Kerosene Hydrodesulphurization Manual Procedures
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Questions and Answers

What should the holder do if the Holder department ceases to exist?

The holder shall return the controlled copy to the Head of Department (HOD).

What happens after a total of 20 revisions or a major change in process to the manual?

The manual will be re-issued, and the revision numbers of all chapters will reset to 00.

What is the document number and revision number of the operating manual?

The document number is OPT/01/KHDS/01 and the revision number is 02.

What major amendment was noted on the amendment sheet regarding control valve hunting?

<p>A provision was added for installing a control valve downstream (FV-2404) to avoid hunting.</p> Signup and view all the answers

What specific valve set points were changed according to the amendments?

<p>The opening set point for UV, 17UV1821A/B was changed from 70% to 40%, and closing from 30% to 20%.</p> Signup and view all the answers

When was the last amendment date recorded in the document?

<p>The last amendment date recorded is 10/07/2023.</p> Signup and view all the answers

What kind of policy was updated in the last amendment?

<p>The QEHS and Energy policy was updated.</p> Signup and view all the answers

What is covered in section 6.5 of the operating manual?

<p>Troubleshooting procedures.</p> Signup and view all the answers

What are the two types of shutdowns mentioned in section 7.1?

<p>Short period shutdown and long period shutdown.</p> Signup and view all the answers

What is the purpose of the reaction section leak test in section 5.4?

<p>To ensure there are no leaks in the reaction section with hydrogen.</p> Signup and view all the answers

What is the focus of section 5.6 in the operating manual?

<p>Catalyst treatment processes.</p> Signup and view all the answers

In section 7.2, what is necessary for restarting the unit after a shutdown?

<p>Specific protocols depending on the time and nature of the shutdown.</p> Signup and view all the answers

What does section 6.1 summarize in the operating manual?

<p>Summary of operating parameters.</p> Signup and view all the answers

What is the first step in the chronology of start-up operations as per section 5.2?

<p>Initiate preparatory procedures.</p> Signup and view all the answers

What does section 5.7 involve regarding the stripper and naphtha stabilizer?

<p>Start-up procedures for these units.</p> Signup and view all the answers

What is emphasized in section 6.4 regarding the reaction section?

<p>Adjustment of operating conditions.</p> Signup and view all the answers

What is the maximum allowable value of sulphur content in hydrotreated kerosene according to the specifications?

<p>The maximum allowable value of sulphur content is 8 wt ppm.</p> Signup and view all the answers

What is the specific gravity specification for hydrotreated kerosene and how does it compare with the provided cases?

<p>The specific gravity specification is a minimum of 0.780, and all cases meet this with a value of 0.793.</p> Signup and view all the answers

According to the specifications, what is the freezing point limit for hydrotreated kerosene?

<p>The freezing point limit is a maximum of -47°C.</p> Signup and view all the answers

In the specifications, what is the maximum volume percentage for total aromatics in hydrotreated kerosene?

<p>The maximum volume percentage for total aromatics is 20.6%.</p> Signup and view all the answers

What is the ASTM D86 boiling point specification for hydrotreated kerosene at the 50% volume point?

<p>The ASTM D86 boiling point specification at the 50% volume point is 205°C.</p> Signup and view all the answers

What is the designed on-stream factor for the unit in hours per annum?

<p>8000 hours per annum</p> Signup and view all the answers

What is the minimum operating cycle recommended for the unit?

<p>3 years between turnarounds</p> Signup and view all the answers

How many days of design feedstock can the unit process in three years?

<p>1095 days</p> Signup and view all the answers

At what percentage of design capacity can the unit operate while maintaining on-specification products?

<p>40%</p> Signup and view all the answers

What is the design flow rate for the KHDS feed in TPH?

<p>75.6 TPH</p> Signup and view all the answers

How long can the unit ideally operate continuously at 100% capacity?

<p>For a minimum of 3 years without turnarounds</p> Signup and view all the answers

What should be the condition of products produced when the unit operates at turndown capacity?

<p>On-specification products</p> Signup and view all the answers

What document outlines the operating manual for the Kerosene Hydrodesulfurization unit?

<p>Doc.No.: OPT/01/KHDS/01</p> Signup and view all the answers

What is the purpose of the design and engineering practices advised for the unit?

<p>To achieve reliable and efficient operation.</p> Signup and view all the answers

When was the last revision date noted for the operating manual of the unit?

<p>10.07.2023</p> Signup and view all the answers

What is the purpose of the operating manual for the Kerosene Hydrodesulphurization unit?

<p>To provide guidelines and procedures for operating the unit safely and efficiently.</p> Signup and view all the answers

What does 'Management of Change' refer to in the context of this operating manual?

<p>It refers to the systematic approach to managing changes in operations, equipment, or personnel to minimize risks.</p> Signup and view all the answers

How many pages are listed in the table of contents for the Kerosene Hydrodesulphurization operating manual?

<p>584 pages.</p> Signup and view all the answers

What is the issue date of the operating manual for the Kerosene Hydrodesulphurization unit?

<p>01.07.2022.</p> Signup and view all the answers

Which annexure contains the format for panel engineer validation?

<p>Annexure A.</p> Signup and view all the answers

What is the revision number listed for the operating manual?

<p>Revision No.: 02.</p> Signup and view all the answers

What kind of recommendations may be included in Annexure B?

<p>Recommendations related to Area Engineer validation.</p> Signup and view all the answers

What does the abbreviation 'SIC' stand for in Annexure C?

<p>System Integrator Certification.</p> Signup and view all the answers

What does the term 'operating manual' generally imply in industrial settings?

<p>A document providing instructions for safe and efficient operation of equipment or processes.</p> Signup and view all the answers

What is the significance of having separate formats for different engineers’ validations?

<p>It ensures that each specific area of validation is adequately addressed according to the role and responsibilities.</p> Signup and view all the answers

Flashcards

Manual Re-issue

A new issue of the manual is released when there are 20 revisions or a major process change.

Manual Re-issue after Merger

A new issue of the manual is released to reflect changes after a merger with BPCL.

Revision Number Reset

A new issue of the manual will have all chapter revision numbers reset to 00.

RO Installation in FV-2404

The manual is updated to include the provision of an RO installation in the FV-2404 downstream area. This is done to prevent valve hunting.

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Additional Isolation Valve in Makeup Line

An additional isolation valve is added to the kerosene makeup line leading to the ASA vessel. This aims to prevent failure and accidental mixing during batch preparation.

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Valve Set Point Adjustment for 17UV1821A/B

The set point for opening the drain valve 17UV1821A/B is changed from 70% to 40%. Additionally, the closing point is changed from 30% to 20%.

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Updated QEHS and Energy Policy

The manual's QEHS and Energy Policy are updated and incorporated into the latest version of the manual.

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Reaction Section

The section of the process where the feedstock (kerosene) is treated with hydrogen to remove sulfur compounds.

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Start-Up Operations

The procedure for getting the Kerosene Hydrodesulfurization (KHD) unit ready for normal operation. It includes steps like pressurization, leak testing, catalyst treatment, and startup of equipment.

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Short Period Shutdown

A temporary shutdown of the unit that lasts for a short period, usually less than 48 hours.

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Long Period Shutdown

A longer shutdown, lasting more than 48 hours, which often involves maintenance, inspection, or catalyst unloading.

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Shutdown Followed by Maintenance, Inspection, or Catalyst Unloading

A shutdown of the unit for maintenance, inspection, or catalyst unloading, usually followed by a complete restart.

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Steam-Out

Involves removing steam from the process equipment to prevent corrosion and ensure safe operation.

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Restart After a Shutdown for Less Than 48 Hours

Restarting the KHD unit after a short period shutdown (less than 48 hours).

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Restart After a Shutdown for More Than 48 Hours

Restarting the KHD unit after a long period shutdown (more than 48 hours).

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Restart After an Emergency Shutdown

A restart procedure that is implemented following an unplanned shutdown caused by an emergency.

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Operating Manual

A document that outlines detailed instructions and procedures for operating a specific unit, such as a kerosene hydrodesulphurization (KHDS) unit.

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Kerosene Hydrodesulphurization

The process of removing sulfur from kerosene using hydrogen.

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Annexure

A section in a document that provides additional information or supporting details, often presented in a separate format.

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Operating Manual

An organized collection of information or documents that outline the various parts of a system, facility, or process. In this context, it refers to the complete document containing operating manuals, annexures, and other important information.

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Management of Change

A formal procedure for managing changes to a system or process, ensuring safety and minimizing risk.

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Revision

A formal record of changes made to a document, including the date of revision, the author, and the reason for the change.

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Recommendation

A process improvement suggestion or an idea proposed to enhance the operation or safety of a unit.

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QEHS

A procedure or a system that aims to improve the safety, environmental performance, and health aspects of operations.

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Energy Policy

A unit's ability to produce a desired output while minimizing the energy consumption involved.

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On-stream Factor

The amount of time a unit is expected to operate continuously per year, typically measured in hours.

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Operating Cycle

The minimum operating time between scheduled maintenance shutdowns, typically measured in years.

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Turndown Capability

The operational capacity of a unit when it's running at its lowest possible rate while still producing the desired products.

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KHDS Feed Specifications

The characteristics of the raw material fed into the kerosene hydrodesulphurization (KHDS) unit.

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Design Flow Rate

The expected flow rate of kerosene feed into the KHDS unit, typically measured in metric tons per hour (TPH).

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Hydrotreated Product Flowrate

The amount of a product produced per hour, measured in kilograms.

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Specific Gravity

A measure of the density of the product compared to water at a specific temperature. A higher value means the product is denser.

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ASTM D86 Distillation

A test that measures the temperature at which different percentages of the product evaporate. It helps indicate the product's volatility and potential for vaporization.

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Reid Vapor Pressure (RVP)

The pressure at which the product will vaporize at a specific temperature. A lower value means the product is less volatile.

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Sulfur Content

A test to measure the amount of sulfur present in the product expressed in parts per million (ppm) by weight. Lower values mean the product is cleaner.

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Study Notes

Operating Manual Revisions and Procedures

  • Revision Control: If there are 20 revisions or major process changes, the manual is re-issued, resetting all chapter revisions to 00.
  • Holder Responsibility: If the Holder department ceases to exist, the controlled copy is returned to the HOD.
  • Manual Information: The provided text is part of an operating manual for a Kerosene Hydrodesulphurization unit (OPT/01/KHDS/01), currently on Issue 02, Revision 02 (dated 01.07.2022 and 10.07.2023). The manual has many chapters and annexures.

Specific Amendments

  • Amendment 1 (01/07/2022): New issue released after merger with BPCL. Included RO installation provisions.
  • Amendment 2 (31/03/2023): Added isolation valve in makeup kerosene to avoid hunting of control valve, and further isolation valve in makeup Kerosene to ASA vessel line for batch preparation. Altered set points for UV valves (17UV1821A/B) from 70% to 40% opening and 30% to 20% closing.
  • Amendment 3 (10/07/2023): Updated QEHS and Energy policies.

Operating Manual Contents (Examples)

  • Table of Contents: Includes sections on start-up operations, pressurization, leak tests, catalyst treatment, capacity increasing, normal operation, process control, troubleshooting, and shutdown/restart procedures.
  • Chapter 6 - Normal Operating Procedure: Details the normal unit operation, operating parameters summary, process control philosophy, operating parameter adjustments, troubleshooting, and alarm/trip settings.
  • Chapter 7 - Normal Shutdown and Restart: Provides detailed procedures for shutdown, and also restarts for short-term and long-term shutdowns, maintenance, inspection, and catalyst unloading circumstances.
    • Includes numerous specific restart instructions based on shutdown duration.
  • Annexures: Include forms for panel engineer, area engineer, and SIC validations along with related recommendations.
  • Management of Change: Included within the manual as a specific annexure.

Specific Equipment Operations (Examples)

  • Positive Displacement Pumps: Start-up tasks include checking mechanical jobs, oil flushing, strainer check, alignment, verifying motor rotation, adjusting stroke, monitoring pump parameters, and handling dry-run and backflow avoidance by bleeding.
  • Shutdown Procedures: Specific order for pumps, including steps to stop the pump, close valves, and drain liquid for maintenance (if necessary). Troubleshooting includes checking suction/discharge pressure issues and mechanical seal leakage.

Unit Design and Operation

  • On-Stream Factor: The unit is designed for 8000 operating hours per year.
  • Turnarounds: Minimum 3-year operating cycles between shutdowns.
  • Turndown Capability: Can operate at 40% of design capacity for making products.
  • Feed Specifications: Provides table about design flow rate (75.6 TPH) for product SR Kerosene.
  • Product Specifications: Detailed product specification tables for hydrotreated kerosene, including specifications like:
    • Specific gravity
    • ASTM D86 vol% figures
    • RVP, TVP
    • Sulphur
    • Freezing point
    • Smoke point
    • Color
    • Cetane Index
    • Total Aromatics

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Description

This quiz covers the revisions and specific amendments to the Operating Manual for the Kerosene Hydrodesulphurization unit. It includes details about revision control, holder responsibilities, and major amendments made since the last issue. Test your understanding of the procedural changes and their implications in the operation of the unit.

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