced to around 68 deg C and pedestal
vibration reduced to 56 microns and turbine bearing vibration reduced to 120 microns
Benefits realized: Now Machine is running below alarm limit continuously from Mar’23.
Page | 85
PARADIP
REFINERY
Page | 86
Case Study – 1
Summary Sheet
Unit category Distillation Unit
Refinery Paradip
Unit AVU
Problem Type Flooding in the CDU Column Naphtha-Kerosene zone since the planned
Refinery shutdown Jul-Aug’20
Solve Method Replacement of conventional trays with new Antifoulant Trays #5-16
Report No. -
Year / Month Jun’22
Title of the report Flooding in the Naphtha-Kerosene zone of CDU Column
Problem Severely fouled trays of Heavy Naphtha and Kerosene Section
Solution Replacement of conventional trays with new Antifoulant Trays #5-16
Problem: Flooding phenomena in the Naphtha-Kerosene zone of CDU column
Duration of Problem: Planned Refinery shutdown Jul-Aug’20 to M&I shutdown Aug-Sep’22
Observation: Post Refinery shutdown in Jul-Aug’20, flooding was observed in the Naphtha-
Kerosene zone of CDU column which was witnessed by the increased pressure drop across
Naphtha-Kerosene zone from normal operating range of 0.12-0.13 to 0.35-0.37 kg/cm2.
Methodology: As per the recommendations of OEM (M/s Koch Glitsch) of column internals,
replacement of conventional trays with new Antifoulant trays #5-16 was carried out in the
M&I shutdown Aug-Sep’22
Analysis:
Based on data analysis, the probable causes of CDU column flooding are as under:
a) Process related problems: Fouling could be one of the reasons contributing to the
increased pressure drop across the heavy naphtha and Kerosene zone (tray #5-13). It
was suspected that over a period of time, the trays in the HN and Kerosene zone might
partially fouled up with salt deposits and the problem was being encountered at higher
T’put level. As per the available literatures, similar kind of phenomena was observed in
some of the worldwide Refineries while processing Canadian/American crudes which
contains “Phosphorus (P)” which could have led to salt deposits in the HN-Kerosene
zone. In this regard, salt deposits were collected from the Kerosene Pump Around
suction strainer for component analysis on 02/10/2020 & 06/10/2020 and it is found
that Calcium (Ca) & Phosphorus (P) are 0.1 %wt. & 0.35 %wt. and 0.08 %wt. & 0.13 %wt.
respectively.
b) Mechanical related problems: Another reason for increase in pressure drop could be
obstruction for the flow due to partial tray damage, etc., and generation of sudden
excessive pressure drop in the HN-Kerosene zone.
c) Deposition of chloride/salts in the top trays (1-14) during low throughput operation of
AVU for a few months (pre shutdown) and during Jul’20-Aug’20 shutdown due to
condensation. Analysis for salt deposits of Kerosene Pump Around suction strainer was
Page | 87
done for the sample collected again on 21/10/2020 and it is found that Chloride and
Phosphorus (P) content are 7.5 %wt. and 0.08 %wt. respectively. It is also pertinent to
note that the chloride content in the boot water of CDU column overhead receiver is
found to be in the range of 10-20 ppm against the allowable limit of 20 ppm.
Further, flooding was managed by processing the crude mix of oAPI in the range of 30-32 and
changes in the operating conditions of CDU column such as operating the column at a higher
pressure, increased PA flows of LAGO & HAGO, low COTs of CDU charge heater, Low stripping
steam flow rate of CDU column/side strippers, etc. It is also evident from the report of Gamma
scanning of CDU column (tray no. 1 to 30) that tray nos. 5 to 13 are partially damaged owing to
either of the reasons stated above. These reasons for flooding in the CDU column were
endorsed by the tray vendor, M/s Koch-Glitsch after analyzing the operating data. Tray vendor
has also suggested to consider the installation of antifouling trays in the Naphtha-kerosene zone
(Tray Nos. 5 to 16) for better run length owing to the processing of various crudes which also
contains Calcium (Ca), Phosphorus (P), etc.,
Corrected action:
During the inspection of CDU Column internals during M&I Shutdown Aug-Sep’22, it was
observed that Tray Nos. 1 to 8 were fully flooded with the salt deposits/debris. As a part of
M&I shutdown, Trays #5-16 in the CDU column were replaced with the Antifoulant trays in
presence of M/s Koch Glitsch’s representative. Pictures related to trays fouling (during
inspection) and installation of new trays are attached below for reference.
Fig.1: Conventional Trays (fouled up)
Fig.2: Mock-up of Antifoulant trays Fig.3: Installed

Antifoulant trays
Page | 88
Benefits realized:
The benefits realized from the replacement of conventional trays with the Antifoulant are
as under:
• Pressure drop across Naphtha-Kerosene zone was decreased from 0.35-0.38 kg/cm2
to 0.07-0.10 Kg/cm2
• Better separation was observed in CDU Column top section which resulted in the
improved Gap between Naphtha-Kerosene zone from 3.3 to 13.6. Representative
graph is attached below.
Naphtha-Kerosene Gap
35
30
PDR M&I
GAP/OVERLAP, deg C
25
Shutdown 2022
20
15
Guarantee (Min), 10
10
5
0
-5
1-Jun-22 1-Jul-22 1-Aug-22 1-Sep-22 1-Oct-22 1-Nov-22 1-Dec-22
Naphtha/KERO Guarantee (Min)
Case Study – 2
Summary Sheet
Unit category Fluidized Catalytic Cracking
Refinery Paradip
Unit INDMAX
Problem Type High Skin Temperature in Riser and Reactor (>343 degC)
Solve Method Refractory Repair and Inspection of Internals
Report No. PDR/INDMAX/2022/01
Year / Month Jul’22
Title of the report High Skin temperature across various section of Riser and Reactor
Problem High Skin Temperature in Riser and Reactor leading to low ROT
operation mode and affecting product yields
Solution Internal inspection in M&I shutdown and Refractory repair
Page | 89
Problem:
High Skin Temperature (>343 deg C) in Riser and Reactor leading to low ROT operation mode
and affecting product yields.
Duration of Problem: Jan’22 to July’22
Observation:
During M&I in Aug-Sept’22, Reactor and Riser was opened for inspections of internals. As can
be seen in below snapshot, the refractory in J-bend of Riser section was severely damaged
after opening end flange. After removal of damaged refractories, metal erosion up to 35-40
mm was observed which led to high skin temperatures (>343 deg C)
Heavy refractory
damage in J bend
area at various
sections
Methodology:
Internal Inspection of Riser & Reactor sections during Aug-Sept’22 M&I.
Analysis: Overtime the refractory in the R-R section had got damaged and skin temperature
monitoring was carried out timely to find out damages in refractory across Reactor &
Regenerator section.
Corrected Action: Refractory repair after inspection of Riser and reactor internals and some
sections in Regenerator. The damaged refractory was removed, and lugs were repaired. New
refractory lining was carried out in J-bend followed by dry out procedure. After dry-out,
inspection was carried out and new refractory was found to be in perfect condition.
After Repair and

completion of dry out
procedure, refractory was
found in perfect conditions
Page | 90
Benefits Realized: Pre shutdown skin temp of J bend > 480 deg C was being observed against
max limit of 343 deg C. Skin temp profile of Riser/J bend is in normal range of ~250 deg C
which is well below limit of 343 deg C after refractory repair.
Case Study – 3
Summary Sheet
Refinery Paradip
Unit INDMAX
Problem Type LP Steam dumping in Refinery
Solve Method To increase LP steam consumption in INDMAX so as to reduce LP
steam dumping without affecting INDMAX Unit parameters.
Report No. PDR/INDMAX/2022/02
Year / Month Oct’22
Title of the report Provision of LP steam in Dilution & Quench steam in INDMAX Riser
Problem LP Steam dumping in Refinery
Solution To increase LP steam consumption in INDMAX so as to reduce LP
steam dumping without affecting INDMAX Unit parameters.
Problem:
LP steam dumping of ~10 MT/hr was observed in Refinery and high MP steam consumption
in Refinery was observed leading to high velocities in MP steam header.
Duration of Problem: Since Jan’22 (Intermittent).
Observation: Intermittent LP steam dumping of ~10 MT was observed in refinery.
Methodology: Alternate source for LP steam consumption was explored in INDMAX unit in
Riser section. It was also explored if MP steam could be replaced with LP steam without
affecting any process parameters. In riser section, dilution and quench MP steam was chosen
to be replaced with LP steam.
Analysis: On consultation with the Licensor and further study, the conversion of MP steam
to LP steam in dilution and quench steam section of Riser was found feasible.
Corrected action: Scheme for provision of MP to LP steam consumption was proposed and
implemented in M&I and later commissioned in Nov’22.
Benefits realized: After implementation & commission of scheme, LP steam dumping has
stopped and in addition MP steam header high velocity issue has been resolved.
Page | 91
Case Study-4
Summary Sheet
Unit category SRU reactor (087-R-001/002 & 086-R-001/002)
Refinery Paradip
Unit SRU-I & II
Problem Type Reactor DP high
Solve Method Replacement/skimming of catalyst
Report No. PDR/SRU/2022/001
Year / Month 2022/Sept
Title of the report Increase in back pressure of reaction furnace of SRU-I & II
Problem Due to increase in pressure drop across reactor, back pressure of the
unit is on increasing trend
Solution Catalyst replaced with new catalyst in R-002 and partial skimming &
partial replacement of catalyst in R-001 of both the units
Problem: Back pressure of both the units (SRU-I & II) was on higher side which restricted t’put of
SRU.
Duration of Problem: Mar’22 to Aug’22
Observation: Back pressure of both the units (SRU-I & II) was on higher as reactors (R-001 & 002)
pressure drop was higher leading to restriction in t’put of SRU units.
Methodology: Inspection of reactors catalyst
Reactor befor catalyst replacement After catalyst replacement

Analysis: Soot deposition was observed in both the reactors of the SRU-I & II,
Corrected action: 15% top portion was skimmed and replaced with new catalyst. 2 nd Converters
complete catalyst was changed with new one since it was in service since 2016.
Benefits realized:
Page | 92
• SRU-1 @8200 Nm3/h acid gas feed & 2600 NM3/hr Sour gas, Back Pressure reduced from
0.56 kg/cm2g to 0.47 kg/cm2g.
• SRU-2 @10500 Nm3/h acid gas feed, Back Pressure reduced from 0.46 kg/cm2g to 0.38
kg/cm2g
Case study – 5
Summary Sheet
Unit category Tail gas line to TGTU and incinerator
Refinery Paradip
Unit SRU & TGTU
Problem Type High back pressure
Solve Method Contotrace Heat tracing System provision
Report No. PDR/SRU & TGTU/2022/002
Year / Month 2022/Sept
Title of the Increase in back pressure of SRU-I & II
report
Problem Due to blockage of tail gas line to TGTU/incinerator, back pressure of
the both the units (SRU-I & II) was increasing
Solution Tail gas line continuous heating provision required, so that any
Sulphur carryover after final condenser (E-007) in the tail gas line will
not solidify and block to line
Problem: Back pressure of both the units (SRU-I & II) was higher which was leading to restriction
in t’put of SRU.
Duration of Problem: Sep’21 to Aug’22
Observation: Back pressure of both the units (SRU-I & II) was higher. During shutdown of SRU it
was observed that the tail gas line to incineration was almost completely block with the Sulphur.
Tail Gas Line blockage
Methodology: Controtracing of tail gas lines was envisaged since tail gas lines are prone to
chokage.
Analysis: Sulfur mist carry over and improper steam tube tracing led to sulfur deposition.
Page | 93
Corrected action: Controtrace Heat tracing System installed in SRU tail gas line (575M) to
avoid/minimize tail gas Sulphur line plugging. Reduce back-pressure issue in SRU thereby enabling
capacity utilization
Tail Gas Line: 36-50” CH Valve Jacketing
Benefits realized:
• SRU-1 @8200 Nm3/h acid gas feed & 2600 NM3/hr Sour gas, Back Pressure reduced from
0.56 kg/cm2g to 0.47 kg/cm2g.
• SRU-2 @10500 Nm3/h acid gas feed, Back Pressure reduced from 0.46 kg/cm2g to 0.38
kg/cm2g
Case Study- 6
Summary Sheet
Unit category P&U
Refinery Paradip
Unit CPP
Problem Type Poor performance of Deaerator resulting in higher LP steam
consumption
Solve Method Major overhauling of Deaerator internals
Report No. PDR/CPP/2022
Title of the report Improve performance of Deaerator
Problem High LP steam consumption in Deaerator.
Solution To replace internal assembly parts in Deaerator with new spray plate,
water liner plates, spray nozzles, trays and tie rods.
Problem:
In PDR-CPP, LP steam flow to both Deaerators-1 & 2 was on higher side by ~40 TPH to
maintain desired level of dissolved oxygen (DO) content in Boiler Feed water (BFW).
Page | 94
Duration of Problem: Nov ‘21 to Aug ’22.
Observation: Upon inspection of deaerator, water box liner plates, spray nozzles, tray and tie rods
found damaged.
Methodology: Inspection of deaerator internals as per OEM (M/s BHEL) recommendation
Analysis: LP steam consumption in deaerator 1&2 was high to maintain desired dissolved O2
content in Boiler Feed water.
Corrective action: Internal inspection was done during M&I and internal assembly parts were
replaced with new Spray plate, Water box liner plates, spray nozzle and Trays and tie rods.
Benefits realized:
• After overhauling Post Aug-Sep’22 M&I S/D, Deaerator performance has improved &
reduction in deaerator steam consumption by ~40 TPH has been achieved.
Page | 95
Case Study – 7
Summary Sheet
Unit category NHT-CCR Unit
Refinery Paradip
Unit CCR Unit
Problem Type Salt or heavy HC deposition at Packinox heat exchangers corrugated
plates
Solve Method Chemical cleaning procedure
Report No. PDR/NHT-CCR/2022/01
Year / Month Aug-Sep’22
Title of the report Packinox Chemical Cleaning
Problem Combined feed exchanger (CFE) of Paradip Refinery CCR unit is Packinox
heat exchanger which is corrugated type and was not cleaned since
commissioning. Cleaning was required to achieve more heat transfer.
Solution IOCL Paradip Refinery performed Chemical Cleaning by fill and Drain
Method in Packinox Exchanger during Aug-Sept’2022 shutdown
PDR CCR PHE One of the largest Packinox of the world (418 m3 shell & Feed side + 81 m3
Effluent side: Total hold-up ~500 m3).
Problem:
Combined feed exchanger (CFE) of Paradip Refinery CCR unit is Packinox heat exchanger
which is corrugated type and was not cleaned since commissioning.
Duration of Problem: Sep’21 to Aug’22
Observation: Cleaning of Packinox CFE was required to achieve more heat transfer.
Methodology: Chemical Cleaning was performed by fill and Drain Method (3 times each side) in
Packinox Exchanger.
Analysis: Chloride level reduction was observed during cleaning
Corrective action: Chemical Cleaning by fill and Drain Method in Packinox Exchanger during
Aug-Sept’2022 shutdown
Benefits realized: Post cleaning & Inspection performance found satisfactory.
Page | 96
Chloride level reduction was observed during cleaning which will improve reliability of
PHE.
Figure 1: Packinox Cutout Figure 2: Top Expansion Bellow
Page | 97
Figure 3: Schematic Set-up for Chemical Cleaning by Chem-Clinzo
Case Study- 8
Summary Sheet
Refinery Paradip
Unit CCR Unit
Problem Type Catalyst circulation issue in CCR Regeneration Section
Solve Method Cleaning of Catalyst Collector Vent Line Filter
Title of the report Catalyst circulation issue in CCR Regeneration Section
Problem No catalyst flow from 042-R-004 bottom Catalyst Collector at
recommended design reduction gas/purge gas flow of 6469 Nm3/h
Solution During M&I shutdown (Aug-Sep’22) Catalyst Collector Vent Line Filter
was opened and same was found filled with catalyst and same was
removed.
Problem:
Problem faced before shutdown:
➢ No catalyst flow from 42-R-004 bottom Catalyst Collector at recommended design

reduction gas/purge gas flow of 6469 Nm3/h.
Page | 98
➢ UOP recommended purge gas vent line strainer cleaning. Catalyst circulation
established after reducing gas Purge gas flow to ~3500 Nm3/h after consulting UOP.
➢ Catalyst circulation was lowered to 40% from normal level of 50%
➢ Constraint to increase RIT /T ’put.
Duration of Problem: May‘22 to Aug’22.
Observation: Upon inspection of catalyst collector vent filter, it was found filled with catalyst and
dust. Figure-1 is enclosed for reference.
Figure 1 Catalyst Collector Vent line filter
Methodology: During Aug-Sep’22 M&I shutdown, catalyst collector vent filter opened for inspection
as per UOP’s recommendation.
Analysis: Catalyst Collector Vent line filter was found to be completely filled with catalyst dust and
fines which restricted purge gas flow which in turn was holding up the R4 catalyst from falling into
catalyst collector.
Corrective action: Catalyst Collector Vent line filter which completely filled with catalyst and
dust was cleaned during M&I shutdown.
Benefits realized:
➢ Post cleaning, Purge gas flow is maintained at ~6550 Nm3/h.
➢ No operational constraint now & reliability improved
Page | 99
Case Study- 9
Summary Sheet
Refinery Paradip
Unit CCR Unit
Problem Type Unreliable operation of Regenerator section due to leakage of CTP
Solve Method Replacement of existing steam tracing to electrical heat tracing
Title of the report Replacement of steam tracing with electrical heat tracing and provision
of skin thermocouples on CTPs
Problem Leakage of CTPs due to unreliable operation of steam tracing leading to
corrosion due to chloride attack in Catalyst transfer pipes
Solution As per UOP’s recommendation, steam tracer was replaced with
electrical heat tracing.
Problem:
➢ Issue of corrosion due to chloride attack in Catalyst transfer pipes (CTPs). Steam tracing was
unable to maintain temperature above acid dew point of chloride (115 °C) in CTP’s
➢ Unreliable Operation
Duration of Problem: Sep ‘21 to Aug’22.
Observation: CTPs were found cracked at nos. of locations especially at the bottom of transfer lines.
Methodology: During Aug-Sep’22 M&I shutdown, catalyst collector vent filter opened for inspection
as per UOP’s recommendation.
Analysis: Issue of corrosion due to chloride attack in Catalyst transfer pipes (CTPs). Steam tracing was
unable to maintain temperature above acid dew point of chloride (115 °C) in CTP’s
Corrective action: As per UOP’s recommendation, steam tracer was replaced with electrical
heat tracing.
Benefits realized: CCR regeneration section reliability improved and monitoring of CTP
temperature also available at DCS now.
Page | 100
HALDIA
REFINERY
Page | 101
Case Study -1
Summary Sheet
Unit category Fluidized Catalytic Cracking Unit
Refinery HR
Unit RFCC
Problem Type CO boiler waterwall tube leak
Solve Method Online leak rectification
Report No. -
Year / Month Sept’2022
Title of the report CO boiler waterwall tube leak rectification by reducing RFCCU t’put from
90 m3/h to 65 m3/h and stopping CO incinerator firing on 28.09.2022
Problem CO boiler waterwall tube leak
Solution Online leak rectification by putting box in outside of CO boiler water wall
tube
Problem:
RFCC CO boiler waterwall tube leak was observed on 22.09.2022 morning shift on Bank tube
zone 1 & 2 area. Exact position of the leak could not be identified properly, so after insulation
removal, it was observed that there is a leak at a distance of around 10mm from the welding of
the fin of the 25th water wall tube of RHS panel.
Duration of Problem: 5-6 days
Observation:
After insulation removal from bank tube leaky zone , it was observed that the leak was
initiated from welding of the fin and propagated and crack was found at a distance of around
10 mm from the welding joint.
Front & Side view of R H side membrane panel of Bank tube: (25th no. tube of RHS)
Page | 102
Close view of the leak:
Leakage at a
distance from the
outside welding of
the fins of waterwall
tube
Methodology:
It was planned to attempt the leak repair on 28 th Sept’2022. Accordingly, following actions
were initiated:
• SOP was prepared and circulated before execution of the job.
• All FCC field personnel were trained at site prior to start of this activity.
• Being a non-routine critical job, JSA was prepared.
• Toolbox talk given to contractor personnel before initiating the repair job.
• All safety precautions were taken care including regular interval CO detection, BA set
application, Heat resistant suit etc. including all PPEs.
• Fire & safety team was present with proper arrangement.
Page | 103
• RFCCU T’put and Feed management to reduce feed CCR to reduce air flow to RGs
and lower the CO generation to the extent possible.
• Execution of the Leak rectification job:
• Prior to start of the leak rectification job, RFCC t’put was gradually reduced from 90 to
65 m3/h. Feed components were adjusted to reduce RGs air flows and Steam
generation from CO boiler for reduction of the Steam drum pressure.
• Following are the operating parameters adjustment prior to doing this critical activity.
Operating parameters BEFORE During Leak rectification

(at 08:00 am 28.09.22)
RFCCU T’put, m3/h 90 65
Feed components: 41/35/14 14/45/6
VGO/UCO/LSVR, m3/h
Total Airflow to RG-1 & 2 and 42030/11970/7520 33410/10430/6900
lift air, kg/h
RG-1 & 2 Dense/Dilute temp, 664/660, 709/718 659/658, 693/694
DegC
CO Incinerator temp, Deg C 970 401
CO boiler BFW flow, kg/h 33900 11060
Steam drum Pr. kg/cm2g 17.5 5.95
Steam drum level, % (SH/Eco 50.4/50.3/50.2/26.4/25.9 49.0/48.8/48.1/41.8/42.2
side)
COB steam generation, kg/h 33250 Venting since 10:30 am
28.09.22
Following interlocks were bypassed during low T’put operation and normalized after
completion of the job & t’put normalization:
RFCCU Interlocks Bypassed & Reason
Normalized
CO Incinerator main FG pr. PLC Due to stoppage of FG firing in
high COI
RG-1/2 & Lift air low flows HS-0103/0104/0105 Due to low T’put
Furnace pass flow low HS-3304/3305 Due to low T’put
Furnace FG pr. low HS-3301 Due to low T’put
Monitoring of Carbon Monoxide (CO) at site by CO detectors & by online monitoring:

After stopping the CO incinerator firing, online CO monitoring was done by F&S at site and
through online monitoring from Control room. The whole CO boiler area was cordoned off
and other on-going jobs were suspended during this activity with close supervision of F&S. CO
reading in gas analyzer (18AI0803) and CO detectors in field were found fluctuating in the
range from 20 to >300 ppm.
Page | 104
Analysis:
The leak was initiated from welding of the fin and propagated and crack was found at a
distance of around 10 mm from the welding joint.
Corrected action:
CO boiler steam drum venting was continuing at a pr. of 6 kg/cm 2g. Steam-water leak was
examined, and welding job was carried out successfully. Later on RFCCU operation was
normalized gradually.
BEFORE AFTER
Benefits realized:
RFCC shutdown was avoided by online leak rectification of the CO boiler water wall leak.
Page | 105
Case Study- 2
Summary Sheet
Refinery HR
Unit RFCC
Problem Type Quality issues in RFCCU LPG & LCN
Solve Method In-house
Report No. -
Year / Month Jun’2022
Title of the report Improvement in Debutanizer overhead LPG condensation by putting
additional existing coolers in HR-RFCC into operation
Problem High LPG weathering and high RVP of LCN
Solution Existing idle HCN coolers used
Problem:
In HR-RFCC unit, there are four Air fin coolers (18-EA-A/B/C/D) & one trim cooler (18-E-43) for
Debutanizer overhead circuit cooling. After MF & Gascon revamp in Dec’2021, debutanizer reflux
temp is required to be maintained around 52 deg C while the reflux temp is maintaining @ 58
deg C resulting in quality issues in LPG weathering and LCN RVP and downstream MSQ unit
system pressurization.
Duration of Problem: From Apr’22 to May’22
Observation:
Due to high reflux temp, the LPG condensation rate was found to be reduced resulting in high
weathering and also slippage in lighters through Debutanizer bottom. Thereby LCN RVP was on
higher side >0.8 w.r.t. normal of 0.6
Methodology:
Existing HCN coolers were proposed to be connected in Debutanizer overhead circuit to enhance
LPG condensation.
Analysis:
Due to high reflux temp, the LPG condensation rate was found to be reduced resulting in high
weathering and also slippage in lighters through Debutanizer bottom.
Corrected action:
It was proposed to line up available Naphtha cooler 18E38A/B in Debutanizer overhead circuit
to reduce reflux temp, to enhance Overhead LPG condensation and to eliminate Debutanizer
pressurization issue. The existing naphtha coolers 18E38A/B used in parallel to existing trim
cooler 18E43.
Debutanizer overhead reflux temp found reduced by 4-7 degC resulting in margin in
Debutanizer bottom temp which helped to produce on-spec products from RFCCU w.r.t LPG
weathering and LCN RVP. Debutanizer over pressurization issue also got resolved by
implementing this scheme.
Page | 106
Benefits realized:
Quality issues in RFCCU LPG & LCN were resolved after implementation of this scheme.
Case Study- 3
Summary Sheet
Refinery HR
Unit RFCC
Problem Type Quality issues in Belco water- high sulphide to ETP
Solve Method In-house & R&D Bio-SR technology
Report No. -
Year / Month Mar’2023
Title of the report Reduction in sulphide, cyanide and TSS in Belco effluent to ETP
Problem High sulphide and cyanide in Belco effluent
Solution New facility for Reduction of sulphide, cyanide and TSS in Belco effluent
Problem:
In HR-RFCC unit, Purge Treatment Unit (PTU) is designed for handling the Belco purge water
of 20 m3/hr. Additionally, 10-15 m3/hr purge water (PTU bypass) is intermittently going to
Belco open pit for aeration and H2O2 dosing before final discharging it to ETP.
During heavy feed/high sulphur feed (HSVR) processing in RFCCU, the sulphide content of the
effluent becomes very high, in the range of 2500-3000 ppm which is not manageable to
reduce by H2O2 dosing only and Belco effluent water to ETP sulphide content becomes very
high.
Duration of Problem: From Jun’22 to Feb’23 (during high sulphur feed processing)
Observation:
It was observed that during heavy feed/high sulphur feed (HSVR) processing in RFCCU, the
sulphide content of the effluent becomes very high, in the range of 2500-3000 ppm which is
not manageable to reduce by H2O2 dosing only.
Methodology:
HR has approached IOCL R&D for treatment process for reduction of sulphide content in Belco
effluent. R&D has recommended for Bacterial treatment process of Belco effluent to reduce
sulphide, TSS & cyanide. Accordingly.
Analysis:
Due to high sulphide in Belco effluent, it was creating high sulphide in ETP water.
Corrected action:
HR has constructed new Belco effluent treatment facility to reduce sulphide and cyanide in
Belco effluent. The facility was commissioned in 10th Mar’23.
Page | 107
Benefits realized:
Quality & environmental issues in Belco effluent and ETP is resolved after implementation of
this scheme.
Case Study -4
Summary Sheet
Unit category Hydrogen Generation Unit
Refinery Haldia Refinery
Unit HGU-II
Problem Type High-pressure drop-in fuel Naphtha circuit to reformer
Solve Method Alternatively Bypass line is arranged for online cleaning Fuel Naphtha
KOD which caused high pressure drop
Report No.
Title of the report Online cleaning of Fuel Naphtha KOD
Problem Chokage in Fuel Naphtha KOD
Solution Alternatively Bypass line is arranged for online cleaning KOD
Problem:
In Aug’22, high pressure drop observed in fuel naphtha circuit which could lead to limitation in
fuel naphtha firing and HGU-II load restriction.
Duration of Problem: One month
Observation:
HGU-II Fuel naphtha KOD (92-V-20) outlet pressure was gradually reducing from 4.5 to 4.2
kg/cm2g though the supply pr. of Fuel naphtha after Fuel Naphtha Vaporizer (92E24A/B) found
increased from 4.4 to 5.5Kg/cm2(g).This pressure drop was leading to increase in opening of
92PV3601 which earlier used to be around 42-44% opened for maintaining 4.4 Kg/cm2(g)
pressure at d/s (92PI3601) of 92-V-20 and it was found 63-64% opened with 4.2 Kg/cm2(g) of
92PI3601 (92V20 pressure).
Methodology:
There was 8’’ inch idle line was present from E-24 B outlet to Fuel naphtha Control valve which
was not in use since erection. Hence line was proper flushed, cardboard blasting done to
remove the impurities. Tracing steam with insulation is arranged to reduce the temperature
drop across the new line.
Analysis:
High PDI observed between E-24 Outlet to FN KOD outlet. There is no PI available in the
immediate inlet of Fuel naphtha KOD. Hence Chokage is suspected in KOD inlet line and its
demister pad. To ascertain the precise location further pressure survey was done. From the
Page | 108
survey, it was observed pressure drop was only across the KOD demister however same could
not be cleaned in unit running condition.
Hence bypass of KOD facility was arranged.
Corrected action:
V-20 was cleaned thoroughly, and its demister pad was replaced with new one. Later it was
taken back in line and unit was normalized.
As per sample result, huge amount of iron content observed. Hence cardboard blasting is
planned for total fuel naphtha circuit in upcoming M&I shutdown.
Benefits realized: HGU-II-unit stoppage/interruption was saved by introducing new bypass line
of FG KOD (92V20).
Page | 109
MATHURA
REFINERY
Page | 110
Case Study-1
Summary Sheet
Unit category Atmospheric & Vacuum distillation Unit (AVU)
Refinery Mathura Refinery
Unit AVU
Problem Type VDU column upset
Solve Method SR pumps common suction Header back-flushing
Report No.
Year / Month Feb’23
Title of the report Unstable VDU operation
Problem Suction loss of SR pumps
Solution SR pumps common suction Header back-flushing
Problem:
Since 28th April’22, occasional suction loss in SR pumps (12-P-05/P5A/P5B) observed. This issue
was observed even at healthy column bottom level. Vibration in discharge header also observed
during cavitation issue. VDU column bottom level build-up observed so VDU section t’put also
reduced. Most of the cavitation issues observed during HS crude processing.
It happened almost every month till Dec’22, thereafter frequency increased and restricted unit
to sustain operation at higher t’put (>1100m3/hr in HS case).
Every time it took 3-4 hours to stabilize the vacuum section. After SR pump healthiness, gradually
SR rundown flow increased to normal value (~300-380m3/hr including quench) and
subsequently unit t’put normalized.
Date & Time Unit T’put (CDU/VDU) Mode
28.04.2022 05:00Hrs 1000/420 HS

15.05.2022 06:15Hrs 1400/545 LS to HS c/o
05.06.2022 17:30Hrs 1490/610 LS to HS c/o
16.07.2022 07:50Hrs 1150/500 HS
05.08.2022 13:30 Hrs 1300/525 HS
06.09.2022 22:30 Hrs 1300/510 HS
30.11.2022 04:30 Hrs 1450/610 HS
03.01.2023 11:55 Hrs 1450/590 HS
13.01.2023 10:24 Hrs 1100/425 HS
13.01.2023 19:12 Hrs 1100/450 HS
30.01.2023 21:25 Hrs 1100/470 HS
Page | 111
6.02.2023 06:52 Hrs & 13:10 Hrs 1400/580 HS

07.02.2023 05:32 & 06:44 Hrs 1000/390 HS
Observation:
1. Initially, in April & May’22, it was observed that column bottom level got stuck-up
(unresponsive). Suction loss happened due to actual drop in column level.
2. Subsequently, suction loss observed even at healthy column bottom level & suction
header pressure.
3. VDU COT & column temperatures profile were observed healthy
4. High column bottom level was maintained to sustain continuous operation.
5. During suction loss in running pump, stand-by pump also could not be taken in line due
to cavitation.
6. Post Nov’22, it was observed that at the time of suction loss in SR pumps, common
suction header pressure (12PI48) dropped, whereas column bottom level(12LC2202) &
bottom pressure increased.
7. Gamma scanning carried out twice (July’22 & Feb’23), which suspected damage of
stripping trays.
8. SR quench sample checked and not observed any lighter material.
9. Stripping steam temperature was under normal condition above 315°C
10. Hot-well off-gas checked for O2 analysis for air ingress, observed nil.
11. SR pumps are having seal plan 54B. Pump’s seal checked and observed intact at time of
suction loss incidents.
12. FLO tapping in SR pump suction header and exchangers observed blinded.
13. VDU stripping steam flow was reduced to minimum during suction loss incidents.
Methodology:
1. Post every suction loss incident, immediately unit t’put reduced for minimizing impact
on column internals and unit t’put restored after normalization of pumps.
2. SR pump’s suction strainers cleaned, no coke & packing material observed.
3. VDU column bottom LT’s (12LI2201/LC2202) flushed with LDO.
4. PT provided in bottom LT’s LP & HP tapping for better monitoring.
5. PT provided in individual suction header of every pump for maintaining healthy pressure
(column level) as column bottom level was not reliable.
Analysis:
To find out the root cause of incident, all probable causes analyzed which could affect suction
starvation of SR pumps, and listed observations against all possible causes:
a) Mechanical Failure of Running SR Pumps

This possibility is ruled out as pumps (both) running smoothly before incidence. Even
standby pump did not take load when attempted to take in line.
b) Condensate Carryover with VDU Stripping Steam
Page | 112
VDU stripping steam temperature and flow were observed healthy before and during
incidence. Pumps seal oil sumps levels observed normal (no water ingress from lube
oil cooler leak); no seal leak was observed in any of pump’s seal plan system during
each incident. so, water carryover can be ruled out as cause of disturbance.
c) Lighter HC dropping in VDU column bottom
VDU column temperatures (draw trays temperature, flash zone temp. & bottom temp)
& vacuum column pressure profile (top/flash zone vacuum) checked and observed
normal before incidence, so can be ruled out as a cause of incidence.
d) High Off-gas generation
VDU COT was gradually increased by panel officer. VDU off-gas pressure was observed
normal <0.1 kg/cm2.
e) Suction Strainer Chocking
Fine coke particles often observed in VAC Slop pump (12P04/4S) and sometimes
severe tube blockage observed in SR circuit exchangers (11E111, 11E28, 11E14). SR
pumps suction strainers mesh size is 5. Coke lumps were never observed in SR pumps
suction strainers, but coke particle of 2-4 mm observed on flanges of SR pump
strainers at the time of every cleaning. So, this possibility can also be ruled out for
reduced SR flow. But Solid coke particle formation is severe concern for VDU
operation.
Coke particles observed in Vac slop

Strainer observed clean
pump 12P04S on 9th May’22
f) Malfunction of Level Indications
Page | 113
Total SR flow continued to increase as bottom LT (12LC2202) was in PRD control with
SR R/D flow to BBU(12FRC51), accordingly total products outflow from VDU column
crossed 693 m3/hr against VDU feed flow of 642m3/hr, which was almost equal
before the incidence on 15th May’22 as per Hairline-1 in Figure-1. This reflects that
VDU bottom LT got erratic, due to suspected partial choking of HP tapping of LT. As
other draw off chimney tray levels were responding, whereas bottom level was almost
stagnant ~80%. VDU column bottom LTs malfunctioning can be validated by increase
in column bottom temperature as bottom level become down.
VDU column
Bottom level
Figure-1: VDU flow balance (inflow vs outflow & SR flow and bottom level
Crude ingress into VDU column bottom with SR quench header
During SR pump suction failure, SR rundown sample was taken to analyze lighter HC
content. This possibility also ruled out as flash point reported >150°C.
Recovery@560°C observed 25.7% (against 15-17% normal value), which reflects
partial dropping of VGO.
Parameter Test Value
Flash Point >150 °C
Simdis IBP 379
5% 455
10% 490
20% Rise of column 537
30% bottom temp 576
40% 616
50% 661
60% 720
g) Flow restriction due to coke deposit or damage of stripping trays
Gamma scanning was carried out in July’22 which concluded that partial damaged of
stripping trays. This can be one of probable cause as Mathura Refinery observed
restriction in SR flow (<300m3/hr against desired 380-400m3/hr including quench).
Page | 114
Coke deposit in stripping trays can also be one of probable cause as DP across stripping
section also observed on higher side.
h) Flow Restriction in vortex breaker

SR pump cavitation issue can also be attributed to restriction in VDU column bottom
vortex breaker as Gamma scanning also suspected restriction in bottom nozzle, which
may be due to coke build-up or due to stripping tray damage.
Since Jan’23, sudden drop in SR pump suction header pressure was observed at the time
of suction loss but rise in bottom pressure observed which indicates that occasional
restriction in bottom nozzle.
Similar phenomenon observed on 6th Feb’23. Frequent suction loss with drop in suction header
pressure at healthy column bottom & flash zone pressure. This indicated partial restriction in
bottom vortex breaker.
Corrected action:
Following corrective actions were taken to sort out SR pump suction loss:
1. SR pumps suction strainers cleaning.
2. LT flushing & PT provision in LP and HP tapping of column bottom LT.
3. COT, column bottom temp, stripping steam temp. checking.
4. SR quench & hot-well offgas analysis.
5. PT provision at individual suction header of SR pumps(12P05/5A/5B).
6. Gamma scanning of column bottom & flash zone to assess any internal damage.
7. SR pumps suction pressure controller loop (PIC) created with SR r/d flow to maintain
healthy suction header pressure.
8. PT also provided in discharge header of SR pumps.
9. SR pump suction header back-flushing with RCO planned to eliminate any coke deposit
in bottom section.
Back-flushing carried-out on 11th Feb’23 after taking VDU section shutdown for 16 hours.
VDU Column bottom back-flushing circuit :
Page | 115
Benefits realized:
Post SR pumps common suction header back-flushing, unit was restarted on same day, following
improvements observed:-
I. Crude T’put increased and sustained above 1350 m3/hr which was restricted upto
1050m3/hr in HS run.
II. SR total rundown flow increased to ~300m3/hr which was earlier restricted to 200 m3/hr.
III. It became possible for Mathura Refinery to achieve STGT which was looking impossible.
IV. DP across stripping trays reduced to ~3-4mmhg from 80-90mmhg.
V. Sustained steady VDU operation since back-flushing activity.
Case Study-2
Summary Sheet
Unit category DHDS (Diesel Hydrodesulphurization)
Unit DHDS
Problem Type
Solve Method
Report No. MR/TS/PS/DHDS/01
Year / Month 2023/Jan
Title of the report DHDS successful LS ATF run
Problem DHDS in PCK mode run used to make LS ATF was failing on freezing
point parameter
Solution DHDS modified feed management and changeover methodology
Problem: DHDS in PCK mode run was used to make LS ATF in Sept’22(trail run 3 days) but it was
failing on freezing point parameter. Hence unable to make LS ATF from DHDS.
Duration of Problem: 3-4 day
Observation:
LS ATF trail run was taken in Sept’22. During the run all plant parameters were maintained as
per SOP. The product quality of LS ATF w.r.t. Sulphur and silver corrosion was achieved. But the
product was failing in freezing point parameter.
Methodology:
Following methodology was adopted in LS ATF trial run of Jan’23:
1. DHDS feed management:-

• DHDS LS ATF feed prepared from AVU during High TAN run. Tank sample testing done
for flash, distillation, density, freezing point.
Page | 116
• Feed IBP maintained 155-160 0C. Feed FBP maintained less than equal to 255 0C. Feed
flash maintained more than 45 0C.
2. DHDS feed changeover:-
• DHDS feed changeover and flushing done at the feed rate of above 110TPH.
• DHDS TCO feed and hot feed line all BVs isolated and blinded to ensure no passing of
cracked and heavy feed.
• Salt dryers were isolated.
• DHDS WABT (R01/R101) minimized to 292/280 0C and maintained to get final product
sulphur greater than equal to 4 ppm.
• DHDS stripper maintained at 2500kg/hr from starting and Stripper Reflux Drum
maintained at 4.6 Kg/cm2
• Stripper Feed/Top/Bottom Temperature maintained at 195/152/1890C.
Analysis:
• Feed and rundown sample were sent in lab. Feed freezing point was reported -54degC.
• Product sample reported Cu corrosion =1b and Ag corrosion = 0. Freezing point of
rundown was about -23degC.
• Feed flow was increased and reactor severity was reduced
• Rundown sample freezing point was reported -52DegC.
SAMPLE DHDS FEED DHDS FEED R / D PCK R / D PCK

DATE 10.01.2023 11.01.2023 11.01.2023 11.01.2023
SHIFT E M M E
Den15 KGV 796.3 795.8
IBP °C 156 155 161
FBP °C 261 236 238
Flash °C 40 43
Moist PPM 100
H2S ABSE
*Ag Co 0
Sulfur PPM 2 2
Sulfur W% 0.115 0.115
95%VOL °C 240 228 227
90%VOL °C 225 221 220
50%VOL °C 197 195 196
10%VOL °C 177 176 178
05%VOL °C 173 172 175
Freezing
point °C -54 -23 -52
Page | 117
Corrected action:
• DHDS LS ATF feed prepared from AVU during High TAN run. Tank sample testing done
for flash, distillation, density, freezing point to ensure proper feed to DHDS.
• TCO & Hot LGO line were blinded in field at B/L.
• Salt dryer 02-V-31A/B were isolated.
• Feed flow was kept relatively high and reactor severity reduced.
• Stripper parameters maintained as shown in table below:
Benefits realized:
Production of LS ATF from DHDS unit to meet LS ATF requirement of Mathura Refinery.
Case Study- 3
Summary Sheet
Unit category CRU
Unit CCRU
Problem Type OPE
Solve Method
Report No.
Title of the report Dechoking of Static Mixer in CCRU Regen gas circuit
Problem Salt deposition in static Mixer
Solution Removing salts by low concentration Acid
Problem:
Lower regeneration gas flow was observed due to increased pressure in the regen circuit.
1 Month
Observation:
Pressure survey was done to identify the location. Static Mixture was identified as the major
pressure loss equipment.
Methodology:
Static Mixture was dropped and salts deposit was visible. Weak acid solution (2% HCl) was
prepared and circulated to dissolve the salts. Once the salts was removed, static mixture was
water washed to remove any residual acid, if left.
Analysis:
Page | 118
Service water was used to make-up in caustic for diluting salts in the caustic. Service water is a
source of high TDS which exaggerating the problem.
Corrected action:
Scheduled cleaning of static mixture is done. A separate agency to carry out the activity is also
lined up. DM water will be used as the diluent and the same will be executed within Mar’23.
Schedule testing of caustic for salts and Na+ equivalent is taken with IOC R&D.
Benefits realized:
Chokage issue is expected to be eliminated as TDS of the circulating caustic tends to be
reduced.
Case Study-4
Summary Sheet
Unit category CRU
Unit CCRU
Problem Type OPE
Solve Method P
Report No.
Title of the report Eliminating the cause to increasing DP in CRU-NHT reactor
Problem Reactor DP was increasing at a steady rate continuously.
Solution Feed filter was replaced.
Problem:
NHT reactor DP was increasing steadily.
6 months
Observation:
Filter Dp was much lower than expected and as presented in its datasheets.
Methodology:
Feed filter was opened as was checked for any damage.
Analysis:
Small crevices were found in the mesh of the feed filter.
Corrected action:
Feed filter mesh was replaced, and DP is now steady. Additionally magnetic filter is being
explored to be placed downstream for enhancing reliability of feed filtration system.
Page | 119
Benefits realized:
Enhanced reliability of CRU-NHT
Case Study-5
Summary Sheet
UNIT CATEGORY New Hydrogen Generation Unit
REFINERY Mathura Refinery
UNIT NHGU
PROBLEM TYPE COR / DES
METHODOLOGY L, B, N, C
ADOPTED
REPORT NO. MR/TS/PS/NHGU/2022/07
YEAR/MONTH 2022/ 07
TITLE OF THE REPORT Increase in Load of NHGU
PROBLEM Restriction in NHGU load
SOLUTION IN BRIEF One to one replacement of all 16 modules of cold APH
(302-E-56B)
Problem:
Restriction in NHGU load
Since Long time.
Observation:
Max NHGU load before Jul’22 was 72% (based on product), due to high ID rpm (due to leaky
cold APH (302-E-56B)
Methodology & Analysis:

To find out the reason for restriction in ID rpm, flue gas analysis at different locations in
convection zone arranged.
Based on Flue gas analysis carried in May-jun’19, leak was suspected in APH (302-E-56A/B).
So, smoke test planned for confirming and identifying leak in APH, if any in M&I 2019.
Leak was confirmed in M&I 2019. However due to unavailability of APH replacement, Leaky
portion attended by welding electrode rods on gap and with sealant filling in gap.
Replacement of all 16 modules of APH suggested in earlier opportunity to resolve the
problem.
Recommendations & Actions Taken:

Procurement of all 16 modules of cold APH (302-E-56B) done by M/M planning. One to one
replacement of all 16 modules of cold APH (302-E-56B) done as a major activity in Jul’22
shutdown
Page | 120
Benefits Achieved:
Load has been increased up to 91% (as per Product) after APH replacement (Restricted to 72%
before S/D)
Heat recovery across New APH has been improved, resulted in increase Combustion air
temperature and reduced Flue gas stack temp.
Design Before S/d After S/d

Load (As per Product), % 100% 72% 91%
ID rpm 990 890 880
Combustion air flow, Kg/hr 178937 150000 151800
NG fuel flow, Kg/hr 4353 3000 3400
Purge gas flow, Kg/hr 67631 34000 44000
Excess O2, % 1.0 3.0
Combustion air Temp, DegC 495 420 483
COT, DegC 885 847 841
Max tube skin Temp, DegC 940 940 938
1st Crossover Temp, DegC 1038 985 1009
2nd Crossover Temp, DegC 600 533 567
Flue gas stack temp, DegC 145 154 138
Case Study-6
Summary Sheet
UNIT CATEGORY New Hydrogen Generation Unit
REFINERY M
UNIT NHGU
PROBLEM TYPE OPE
METHODOLOGY L,R
ADOPTED
REPORT NO. MR/TS/PS/NHGU/2022/07/02
YEAR/MONTH Jul’22
TITLE OF THE REPORT Provision of Bypass duct to SAPH (302-E-58)
PROBLEM High pressure drop across 302-E-58 has caused rise in FD
fan rpm to its maximum operating value of 1242.
SOLUTION IN BRIEF Provision of Bypass duct to SAPH
Problem:
FD fan of reformer is discharging combustion air into Heat recovery section of Reformer duct
in which vent steam is used for pre-heating combustion air, subsequent to 302-E-58(vent
Page | 121
steam combustion air pre-heater), combustion air is further heated in APH(302-E-56A/B) so

that final temperature of combustion air before burner is approximately 500 Deg C. Any
resistance in combustion air flow path induces increase in rpm of FD fan in order to maintain
air to fuel ratio for complete combustion. High pressure drop across 302-E-58 has caused rise
in FD fan rpm value to 1350(Design rpm: 1480).
Since 2020.
Observation:
Any resistance in combustion air flow path induces increase in rpm of FD fan in order to
maintain air to fuel ratio for complete combustion.
It has been observed that Delta P across SAPH (302-E-58) use to increase after every 1.5 -2
years of operation post shutdown/ cleaning of SAPH. SAPH (302-E-58) choking is a perennial
problem leading NHGU plant load restriction. In Sep’17, a 16” bypass line was also provided
to sustain unit load in case of SAPH choking.
Since last M&I (Dec’19), pressure drop across SAPH is again increasing due to gradual
chocking. NHGU FD Fan rpm has reached to 1350 @ 65 % of unit load (design rpm: 1480). The
existing 16” bypass is kept fully open to give temporary relief in Delta P, however, DP across
E-58 was still on higher side i.e. 400 mmwc. Location of process cooling tower near to the FD
fan suction may be the probable reason for frequent chokage of SAPH at a very slow rate.
Methodology:
Discussion with operation and maintenance were carried out to identify the probable causes
and remedies of the problem.
Analysis:
✓ A by-pass duct 302-E-58 is proposed. In case the pressure drop increases significantly,
cleaning of SAPH may be carried out within 2-3 days keeping bypass open. Because of
diversion of air through bypass, pressure drop across 302-E-58 will reduce.
✓ Reduction in pressure drop will help in reduction in FD fan rpm but it will reduce heat
recovery by 302-E-58. Partly heat will be recovered through downstream APH whose
by-pass is approx. 20% open and rest of heat will be compensated by slightly additional
fuel requirement.
✓ After cleaning, 302-E-58 can be taken in line.
Recommendations & Actions Taken:
Following action was initiated and completed in Jul’22

✓ A scheme of HGU-2 SAPH bypass prepared to provide bypass duct of 302-E-58 (SAPH)
along with dampers for online cleaning of exchanger. Bypass duct was in-house
manufactured by Mechanical team and Commissioning of Bypass duct of SAPH (302-E-
58) in NHGU done in Jul’22.
Page | 122
Benefits Envisaged:
NHGU run length between two M&I could be increased from 2 year to 3 years or more.
Case Study-7

Refinery MR
Unit FCCU
Problem type
Solve Method By increasing BFW flow acoss the
economizer and identifying the leak
Report No
Year/Month Nov’22
Title of the report FCC Economizer pressure fluctuation and
frequent PSV popping issue
Problem: FCC Economizer pressure fluctuation and frequent PSV popping issue. Due to which
Economizer was bypassed completely after high PSV popping and pressure fluctuation (not
safe operation) on 01.07. 2022. Image attached below:
Duration of problem: 1 month

Root cause analysis:
Pressure fluctuation is due to low flow of water in economizer tube and dual phase
formation inside the Economizer, so to increase the water load to Economizer, hot water to
CCRU and HGU1 was line up from Economizer outlet. After lineup to HGU-1 and CCRU,
pressure fluctuation was not observed in Economizer. Pressure is constant at value of
31.5kg/cm2g. Image attached below:
Page | 123
DM consumption increased in FCC CO boiler by ~10MT/hr (Earlier it was 37MT/hr and now
47MT/hr) to increased the flow across the Economizer. Image attached below
Conclusion:
1. Bank-1 is isolated and will be rectified in next opportunity or shutdown.
Bank-2 taken in line and steam generation increased by around 2MT/hr
1. Part of Economizer outlet BFW is routed to CCRU and HGU-1

2. Economizer bank-1 will be not rectified in co boiler running condition as inlet and
outlet damper are not working and issue of flue gas passing .
3. Stack temperature reduced from 367deg C to 306 deg C ( delta T:61 deg C).
Page | 124
Case Study-8
Summary sheet
Unit category Tertiary unit (Octamax)
Refinery MR
Unit Octamax
Problem type
Solve Method
Report No
Year/Month Aug’22
Title of the report Octamax reactor basket collector failure and
thermo well bending issue
Problem:
Octamax reactor basket collector failure and thermo well bending issue
Duration of problem: 30 days
Observation:
It was observed that high Catalyst fine (molecular resin) found in the MS tank pump strainer
and also in Octamax product line, which indicated that the lag reactor bottom basket collector
was damaged from which catalyst fines were carry to the product.
Methodology
When the lag reactor was opened, the collector was found damaged from which catalyst fine
are travelling to the r/d line.
Thermo well found bending upward direction and also one of the thermo well of 401-R-3
found leaked from threaded joint of main element.
Damaged dimer
reactor bottom
collector
Page | 125
Leaked thermo well

from threaded joint
Root cause analysis:

Failure of basket collector:
The root cause analysis (RCA) for the failure of the basket collector is completed by R&D and
it is found that the failure is due to corrosion and erosion
Thermowell issue: the thermowells was found bent in upward direction even after
revisioning the backwashing SOP from Bottom-to-Top to Top-to-Bottom direction of flow. .
It envisaged that the root cause for the same may be due to soaking of catalyst with water
during regeneration cycle which causes swelling of the catalyst bed.
R&D has recommended suspending the catalyst regeneration step till the new thermo well
design is installed.
Corrected Action:
• New design basket collector was installed in the bottom of reactor. The new design
will be consisting of increased open area, higher pressure drop allowance and MOC
will be changed to ASTM A 580/A580M Gr. 440A (UNS S44002). Additionally, either
the thickness of screen bottom ring, stiffener ring, lifting lug and hold down lugs will
be specified or mechanical strength will be increased to enhance safety factor.
• New thermo well design (flexi) with radial orientation is proposed by the R&D.
• New basket filter(401-G-02A/B) with 100# mesh was installed in the r/d to capture
the remaining fines
Benefit:
Catalyst fine carryover to MS tank has been stopped to nil. Hence quality improvement and
Pump strainer chock age has been reduced.
Page | 126
DIGBOI
REFINERY
Page | 127
Case Study- 1
Summary Sheet
Unit category CRU
Refinery Digboi Refinery
Unit CRU
Problem Type Plant Reliability
Solve Method Root Cause Analysis
Year / Month Sep’22
Title of the report CRU NHDT reactor high Delta. Pressure issue
Problem CRU NHDT reactor high Delta. Pressure issue
Solution Catalyst skimming & addition of guard bed catalyst
Problem:
In DR, heavy naphtha (which contains Coker naphtha, DHDT naphtha, SRN & Guwahati naphtha)
is processed in CRU NHDT for removal of sulphur, nitrogen, oxygen & other impurities. There is
frequent problem of high DP issue in the reactor, due to which CRU throughput got restricted &
catalyst skimming is required.
Perennial issue (Skimming & partial catalyst replacement done in every 2 to 3 years)
Observation:
During reactor opening, we found heavy soft coke deposition over the bed leading to high DP
issue.
Methodology:
Root Cause Analysis with the help of licensor (M/s Axens).
Analysis:
Feed & coke sample analysis was done.
• As the feed storage tanks are not Nitrogen blanketed, there is high potential of
air/oxygen ingress into the feed from the storage tanks.
• Also, as the Guwahati naphtha is brought to IOCL Digboi refinery via road tankers, this
yet again leads to the ingress of oxygen into Guwahati naphtha during transportation
which is processed in NHT along with olefins and diolefins containing feed from MSQU
splitter bottom.
• The olefins and diolefins present in the feed (due to Coker naphtha) are highly capable
of gum formation in presence of oxygen that ingresses in the feed stream via storage
tanks as the tanks are not Nitrogen blanketed.
• It is important to note that even when olefins/diolefins are present in traces and if
feed is stored in a non-blanketed tank (containing dissolved oxygen), this can lead to
severe fouling of feed/effluent exchangers and reactor due to gum formation
(catalysed by iron).
Page | 128
• The fouling material/gum gets deposited over exchangers and also plugs the reactor
top (as observed during inspection) leading to high pressure drop build up during
normal operation.
Corrected action:
• As CRU feed tanks are not nitrogen blanketed, HN (containing Coker naphtha) from
MSQU is being directly processed in CRU, to avoid gum formation in tanks.
• Most of the Coker naphtha was diverted to DHDT and stabilized naphtha from DHDT
was processed in CRU.
• CRU NSU top temperature is being maintained above 110 oC to remove oxygenates
from Guwahati Naphtha.
• CRU NHDT Rx catalyst skimming done in Sept 2022 and three types of guard bed
catalysts were loaded in the Rx (removing top bed ceramic balls & trash basket) as
shown below.
Benefits realized:
• CRU NHDT Rx delta pressure is observed to be steady after Sep’22 start-up.

• CRU NHDT t’put restriction has been removed.
Case Study- 2
Summary Sheet
Refinery Digboi Refinery
Unit Solvent De-waxing Unit
Problem Type Leakage of Chemical
Solve Method Replacement with new elbow
Report No. 2
Year / Month June 2022
Title of the report Pinhole leakage of MIBK line from elbows
Problem Leak of MIBK
Solution Leaky elbow replaced
Problem:
Pinhole leakage of MIBK from 1.5” socket welded elbow of reflux line to 08-CC-304 (Foots oil
stripper of SDU) observed on 09/06/2022. Subsequently the leakage was arrested by online
composite wrapping.
01 day
Page | 129
Observation:
• Thickness survey of all MIBK lines from Pump outlet (08-PA-304) to stripper column carried
out.
• Thickness reduction noticed in 09 nos. of socket elbows
Methodology:
• Failed sample sent to R&D for analysis.
Analysis:
• Parent Material Defect
• Erosion/ corrosion due to impingement effect in socket welded elbow
• Softening of parent metal of elbows
• There exists no socket welded elbow in similar circuit of SDU of NRL.
• Butt Welded elbows are in use in similar service.
• Similar feedback received from CPCL during “Wax Producer’s Conclave” held at Digboi
Corrected action:
• In June 2022, all 09 nos. of elbow including the leaky one was repaired by composite
wrapping
• Later 34 nos. of SW elbows were replaced with BW LR elbow during Sept 2022 S/D
including the leaky elbow, in the similar service and line size.
• Monthly thickness survey of replaced elbows carried out till January 2023 and no further
thickness loss observed since replacement in Sept 2022.
Benefits realized:
• Improved reliability obtained
Page | 130
BONGAIGAON
REFINERY
Page | 131
Case Study – 1
Summary Sheet
Refinery Bongaigaon Refinery
Unit INDMAX
Problem Type High BS&W in slurry
Report No. Method of elimination
Year / Month 2023/January
Solve Method Internal Brainstorming & Discussion with Licensor
Report No.
Title of the report INDMAX unit shutdown observation report
Problem High BS&W in slurry circuit causing frequent leakages
Solution Cyclone dip leg choking was found during shutdown inspection which was
cleared.
Problem:
INDMAX unit was observing very high BS&W which resulted in erosion of MF bottom circuit
CVs and associated piping causing leakages and multiple unit interruptions during the month
of Dec’22.
~ One month (Nov-Dec’22)
Observation:
1. Even at normal Rx level, huge catalyst carryover was taking place to the MF column.
2. PSD analysis of E-cat was showing loss of fines along with heavier particles causing
increase in APS of circulating catalyst.
3. Rx steams were at maximum value and t’put was maintained above turndown.
Corrective action:
1. Discussion with licensors M/s Lummus and IOCL R&D for the probable causes of this
issue.
2. Discussion with IOCL FCC experts
3. Increased frequency of MF Bottom BS&W and E-cat analysis
Analysis:
During shutdown inspection of Rx secondary cyclones, huge chunks of coke were found in both
the cyclones causing choking of dip legs. This was the reason of high catalyst carryover to the MF
resulting in multiple interruptions. Coke was deposited over the primary cyclone barrel outer
periphery over the course of time. Cyclone diplegs were dechoked and coke was cleared from
secondary cyclone barrel outer periphery.
Page | 132
Benefits realized:
Unit was started up in presence of licensors and feed t’ put was able to maintain at ~75%.
Page | 133
Case Study – 2
Summary Sheet
Unit INDMAX
Problem Type Breaking of Riser Top plug while opening
Solve Method Special tool used for annular chipping
Report No.
Year / Month 2023 / Jan
Title of the report Taking out Riser Top plug without damaging
Problem Riser top plug gets broken in order to remove / Pull it for riser inspection
Solution Special tool used for annular chipping and dislodging the plug from its
position
Problem:
Riser Top plug is made up of Refractory material with strainer ring inside and welded with clits
along riser internal periphery. The same was required to be opened and removed for Riser
inspection by Licensor and BGR inspection team. While removing the same it had to be broken
in July-22 shut down before it comes out from its position.
Dismantled Plug- July 2022 Position of plug
Shut down of INDMAX unit in Jul’22
(Almost 3 days for plug dismantling and 2 days for recasting with metallic shuttering etc.)
Methodology:
16 mm dia MS rod was in-house heated and made thin from one end so that the same can hit
the minor annular sealing space available on neck to neck basis. The length of the rod is kept in
such a way that hammering can be done by standing outside on platform available to achieve
maximum hammering effort on pin point manner without damaging the plug body / riser internal
surface. This precise hammering effort turns the annular sealing material lose and facilitates the
plug removal by pulling the same through chain pulley block.
Page | 134
400 mm
1400 mm
TOOL
Removed Plug- Without Damage
Analysis:
Pinpointed hammering effort achieved by using the in-house modified tool
Corrected action:
After required annular chiseling the plug gets lose at its position without getting any damage on
its body .
Benefits realized:
1. Saving of Refractory material.
2. Saving of Turn-around time (approx. 2 days) for making the new plug
3. Cost saving of new plug.
4. Early plug removal to facilitate man entry and inspection.
Page | 135
Case Study-3
Summary Sheet
Unit category Utility unit
Unit Hydrogen Generation Unit
Problem Type Hot spot in reformer tubes
Solve Method Analysis and troubleshooting
Report No.
Year / Month 2022/May
Title of the report Giraffe neck pattern in reformer tubes
Problem Hot spot (giraffe neck pattern) in reformer tubes post start-up
Solution Steaming of reformer catalyst
Problem:
Red hot spots were observed in total 6 no. tubes of the top fired reformer (tube no. 25 and 26
of the C-pass, tube no. 11 and 12 of B-pass and tube no. 11 and 12 of D-pass).
The hot spots were observed in top portion of tubes in the pattern of giraffe neck. Hot spots in
the tubes are detrimental for tube life.
Temperature of the tubes at hot spots was ~830°C against temperature in other tubes ~800°C
(~30°C higher than other tubes at same height in reformer).
The problem was 1st observed after start-up of unit in last week of Feb’22 and was observed till
next shutdown in last week of May’22 (total duration: 3 months)
Observation:
The hot spot (giraffe neck pattern) was 1st observed after start of unit in the top portions of 6
tubes. There was no major change in hot spot with T ‘put, neither the CH4 slippage from reformer
was observed to be increased.
However, appearance of hot spots is detrimental for tube life. Also, temperature of the tubes at
hot spots was ~830°C against temperature in other tubes ~800°C (~30°C higher than other tubes
at same height in reformer).
Methodology:
Observation → brainstorming → Root cause analysis → discussion with catalyst vendor for all
possible solutions → finalization of solution (steaming) → execution.
Analysis:
There were no signs of hot spots (giraffe neck pattern in reformer tubes) in the operation of unit
before start-up. It was suspected that during shut down, the purging of the system with nitrogen
was not properly carried out. The lab results were showing nil hydrocarbons in 2 consecutive
samples. However, there must have been small pockets of hydrocarbon in the system which
slipped to reformer during shutdown.
Exposure of hydrocarbon to the catalyst in reformer tubes (top portion) in absence of steam
and/or hydrogen resulted in coking.
Page | 136
Later, after start-up, it was suspected that due to deposition of layer of coke on the catalyst in
top portion of 6 tubes (tube no. 25 and 26 of the C-pass, tube no. 11 and 12 of B-pass and tube
no. 11 and 12 of D-pass), no/ limited reforming reaction (reforming reaction is endothermic in
nature) was occurring in the affected portion of tube resulting in hot-spot.
Corrected action:
It was envisaged that the coke layer needs to be removed from the surface/pores of the reformer
catalyst in affected portion of tube. Catalyst vendor also ascertained that such phenomenon is
reversible and can be tackled by carrying out steaming in the reformer catalyst.
Therefore, steaming for catalyst was planned and carried out in 1st opportunity shutdown (last
week of May’22) in consultation with catalyst vendor.
Steaming was carried out as per catalyst vendor (duration, temperature at each stages), The CO2
/ CO and pH was observed in the samples from cold collector and reformer O/L to check for de-
coking during the steaming of the catalyst. The steaming was concluded when no CO 2 / CO was
observed with pH near 7.0 in the cold collector sample and reformer O/L sample.
It is worth mentioning that the hot spots were critically monitored during operation between
last week of Feb’22 and May’22 and checked that it never crossed the limits for max TMT.
Benefits realized:
After starting up the unit (after carrying out the steaming in last week of May’22) on 2 nd Jun’22,
no hot spots (giraffe neck pattern) were observed in the tube no. 11 and 12 of B-pass & tube no.
11 and 12 of D-pass. Very slight hot spots were observed in the tube no. 25 and 26 of the C-pass.
The temperature difference of the hot portion of the tube #25 and #26 in C-pass from the other
tubes at same height was reduced from 30°C to ~8-10 °C.
The unit was operated at 100% T ‘put for 3 days (>80% of design capacity for ~7 days) in 3 rd week
of Jun’22 during PGTR of the unit. No deterioration in hot spots was observed in tube #25 and
#26 of Pass-C. Also, no new hot spots appeared in any tube of the reformer during entire PGTR
attempt and thereafter till date.
Page | 137
Case Study-4
Summary Sheet
Unit category Sulphur Recovery Unit
Unit Tail Gas Treating section of new Sulfur Recovery Unit
Problem Type High back pressure in new SRU
Report No.
Title of the report Choking in quench column of TGT section
Problem Pump suction strained choked with commissioning material
Solution Pump suction strained and line cleaning/ column de-choking
Problem:
No/low flow of quench water was observed in the quench column.
The problem was 1st observed after start-up of unit in third week of Sep’22 and was observed till
end of Sep’22 (total duration: 3 weeks)
Observation:
Very low flow of quench water was observed in quench column in TGT section. Also, back
pressure of the unit was gradually increasing and attained value near tripping limits (actual/ max.
design: 0.6 / 0.8 kg/cm2g)
Methodology:
Observation → brainstorming → Root cause analysis → finalization of solution → execution
Analysis:
Choking was suspected in the quench column of the TGT section. It was cross-checked by
carrying out the pressure survey in the plant (pressure monitoring through various PTs installed
in the unit). Also, it was observed that the quench water flow to the quench column was very
low resulting in frequent increase in temperature of the quench column.
It was suspected that sulfur slippage was occurring to quench column resulting in choking in the
section. Also, it was suspected that certain material (probably debris) mixed with sulfur was
choking the quench water pump strainer.
Corrected action:
Unit was taken under shutdown, column was opened for inspection and found that the demister
at the column top O/L was choked with sulfur.
Also, pump strainer was found to be choked with debris (commissioning debris in the line
accumulated over time) and choked the pump suction strainer.
Benefits realized:
With the cleaned strainer, flow of quench water to the column was maintained post start-up.
Also, no further signs of choking were observed in the quench column till date.
Page | 138
Case Study-5
Summary Sheet
Unit category OM&S
Unit New TTL loading bay
Problem Type Vibration in Bay & pipeline during loading & unloading
Report No.
Year / Month 2023/ February
Title of the report Hammering of pipeline at New TTL bay
Problem Vibration in Bay & pipeline during loading & unloading
Solution Hammering of pipeline has been reduced & system has been more
efficient.
Problem:
Since commissioning of New TTL bay there was significant hammering in loading bays &
associated pipelines while loading of products in tank trucks. Fluctuation in pump Discharge
pressure at pump house was also observed because of hammering.
Since commissioning of New TTL bay in June-2021.
Observation:
➢ Maximum hammering was observed in HSD loading bays and it occurred at the time of
start & finish while each compartment of tank truck are loaded.
➢ At a time 2 Nos. of HSD pumps were operating and the discharge valve of both these
pumps were throttled.
➢ The total Flow requirement when all the 4 HSD bays are loaded at a time is 220m^3/hr.
➢ It was noticed that when the pressure in upstream of DCV in the bay reduced below
2Kg/cm^2 there was a lag in DCV closing time and fluid flowed to tank truck more than
the setting in batch controller.
➢ The vibrations damper was installed in HSD header line at approx 70m away from the
bay.
➢ The bypass of minimum flow control valve of pump was kept open to dampen the
Vibrations.
➢ The downstream of minimum flow control valve was connected to pump suction line at
a distance of 15m away from pump suction.
➢ The valve of recirculation line at TTL bay of HSD was throttled to dampen the vibrations.
Analysis:
➢ The BEP of HSD pump was 240m3/hr with differential pressure of 7.9kg/cm2and
Maximum Flow demand at TTL bay was 220m3/hr. In-spite of the same 2 Nos. of HSD
pumps were running at a time with discharge valve of both pump in throttled position
for catering to the flow demand of bay.
Page | 139
➢ Presence of a 90-degree bend at a distance less than 5 times of pipe diameter in

downstream of DCV, which leads to improper functioning of DCV.
➢ The vibration dampers were installed in HSD header line at approx 70m away from the
bay which is nonstandard practice.
➢ Downstream of minimum flow control valve was connected to pump suction line just at
a distance of 15m away from pump suction. This could lead to premature failure of pump
as the minimum flow control valve downstream pressure is high (~6- 7.5kg/cm^2g) and
pump suction line pressure is very low(~0.1kg/cm^2g).
➢ Anti-cavitations trim was not installed inside DCV which can be the major cause for
hammering.
Corrected action:
➢ The impeller of pump was trimmed from Rated diameter to 255mm to lower the
discharge pressure of pump and compared to earlier lesser throttling was done vide
discharge valve to shift the operating point in performance curve.
➢ The bend was shifted to approximate distance of 15 times of pipe diameter from DCV.
➢ In new TTL, 2 Nos. of vibration dampers were installed over HSD main header line vary
near to loading bay and another 1No. each were installed directly over 2 no. individual
loading lines at bays.
➢ Downstream of minimum control valve to be connected to far away from pump suction.
➢ Anti cavitations trim was installed inside DCV of all the TTL bays.
Benefits realized:
➢ All the bays of TTL are operating properly and no hammering/vibrations observed at all
loading points/bay & its associated pipelines.
➢ There is no fluctuation of discharge pressure of pump because of hammering.
➢ Single HSD pump is in operation now and the entire TT Loading demand of HSD can be
possible with energy savings (one motor operation).
**************
Page | 140
Complied By: Urvashi Aggarwal, AMPS

Refineries Headquarters,
New Delhi
Page | 141

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COMPENDIUM

18 Troubleshooting of intermittent increase in HCU RGC Drive Turbine JB 68

2. Increase in leaching of chloride from CCRU catalyst observed.

3. Probability of increase of moisture content in reactors loop checked – CCR

6. As per advisory from unit licensor, this DP decreased to 1.1 kg/cm2.

8. Trend for DP across RDZ and R-1:

Observation and Analysis:

Before condenser tubes After condenser

NSU Feed bottom exchanger 01-EE-001 cleaning

after feed control (Feed CV OP: 100%, bypass also

5. Screen after additional support:

Description Design PGTR 01.01.2022 June’22 Remarks

DIH pumpback 13.5 12.5 11 Flow to be increased to

Corrective actions taken:

Corrective actions taken:

Deaerator Stripping steam, Dissolved oxygen in Condensate

0.2 4000-4500 0.93 reduced

Duration of Problem: 18 Aug’22-20 Aug’22

KHT Rundown Sulphur

Sample Name: KHT Stripper Bottom on 18.08.2022

100 227 4.6

Sample Name: Heart cut (KHT FEED) on 18.08.2022

Same exercise was done for 2061-E-01 (1/2) & 2061-E-11

SN Reactor effluent Sulphur, ppm

Corrected action: On 20.08.2022 @ 20:00 hrs. KHT shutdown was taken.

2061-E-01(2) – KHT combined feed

Duration of Problem: 1-4 Aug ‘22

Results of off-spec tank Tk-001A dated 1.8.2022.

Parameters UOM Result

2.7 2.8 3.0

• MAB discharge pressure was decreased from 3.7kg/cm2g to 3.47kg/cm2g due to

Duration of Problem: From 04.09.2022 to 14.11.2022

S.no. Action taken Observation

S-2 C/D S-2 E/F S-2 G/H

BFW from TPS

Figure 1: Schematic of BFW injection in overhead condensers

Flash zone pressure trend

Duration of Problem: From 28.02.2023 to 01.03.2023

Duration of Problem: Feb’23

Observation: Increased nitrogen consumption was observed during activation cycle.

Duration of Problem: From 20.10.2022 to 24.11.2022

Observation: Pressure drop was increasing and affecting reactor regeneration.

Duration of Problem: From 20.08.2022 to 24.11.2022

Duration of Problem: From 15.08.2021 to 24.11.2022

Methodology: Control valve opened to analyze the problem during Nov-Dec`22.

• Metallic piece removed and valve internals checked for damage.

Duration of Problem: For 6 months after commissioning.

Duration of Problem: From 07.03.2023 to 08.03.2023.

Observation: Sweet gas H2S was found higher than design.

Duration of Problem: From 01.10.2021 to 24.11.2022

Corrected action to Sustain unit operation:

Case Study -10

Fig: Hot tapping on 18” Cooling water supply line

• Troubleshooting carried out without unit shutdown.

Duration of Problem: Since unit commissioning.

Duration of Problem: Since unit commissioning.

Duration of Problem: Nov’22-Dec’22

Duration of Problem: Since Commissioning to Dec’22

Checking of pump internals

Flinger sleeve Impeller Thrust Bearing

Solution To rectify the vibration issue at operating RPM, in-situ dynamic

Problem: High Vibration in CDU ID Fan

Duration of Problem: Problem was resolved after dynamic balancing in Mar 23

Duration of Problem: 16th June’22 to 19th June’22