OPT 001 Operating Manual Common Signed Copy PDF

KHDS OPERATING MANUAL (ISO 9001:2015, ISO 14001:2015 ISO 45001:2018, EnMS 50001:2018) (OPT/01/KHDS/01) BHARAT PETROLEUM CORPORATION LIMITED BINA, MADHYA PRADESH  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL...

KHDS OPERATING MANUAL (ISO 9001:2015, ISO 14001:2015 ISO 45001:2018, EnMS 50001:2018) (OPT/01/KHDS/01) BHARAT PETROLEUM CORPORATION LIMITED BINA, MADHYA PRADESH  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 1 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 POLICIES Date of Rev. :- 10.07.2023 INTEGRATED MANAGEMENT SYSTEM  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 2 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 POLICIES Date of Rev. :- 10.07.2023 EnMS  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 3 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 DISTRIBUTION LIST Date of Rev. :- 10.07.2023 1. Distribution of this Manual shall be controlled by IMS Core Team Member. DISTRIBUTION LIST The controlled copies of this manual are distributed as per the list given below: Sr. Copy No. Controlled copy holder No. 01 -- MASTER COPY (HOD) 02 00 SERVER COPY 03 01 MANAGER KHDS 04 02 KHDS PANEL 05 03 KHDS SHIFT INCHARGE 06 04 AREA MANAGER 07 05 KHDS AREA INCHARGE 2. The Master copy of this manual shall be maintained by IMS Core Team Member. 3. Controlled copy of manual shall be issued as per approved distribution list, which shall be revised under authority of HOD as and when required. Manual can also be issued to other officials with due approval of HOD. 4. In case of Holder department ceases to exit, the controlled copy shall be returned to HOD by the holder. 5. If there are total no of 20 revisions in the entire manual or any major change in process, the manual will be re-issued from 1, 2, 3 ………. After re-issue the revision number of all the Chapters of the Manual will turn to be 00.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 4 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 AMMENDMENT Date of Rev. :- 10.07.2023 AMMENDMENTS SHEET ISSUE REMARK Sr. No. DOC. NO. DETAILS OF /REV. DATE AMMENDMENTS NO. 01/07/2022 NEW ISSUE RELEASED AFTER 1 02/00 OPT/01/KHDS/01 MERGER WITH BPCL Provision of RO installation in 17- Page-51 2 02/01 FV-2404 downstream to avoid OPT/01/KHDS/01 31/03/2023 hunting of control valve Provision of additional isolation SOP/01/KH valve in makeup Kerosene to ASA DS/063, 3 OPT/01/KHDS/01 02/01 31/03/2023 vessel line for batch preparation Page-306 to avoid failure/Passing of other isolation valve. The set point for opening of drain Page- 211 UV, 17UV1821A/B (ON/OFF valve) 4 OPT/01/KHDS/01 02/01 31/03/2023 changed from 70 % to 40% of 17LT 1821 A/B and closing of UV changed from 30 % to 20%. 5 OPT/01/KHDS/01 02/02 10/07/2023 QEHS and Energy policy updated.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 5 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 USER GUIDE Date of Rev. :- 10.07.2023 USER GUIDE INTRODUCTION This manual is the guiding part of the operating activities of Kerosene Hydrodesulphurization Unit in BINA, Refinery. This manual is a representation and documentation of the sound operating practice which has evolved over the years of operation. PURPOSE To describe the operating system in above unit. To serve as a guide/training aid to all the employees of the unit. SCOPE This manual details the feed, products, utilities, equipment's, etc., associated with the above unit. The activities of the key functions which affect the process along with Start-up, Shutdown, and emergency procedures along with brief description of the equipment are detailed here. PREPARATION, REVIEW, APPROVAL This manual is prepared by the KHDS section, and to this effect, concerned manager shall be signing in the 'PREPARED BY' column in the cover sheet of this manual. Each edition of the Manual is released after review by the Section Head. To this effect, the Section Head shall, be signing in the 'REVIEWED BY' column of the cover page. This Manual shall be approved by the Department Head in the 'APPROVED BY' column of the cover page. IDENTIFICATION AND DISTRIBUTION The controlled copies of the manual shall be distributed to various personnel as per the 'Distribution List'. Such copies shall be clearly identified by 'CONTROLLED COPY' stamp on the cover sheet of the manual. The responsibility for distribution of this manual shall belong to the Department Head.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 6 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 USER GUIDE Date of Rev. :- 10.07.2023 AMENDMENTS Only Department Head is authorised to record changes to this manual and approve them. When changes are incorporated to any page of this manual, the whole section shall be reissued with updated revision status (incremented by 1). The amended sections shall be distributed to the controlled copyholders by the Department Head along with the amendment sheet and covering letter. The manual holders shall be responsible for inserting the amended section along with the amendment sheet in the manual and destroy the obsolete section. The manual holders shall sign and return the covering letter as token of updating his manual to Department Head and destroy the obsolete section. MASTER COPY The master copy of Manual shall be maintained by Department Head. In case of any doubt, regarding the contents of the manual, check with the Unit Manager. POLICY FOR HAND WRITTEN CHANGES No hand written changes shall be done in this manual. REVISION OF MANUALS Currently, the operating manuals are reviewed as and when required based on the developments in the process plants. In addition to the above, all operating manuals of each plant shall be reviewed by the Unit Head prior to 31st of January and the changes shall be approved by the Departmental Head (Process). NOTICE 1. This Manual is property of Bina Refinery and no part of it can be copied or photocopied or reproduced in any other way without the prior consent from the department head in writing. 2. The manual holders shall return their copies to the Department Head a. When leaving the organisation temporarily / permanently. b. When asked by the department.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 7 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 USER GUIDE Date of Rev. :- 10.07.2023 INDEX 1. Section -1 KHDS Operation 2. Section -2 DCS operation 3. Section -3 Pre-commissioning Procedure 4. Section -4 Training Module  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 8 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 TABLE OF CONTENTS Table of Contents INTEGRATED MANAGEMENT SYSTEM....................................................................................... 1 EnMS............................................................................................................................................... 2 SECTION-1.................................................................................................................................. 19 OPERATING MANUAL............................................................................................................. 19 Chapter - 1..................................................................................................................................... 20 Introduction............................................................................................................................... 20 1.1 INTRODUCTION.............................................................................................................. 21 1.2 UNIT CAPACITY.............................................................................................................. 21 1.3 ON STREAM FACTOR AND RUN LENGTH................................................................. 21 1.4 PLANT TURNDOWN CAPABILITY............................................................................... 22 1.5 FEED AND PRODUCT SPECIFICATION SPECIFICATIONS...................................... 22 1.6 EQUIPMENT LIST............................................................................................................ 31 Chapter 2....................................................................................................................................... 48 2.1 PROCESS DESCRIPTION................................................................................................ 50 2.2 UTILITY SYSTEM............................................................................................................ 54 2.3 KHDS HEATER FIRING AND DAMPER CONTROL PHILOSOPHY......................... 56 2.4 OFFSITE SYSTEM............................................................................................................ 58 Chapter - 3..................................................................................................................................... 60 CHEMICAL REACTIONS AND CATALYSTS........................................................................ 60 3.1 INTRODUCTION.............................................................................................................. 61 3.2 CHEMICAL REACTIONS................................................................................................ 62 3.2.1 Chemical Reactions.................................................................................................................... 62 3.3 CATALYST........................................................................................................................ 66 3.3.1. Catalyst characteristics............................................................................................................. 66 3.3.2. Catalyst mechanism.................................................................................................................. 67 3.3.3. Catalyst contaminants.............................................................................................................. 67 3.3.4. Temporary poisons................................................................................................................... 68 3.3.5. Permanent poisons................................................................................................................... 68  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 9 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 3.4 PROCESS VARIABLES.................................................................................................... 70 3.4.1 Independent Variables........................................................................................................ 70 The process variables are.................................................................................................................... 70 3.4.2 Temperatures (WABT: Weight Average Bed Temperature)............................................... 71 3.4.3 Liquid Hourly Space Velocity............................................................................................... 73 3.4.4 Hydrogen Partial Pressure.................................................................................................. 74 3.4.5 Hydrogen Recycle Ratio...................................................................................................... 74 3.4.6 Catalyst Activity................................................................................................................... 75 3.4.7 Action of Process Variables on Reactions........................................................................... 75 CHAPTER – 4.............................................................................................................................. 78 PRE-COMMISSIONING............................................................................................................. 78 PROCEDURE / PREPARTION................................................................................................... 78 FOR START UP........................................................................................................................... 78 4.0 INTRODUCTION.......................................................................................................... 79 4.1 MECHANICAL COMPLETION.................................................................................. 79 4.2 PRE-COMMISSIONING - INTRODUCTION............................................................. 80 4.3 PRECOMMISSIONING ACTIVITIES......................................................................... 81 4.4 INSPECTION................................................................................................................. 82 4.5 PREPARATION OF UNIT............................................................................................ 83 4.6 BROAD GUIDELINES FOR CHECKING A UNIT FOR COMPLETENESS (CHECK- LISTING)................................................................................................................ 84 4.7 PREPARTION OF START UP BY LICENSOR.......................................................... 95 4.7.1 CHRONOLOGY OF OPERATIONS........................................................................ 95 4.8 EQUIPMENT AND UNIT INSPECTION BY LICENSOR......................................... 97 4.9 PRELIMINARY OPERATIONS................................................................................. 102 4.10 DRYING OUT THE REACTION SECTION.......................................................... 105 4.11 CATALYST LOADING.......................................................................................... 108 CHAPTER - 5............................................................................................................................. 130 COMMISSIONING ACTIVITIES AND FIRST START-UP................................................... 130 5.0 FIRST START UP....................................................................................................... 131 5.1 STATUS OF THE UNIT............................................................................................................ 131  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 10 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 5.2 CHRONOLOGY OF START-UP OPERATIONS...................................................... 132 5.3 PRESSURIZATION OF LP SECTIONS......................................................................... 135 5.4 REACTION SECTION LEAK TEST WITH HYDROGEN.......................................... 135 5.5 FILLING / ESTABLISHING LEVELS / DEWATERING TO SLOPS IN LP SECTIONS 137 5.6 CATALYST TREATMENT........................................................................................ 143 5.7 STRIPPER & NAPHTHA STABILIZER START-UP............................................... 153 5.8 INCREASING CAPACITY............................................................................................ 154 CHAPTER – 6............................................................................................................................ 159 NORMAL OPERATING PROCEDURE................................................................................... 159 6.0 NORMAL OPERATION OF THE UNIT................................................................... 160 6.1 SUMMARY OF OPERATING PARAMETERS........................................................ 160 6.2 CONTROL PHILOSOPHY OF THE PROCESS – REACTION SECTION.......... 171 6.3 OPERATING PARAMETERS.................................................................................... 172 6.4 ADJUSTMENT OF OPERATING CONDITIONS – REACTION SECTION.......... 177 6.5 TROUBLESHOOTING............................................................................................... 178 6.6 SET VALUES OF ALARM/TRIP INTERLOCK....................................................... 185 CHAPTER – 7............................................................................................................................ 219 NORMAL SHUTDOWN AND RESTART OF THE UNIT..................................................... 219 7.0 SHUTDOWN PROCEDURE AND RESTART OF THE UNIT.............................. 220 7.1 NORMAL SHUTDOWN............................................................................................. 220 7.1.1 GENERAL........................................................................................................................... 220 7.1.2 SHORT PERIOD SHUTDOWN............................................................................................. 220 7.1.3 LONG PERIOD SHUTDOWN............................................................................................... 222 7.1.4 SHUTDOWN FOLLOWED BY MAINTENANCE, INSPECTION, OR CATALYST UNLOADING.. 224 7.1.5 SHUTDOWN OF STRIPPING SECTION AND NAPHTHA STABILIZER SECTION..................... 225 7.1.6 STEAM-OUT.............................................................................................................................. 226 7.2 UNIT RESTART.......................................................................................................... 227 7.2.1 RESTART AFTER A SHUTDOWN FOR LESS THAN 48 HOURS.............................................. 227 7.2.2 RESTART AFTER A SHUTDOWN FOR MORE THAN 48 HOURS........................................... 227 7.2.3 RESTART AFTER AN EMERGENCY SHUTDOWN................................................................. 227  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 11 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 7.3 EMERGENCY SHUTDOWN..................................................................................... 228 7.3.1 GENERAL.................................................................................................................................. 228 7.3.2 AUTOMATIC EMERGENCY SHUTDOWN / SAFETY LOGIC SEQUENCES.............................. 229 7.3.3 EMERGENCY DEPRESSURIZATION SYSTEM....................................................................... 229 7.3.4 REACTION SECTION SHUTDOWN AFTER EMERGENCY DEPRESSURIZATION.................... 230 7.3.5 FIRE IN THE UNIT (OPERATOR INITIATED SHUTDOWN).................................................... 231 7.3.6 RECYCLE COMPRESSOR FAILURE...................................................................................... 231 7.3.7 REACTOR HEATER TUBE RUPTURE.................................................................................... 231 7.3.8 FEED PUMP FAILURE............................................................................................................... 232 7.3.9 MAKE-UP GAS FAILURE............................................................................................................ 233 7.3.10 REACTOR HEATER SHUTDOWN.............................................................................................. 233 7.3.11 WASH WATER PUMP FAILURE............................................................................................... 234 7.3.12 REACTOR EFFLUENT AIR COOLER........................................................................................... 235 7.3.13 UTILITY FAILURES................................................................................................................... 235 7.4 IMPORTANT SHUTDOWN NOTES......................................................................... 236 CHAPTER – 8............................................................................................................................ 237 CATALYST SPECIFICATIONS AND SPECIAL PROCEDURES......................................... 237 8.1 SUPPLIER................................................................................................................... 238 8.2 CATALYST SPECIFICATIONS................................................................................ 238 8.3 PACKAGING, HANDLING AND STORAGE.......................................................... 245 8.3.1 PACKAGING.............................................................................................................................. 245 8.3.2 HANDLING RECOMMENDATIONS............................................................................................ 245 8.3.3 STORAGE RECOMMENDATIONS.............................................................................................. 246 8.4 CATALYST SULPHIDING........................................................................................ 246 8.5 CATALYST HYDROGEN STRIPPING.................................................................... 247 8.6 CATALYST EX-SITU REGENERATION................................................................. 247 8.7 CATALYST UNLOADING........................................................................................ 247 8.7.1 USED CATALYST UNLOADING FOR DISPOSAL.......................................................................... 248 8.7.2 UNLOADING FOR EX-SITU REGENERATION.............................................................................. 248 8.7.3 UNLOADING FOR REACTOR VESSEL INSPECTION.................................................................... 249 8.7.4 SPENT CATALYST HANDLING AND FURTHER TREATMENT...................................................... 249  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 12 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 8.9.1 MAIN STEPS.............................................................................................................................. 252 8.9.2 EFFLUENT MANAGEMENT....................................................................................................... 253 8.10 AUSTENITIC STEEL PROTECTION.......................................................................... 253 8.10.1 POLYTHIONIC ACID ATTACK................................................................................................... 253 8.10.2 PROTECTION AGAINST POLYTHIONIC ACID ATTACK.............................................................. 253 8.10.3 PREVENTING THE FORMATION OF POLYTHIONIC ACIDS....................................................... 254 8.10.4 NEUTRALIZATION................................................................................................................... 254 CHAPTER – 9............................................................................................................................ 259 GENERAL EQUIPMENT.......................................................................................................... 259 OPERATING PROCEDURE..................................................................................................... 259 9. GENERAL EQUIPMENT OPERATING PROCEDURES............................................ 260 9.1 CENTRIFUGAL PUMPS............................................................................................ 260 9.2 POSITIVE DISPLACEMENT PUMPS....................................................................... 262 9.3 RECIPROCATING COMPRESSORS............................................................................ 263 9.4 HEATEXCHANGERS..................................................................................................... 267 9.5 STORAGE TANKS..................................................................................................... 269 CHAPTER – 10.......................................................................................................................... 284 SAFETY PROCEDURES.......................................................................................................... 284 10. GENERAL PLANT SAFETY........................................................................................... 285 10.1 IDENTIFICATION OF HAZARDS AND ACTIONS REQUIRED TO BE TAKEN.. 285 10.2 WORK PERMIT PROCEDURE.................................................................................... 285 10.3 MAINTENANCE AND REPAIRS................................................................................ 288 10.4 PREPARATION FOR VESSEL ENTRY...................................................................... 289 10.5 HAZARDOUS AND TOXIC SUBSTANCES.............................................................. 294 10.6 FIRE PREVENTION & FIRE FIGHTING.................................................................... 305 10.7 USE OF LIFE SAVING DEVICE.................................................................................. 307 10.8 SAFE OPERATION OF FURNACES........................................................................... 307 10.9 SAFETY PROCEDURES AND SAFETY IN SAMPLING.......................................... 307 10.10 GENERAL SAFETY GUIDELINES........................................................................... 309 10.11 SAFETY RULES FOR PARTICULAR OPERATIONS............................................. 310 CHAPTER – 11.......................................................................................................................... 313  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 13 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 SAMPLING AND LABORATORY.......................................................................................... 313 ANALYSIS PROCEDURE........................................................................................................ 313 11. SAMPLING PROCEDURE AND LABORATORY ANALYSIS...................................... 314 11.1 SIGNIFICANCE OF EACH ANALYSIS...................................................................... 314 11.2 Recommended methods and frequency.......................................................................... 318 Chapter-12................................................................................................................................... 323 Fire Fighting facilities and communication set-up..................................................................... 323 12.1 Fire Fighting Facilities.................................................................................................... 324 12.2 Communication Setup..................................................................................................... 329 Chapter-13................................................................................................................................... 331 Master blind and RO list............................................................................................................. 331 CHAPTER-14............................................................................................................................. 358 KHDS ELECTRICAL SYSTEM............................................................................................... 358 POWER DISTRIBUTION...................................................................................................... 359 ANNEXURE – I......................................................................................................................... 369 PROCESS FLOW DIAGRAM................................................................................................... 369 ANNEXURE – II........................................................................................................................ 371 STARTUP SKETECHES........................................................................................................... 371 ANNEXURE – III....................................................................................................................... 372 CAUSE AND EFFECT DIAGRAM.......................................................................................... 372 ANNEXTURE – IV.................................................................................................................... 373 MPT CURVE of KHDS HDT Reactor (17-RB-00-101)............................................................ 373 And.............................................................................................................................................. 373 Mail Communication with Licensor........................................................................................... 373 SECTION-2................................................................................................................................ 381 DCS OPERATION..................................................................................................................... 381 1. INTRODUCTION TO BINA REFINERY DCS SYSTEM................................................... 383 1.1 CENTRAL CONTROL ROOM:...................................................................................... 383 1.2 SATELLITE RACK ROOMS:......................................................................................... 383 1.3 KHDS SYSTEM CONFIGURATION............................................................................. 383 1.4 SCHEMATIC OF SYSTEM CONFIGURATION........................................................... 384  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 14 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 2. System Configuration – CENTUM VP.................................................................................. 386 2.1.1 The Field Control Station (FCS).................................................................................... 386 2.1.2 The Engineering / Operator Station (ENG / HIS).......................................................... 386 2.1.3 The Communication Network........................................................................................ 387 3. BASIC CONTROL PHILOSPHY.......................................................................................... 390 3.1 BASIC CONTROL LOOP:............................................................................................. 390 3.2 PROCESS CONTROL METHOD:.................................................................................. 391 3.3 PROCESS CONTROL SYSTEMS:................................................................................. 391 4. FIELD CONTROL STATION & HUMAN INTERPHASE STATION................................ 399 4.1 Field Control station (FCS):‐............................................................................................ 399 4.2 HUMAN INTERFACE STATION (HIS): ‐..................................................................... 400 4.3 INTRODUCATION & TYPE OF HIS:............................................................................ 400 4.4 HIS SPECIFICATION:.................................................................................................... 401 4.5 ADDRESS SETTING FOR FCS & HIS:......................................................................... 401 4.6 HIS Desktop Layout......................................................................................................... 402 4.7 System Message Banner................................................................................................... 403 5. COMMUNICATION NETWORK:........................................................................................ 418 5.1 V‐Net (Communication Bus):........................................................................................... 418 5.2 ETHERNET (Communication Bus)................................................................................. 419 5.3 Communication Gateway Unit (CGW):........................................................................... 419 5.4 Bus Convertor (BCV):...................................................................................................... 419 5.5 DOMAIN CONCEPT: ‐................................................................................................... 419 5.6 FIELD BUS:..................................................................................................................... 420 6. INTRODUCTION TO OPERATION AND MONITORING WINDOWS:.......................... 422 6.1 SYSTEM DEFINED WINDOWS:................................................................................... 422 6.2 USER DEFINED WINDOWS:........................................................................................ 422 6.3 METHOD OF CALLING WINDOWS:........................................................................... 422 7.USER DEFINED WINDOWS................................................................................................ 424 7.1 CONTROL GROUP WINDOW:...................................................................................... 424 7.2 GRAPHIC WINDOW:..................................................................................................... 429 7.3 OVERVIEW WINDOW:.................................................................................................. 431  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 15 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 7.4 TREND WINDOW:.......................................................................................................... 433 8.SYSTEM DEFINED WINDOWS........................................................................................... 440 8.1 OPERATING THE INSTRUMENT FACEPLATE:........................................................ 440 8.2 SYSTEM MESSAGE WINDOW:.................................................................................... 453 8.3 PROCESS ALARM WINDOW:...................................................................................... 461 8.4 OPERATOR GUIDE MESSAGE WINDOW:................................................................. 468 8.5 PROCESS REPORT WINDOW:..................................................................................... 470 8.6 HISTORICAL MESSAGE REPORT WINDOW:........................................................... 473 8.7 TUNING WINDOW:........................................................................................................ 476 8.8 SYSTEM STATUS OVERVIEW WINDOW:................................................................. 482 SECTION-3................................................................................................................................ 483 PRECOMMISSIONING PROCEDURE CHECKLIST MANUAL.......................................... 483 PRECOMMISSIONING PROCEDURE.................................................................................... 484 1. Water flushing of pipelines:................................................................................................ 485 2. AIR CARDBOARD BLASTING OF PIPELINES:............................................................ 486 3. STEAM BLOWING PROCEDURE:.................................................................................. 486 (a.) Procedure:‐............................................................................................................................... 487 (b.) COOLING WATER HEADER FLUSHING PROCEDURE:................................................................... 487 4. FLUSHING PROCEDURE AND CONTI`NUITY CHECK PROCEDURE FOR U/G SYSTEM:................................................................................................................................ 487 (a.) CBD flushing and continuity check:............................................................................................ 487 (b.) CRWS FLUSHING PROCEDURE:................................................................................................... 488 (c.) FLUSHING PROCEDURE FOR OWS:.............................................................................................. 488 (d.) BCS FLUSHING PROCEDURE:...................................................................................................... 489 (e.) BCR FLUSHING PROCEDURE:....................................................................................................... 490 (f.) FIRE WATER HEADER FLUSHING:................................................................................................ 490 5. PUMP TEST RUN PROCEDURE:................................................................................... 491 PRECOMMISIONING CHECKLIST........................................................................................ 493 1. STORM WATER SYSTEM CHECKLIST:...................................................................... 494 2. FIRE WATER HEADER CHARGING CHEKLIST:‐..................................................... 495 3. UG PIPING CHECKLIST:‐.............................................................................................. 496  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 16 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 4. ABOVE GROUND PIPING CHECKLIST....................................................................... 497 5. COOLING WATER HEADER CHARGING CHECKLIST:‐........................................ 498 6. LP STEAM HEADER CHARGING CHECKLIST:‐....................................................... 500 7. MP STEAM HEADER CHARGING CHECKLIST:‐..................................................... 502 8. PLANT AIR HEADER CHARGING CHECKLIST:‐..................................................... 504 9. INSTRUMENT AIR HEADER CHARGING CHECKLIST:‐......................................... 504 10. NITROGEN HEADER CHARGING CHECKLIST:‐.................................................... 505 11. PORTABLE WATER HEADER CHARGING CHECKLIST:‐.................................... 506 12. PRECOMMISSIONING AND COMMISSIONING CHECKLIST OF FLARE HEADER:‐............................................................................................................................. 507 13. PRECOMMISSIONING AND COMMISSIONING CHECKLIST OF CONTROL VALVE:‐................................................................................................................................ 509 14. PRECOMMISSIONING AND COMMISSIONING CHECK LIST OF MOV/ON‐OFF VALVE:‐................................................................................................................................ 510 15. CHECKLIST OF PROPER INSTALLATION AND FUNCTIONING OF INSTRUMENTS.................................................................................................................... 511 16. CHECKLIST OF SAFETY VALVE:‐............................................................................. 512 17. PRECOMMISSIONING AND COMMISSIONING CHECKLIST OF FINFAN :...... 513 18. PRECOMMISSIONING AND COMMISSIONING CHECKLIST OF TRACING STEAM................................................................................................................................... 515 19. INSULATION CHECKLIST:‐....................................................................................... 516 20. CHECKLIST FOR CARRYING OUT LEAK TEST:‐.................................................. 516 21. PRECOMMISSIONING & COMMISSIONING CHECKLIST FOR FUEL GAS HEADER CHARGING:‐....................................................................................................... 519 22. PRECOMMISSIONING AND COMMISSIONING CHECKLIST OF FUEL OIL HEADER CHARGING:‐....................................................................................................... 521 23. HEATER CHECKLIST :................................................................................................ 523 (a.)FOR COILS:................................................................................................................................... 523 (b.) REFRACTORY:............................................................................................................................. 523 (c.)GENERAL (HEATERS):................................................................................................................... 523 (d.) BURNER AND ITS ASSEMBLY CHECKLIST................................................................................... 525 (e.) HEATER BOX CHECKLIST............................................................................................................. 528 24. CHECKLIST FOR STREAM TRAP:.............................................................................. 529  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 17 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 25. CHECK LIST FOR COMPRESSOR:............................................................................. 529 26. PREPARTION OF START UP BY LICENSOR:....................................................... 530 27. VESSEL CHECKLIST:‐.................................................................................................. 531 (a.) FEED SURGE DRUM (17‐VV‐HI‐101).......................................................................................... 532 (b.) COLD SEPERATOR (17‐VV‐HI‐102).............................................................................................. 532 (c.) RECYCLE GAS KOD (17‐VV‐HI‐103)............................................................................................. 534 (d.) WASHING WATER DRUM (17‐VV‐VI‐104).................................................................................. 535 (e.) STRIPPER REFLUX DRUM (11‐V‐HI‐105).................................................................................... 536 (f.) OFF GAS SUCTION KNOCK OUT DRUM (17‐VW‐HW‐106)......................................................... 537 (g.) OFF GAS DISCHARGE KNOCK OUT DRUM (17‐VW‐HW‐107)..................................................... 538 (h.) NAPHTHA STABILIZER REFLUX DRUM(17‐VW‐HW‐108)............................................................ 539 28. COLUMN CHECKLIST:................................................................................................ 539 (a) Stripper Column/ Naphtha stabilizer (17‐CC‐00-101/ 17-CC-00-102)........................................ 539 SECTION 4................................................................................................................................. 542 TRAINING MANUAL............................................................................................................... 542 Chapter-1 Introduction................................................................................................................ 543 Refinery at a glance................................................................................................................ 543 BR Kerosene Hydrodesulphurization (KHDS) Unit............................................................... 543 Chapter-2..................................................................................................................................... 549 Training Objective and Methodology......................................................................................... 549 Objective................................................................................................................................. 550 Methodology of training......................................................................................................... 550 Duration of training................................................................................................................. 551 How to read a process P & ID................................................................................................ 553 Assistant/Field Shift Engineer responsibilities....................................................................... 558 Panel Engineer responsibilities............................................................................................... 560 Shift Incharge responsibilities................................................................................................. 560 Job certification process.......................................................................................................... 562 Documents to be referred........................................................................................................ 562 Chapter-3..................................................................................................................................... 563 Questionnaire for the Unit.......................................................................................................... 563  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 18 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 TABLE OF CONTENTS Date of Rev. :- 10.07.2023 Chapter-4 Annexures.................................................................................................................. 573 Annexure A: Format for Panel engineer validation............................................................... 574 Annexure B: Format for Area Engineer validation................................................................ 576 Recommendations......................................................................................................................... 577 Annexure C: Format for SIC validation................................................................................. 578 Recommendations......................................................................................................................... 579 ANNEXURE-I............................................................................................................................ 580 MANAGEMENT OF CHANGE................................................................................................ 580  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 19 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 INTRODUCTION Date of Rev. :- 10.07.2023 SECTION-1 OPERATING MANUAL  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 20 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 INTRODUCTION Date of Rev. :- 10.07.2023 Chapter - 1 Introduction  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 21 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 INTRODUCTION Date of Rev. :- 10.07.2023 1.1 INTRODUCTION Bina refinery is operating a 7.8 MMTPA Refinery at Bina with associated crude receipt and handling facilities, cross country pipelines, marketing terminal etc. The refinery was commissioned in March 2011. Post de-bottlenecking project, wants to reduce the Kerosene production from the refinery due to falling consumption trend of Kerosene. In revised BS-VI specification of HSD, which will come into effect from year-2020, the lower limit of density has been removed. Bina refinery will utilize this relaxation to blend excess kerosene into HSD after desulphurization. Final HSD after blending of desulphurized Kerosene will meet BS-VI specifications. In view of this BR intends to set up Kerosene Hydrodesulphurization (KHDS) Unit. The hydrotreated Kerosene from KHDS will also meet BS-VI Kerosene and BS-VI ATF properties Bina Refinery has awarded EIL the PMC job for installation of New Kerosene Hydrodesulphurization (KHDS) unit at Bina refinery. This document constitutes Operating philosophy, Shutdown philosophy and Control philosophy for Kerosene Hydrodesulphurization (KHDS) unit. 1.2 UNIT CAPACITY The feed to the KHDS unit is straight run Kerosene from Crude Distillation Unit (CDU). Design capacity of KHDS unit is 0.6 MMTPA. Design of the equipment in the KHDS unit has been based on the following cases: Design Case, Start of Run (Hot feed and Cold feed) Design Case, End of Run (Hot feed and Cold feed) The Start of Run (SOR) case is based on a catalyst activity under normal Start of Run operating conditions. The End of Run (EOR) case takes into account a decrease in catalyst activity, which is maintained by more severe End of Run operating conditions. 1.3 ON STREAM FACTOR AND RUN LENGTH The unit shall be designed for an on-stream factor (operating hours) of 8000 hours per annum towards arriving at the hourly processing rate but the unit design and engineering practices advised shall allow a minimum operating cycle of 3 years between turnarounds with units operating continuously at 100% capacity. i.e., to process 3 x 365 = 1095days design feed stock.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 22 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 INTRODUCTION Date of Rev. :- 10.07.2023 1.4 PLANT TURNDOWN CAPABILITY The unit shall be capable of a turndown (minimum operable hydraulic capacity) at 40% of design capacity for design case while making on-specification products. 1.5 FEED AND PRODUCT SPECIFICATION SPECIFICATIONS 1.5.1 KHDS feed The specifications of the feed to KHDS unit are given in following tables. Table 1.5.1: Feed Characteristics S.N. Feed Details Unit SR Kerosene 1 Design Flow rate TPH 75.6 2 Sp. Gravity at 15 °C 0.792 3 Sulphur wt% 0.256 4 Nitrogen ppmw 1.585 5 Distillation (D-86) 6 IBP vol% °C 145.0 7 5 vol% v °C 156.4 8 10 vol% °C 164.0 9 30 vol% °C 184.6 10 50 vol% °C 196.9 11 70 vol% °C 210.4 12 90 vol% °C 231.7 13 95 vol% °C 241.3 14 FBP vol% °C 256 to 270 15 Acidity (mg KOH/g) 0.038 to 0.06 16 Viscosity (kinematic) at 50°C (cSt) 1.025  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 23 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 INTRODUCTION Date of Rev. :- 10.07.2023 17 Viscosity (kinematic) at 40°C (cSt) 1.171 18 Paraffins (% vol) 50.99 19 Aromatics (% vol) 16.79 20 Naphthenes (% vol) 29.67 21 Olefins (% vol) 0.000 22 Naphthalenes (% vol) 0.890 23 Smoke Point (mm) >25 24 Freeze Point °C -49.5 25 Colour (saybolt no.) >15 1.5.2 H2 Makeup Characteristics Table 1.5.2: Make up Hydrogen quality from HGU S. N. Parameter Specifications 1 Hydrogen purity, mol % (min) 99.5 min 2 Nitrogen, mole ppm 20.0 - 650 3 Water, mole ppm 50 max 4 CO+CO2, mole ppm 20 max 5 Chlorine+ Chlorides, mole ppm 2 max 6 Methane, mole % balance  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 24 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 INTRODUCTION Date of Rev. :- 10.07.2023 1.5.3 Wash Water Licensor will preferably use sour water produced within the unit as injection wash water. Stripped sour water with 100 ppmw H2S and 100 ppmw NH3 (from Sour Water Stripping Unit – outside Licensor’s scope) shall preferably be used as make-up injection wash water. Additional wash water requirement shall be met from steam condensate from condensate header. DM water / BFW / steam condensate shall be used as back-up injection wash water. Licensor to indicate basis of selecting wash water rate such as % ammonium salts, % impurity etc. (Remark- Wash Water Pump motor rating changed from 5.5 KW to 7.5KW) Table 1.5.3: Quality of Stripped Sour Water (From Sour water stripper for Hydro processing Units) Parameters Value H2S, ppmw (max) 100 NH3, ppmw (max) 100 Oxygen, ppbw,max 15 Iron, ppmw (max) 1 Nonvolatile residue, ppmw (max) 2 pH, max >7.5 Parameters Value Chloride, ppmw max 50 Mg hardness NIL Sulfates NIL Sodium mg/l 1-3 Silica mg/l, max 0.05 Conductivity µmho/cm, max 10 Total Suspended Solids (ppmw) NIL  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 25 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 INTRODUCTION Date of Rev. :- 10.07.2023 1.5.4 KHDS Product Specifications The KHDS unit is designed to produce products as per the specifications given in following tables. Table 1.5.4.1: KHDS Product Specification Hydrotreated Kerosene Hot Feed Cold Feed Case Case Method Specification SOR EOR SOR EOR Hydrotreated Product 71,722 71,722 71,784 71,784 flowrate, kg/hr Specific gravity, d15/4 D4052/D1298 0.780 Min 0.793 0.793 0.793 0.793 ASTM D86, °C, vol% - 1% 161 161 161 161 - 5% 171 171 171 171 - 10% Max 205 177 177 177 177 - 30% 193 193 193 193 - 50% 205 205 205 205 - 70% 219 219 219 219 - 90% 241 241 241 241 - 95% 252 252 252 252 - 98% 270 270 270 270 RVP (2), kg/cm2 a 0.003 0.003 TVP, kg/cm2 a 0.007 0.007 Sulphur FX or UV, wt ppm D2622/D5453/D7039 Max 8 50 Freezing point, °C D2386 Max -47 Same as Feed Same as Feed Smoke point, mm D1322 19 Min Not less than Not less than Feed Feed Color SAYBOLT D156 +10 Min Same as Feed Same as Feed Cetane Index D4737 Not worse Not worse than feed than feed Total Aromatics, vol% D1319/ 20.6 Max < 20.6 < 20.6 IFP9409/D2425 D6379 1) Range of ASTM D5453 (UV fluorescence): 1 - 8000 wt ppm S. Range of ASTM D2622 (WDXRF): 3 wt ppm - 4.6 wt% S. Range of ASTM D7039 (monochromatic WDXRF): 4 - 500 wt ppm S. 2) Calculated by Pro II API Naphtha method. Table 1.5.4.2: KHDS Naphtha Specification KHDS Naphtha Hot Feed Cold Feed Specification SOR EOR SOR EOR Naphtha flowrate, kg/hr 3,638 3,675 3,638 3,675 Specific gravity, d15/4 0.764 0.764 0.764 0.764 ASTM D86, °C, vol%  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 27 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 Revision No.: 02 INTRODUCTION Date of Rev. :- 10.07.2023 - 1% 116.6 103.7 116.6 103.7 - 5% 121.1 121.0 121.1 121.0 - 10% 121.4 121.2 121.4 121.2 - 30% 123.1 122.9 123.1 122.9 - 50% 126.8 126.7 126.8 126.7 - 70% 131.9 131.8 131.9 131.8 - 90% 140.1 140.0 140.1 140.0 - 95% 145.4 145.4 145.4 145.4 - 98% 180 Max 158.4 158.4 158.4 158.4 Sulphur, wppm 5 Max 9. The solution to be more effective shall be at ~ 50°C while performing the soaking. 0.1 to 0.2% of an alkaline tensio-active could be added to improve the wetting 0.5% maximum of NO3Na could be added, but no excess is allowed, otherwise this may have a negative impact on the carbon steel Some customers add some corrosion inhibitor to enhance the protection (shall be water soluble) 8.10.4.1 Equipment to Which the Above Precautions Apply Equipment Service Material 17-FF-00- Reactor Feed Heater (Tube SS 321 / SS 347 101 material – Process side) 17-EE-00- Reactor Feed / Effluent 101 Exchangers SS 321 / SS 347 Clad / Overlay A/B/C/D (C/D Tubes and D Shell) 17-RB-00- HDT Reactor SS 321 / SS 347 Clad / Overlay 101 8.10.4.2 Lines to Which the Above Precautions Apply The neutralization should be also applied to all stainless steel lines. 8.10.4.3 Application of the Neutralizing Solution  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 256 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023 Washing of equipment with neutralizing solution is only expected when the contact of stainless steel surfaces with air cannot be avoided (example: reactor inspection) and in the case when only this protection is effective. The simplest method of neutralization is to install a temporary mix/storage tank for preparation and storage of the soda ash solution. This tank should be equipped with a circulation pump. Suitably armored hoses can then be used to connect the pump discharge to the equipment to be neutralized. The hoses should be flanged to suit the neutralization stub flanges which will be fitted to line ends when the neutralization spool pieces are removed. By the same method a return route can be installed back to the tank, so allowing circulation of the solution. It may be necessary to mix several batches of the solution in order to fill some items of equipment. The strength of the solution should be regularly checked in order to maintain the 2 wt% value. For equipment where it is possible to perform a circulation of the solution through the equipment, 2 hours of circulation should be sufficient to perform the neutralization. For equipment where it is only possible to completely fill the equipment and not circulate, 4 hours should be sufficient to neutralize the equipment if the solution is left to stand in the equipment. For vessels that are too large to fill completely (possibly due to foundation limitations), the reactor for example, the solution should be applied internally using a high pressure hose fitted with a spray nozzle. To do this the vessel will have to be opened for entry but kept under a nitrogen atmosphere. One man wearing fresh air breathing apparatus will then enter the vessel and apply the solution with the hose, taking care to wet all the surfaces. The solution is then allowed to dry before the vessel is aerated ready for entry. In the particular case of a reactor wall, to ease and optimize the procedure the following system can be and is actually used: a rotating spray nozzle is progressively dropped down the reactor with a cable, from the distributor tray or even from the upper man hole if possible. The rotating movement of the spray wets the wall completely. The necessary washing solution volume is typically 5 to 6 m3 for a washing duration of 2 hours. The washing solution can be drained at the reactor outlet line through a purge or a thermowell nozzle, and be recycled with a pump and reused for washing. In that case the volume can be decreased by about half.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 257 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023 For the heater, if the heater has to be opened to atmosphere, the coils shall be protected the same way as mentioned above. Then for vertical coils, they have to be washed out using demineralized water to remove the soda ash which may be trapped in the bottom elbows. After the water wash is performed the coils are put under nitrogen atmosphere and pilots will be light up to dry the coils at low temperature. If the recycle compressor can be started at the same time this will help to dry and to remove water which may have accumulated in the bottom elbows. Note on the external surface of fired heater tubes, the sulphur contained in the fire heater fuel oil/gas will progressively lead to sulphides deposits that may lead to stress corrosion cracking. During long-term shutdown, if the heater pilots have to be stopped and the heater casing cooled down, the external surface of the heater tubes should be sprayed with soda ash solution to prevent polythionic acid stress corrosion cracking, taking care not to damage the refractory. In the case of heat exchangers and relevant piping: The system shall be soaked at once by filling it with the prepared soda ash solution (containing some nitrite) then soak for 4 hours and drain the solution. The film, which is adhering to the metallic part, will dry up and a fine white powder of soda ash will remain to protect it against polythionic corrosion. Do not attempt to remove this white powder, as it is this layer which will protect the metal against polythionic induced corrosion. If the same equipment has to be cleaned using high pressure water (this shall be demineralized water with less than 10 ppm chlorides) to remove scales or deposits and if it not immediately put back in place and preserved under nitrogen atmosphere, then it must to be sprayed again with the soda ash solution (with nitrite). Normally it is not necessary to wash out with demineralized water after the equipment had been reinstalled. The small amount of soda ash deposit on the metal will be washed out at the restart of the unit. However, one will have to ensure that there is no location that soda ash could become accumulated; otherwise this very location shall be flushed with demineralized water. In the case of nozzles and drains included in the system which was soaked with the soda ash solution:  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 258 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023 Special attention will be paid to the nozzles and drains where soda ash has accumulated. These parts shall be as far as possible washed out with demineralized water to remove the soda ash or shall be properly drained out during the plant commissioning to avoid any soda ash to staying idle for long duration. Depending on the material and temperature, caustic embrittlement could occur, especially in the locations where welding’s were not post heat- treated. Warning: Oxygen content of the nitrogen used to prevent corrosion should not exceed 500 vppm. During the period where the work is performed, it is necessary to make sure that the protective layer on the overlay or internals is not destroyed. This will result in the loss of the protection. For process equipment that have been cleaned using high pressure demineralized water (less than 10 ppm chlorides content), it is much safer to spray soda ash solution on them again if they are not immediately put back in place and kept under nitrogen. A balance should always be made by the refiner between the risk of polythionic attack and the risk of chloride attack. This balance must be made based on the refiner’s own experience.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 259 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023 CHAPTER – 9 GENERAL EQUIPMENT OPERATING PROCEDURE  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 260 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023 9. GENERAL EQUIPMENT OPERATING PROCEDURES This section covers the general procedure for operation and trouble shooting of commonly used equipment like pumps, heat exchangers and furnace etc. For specific information and more detail refer vendor's manuals. 9.1 CENTRIFUGAL PUMPS a) Start-up i. Inspect and see if all the mechanical jobs are completed. ii. Establish cooling water flow where there is such provision. Also open steam for seal quenching in pumps having such facilities. iii. Check oil level in the bearing housing, flushing may be necessary if oil is dirty or contains some foreign material. iv. Rotate the shaft by hand to ensure that it is free and coupling is secure. Coupling guard should be in position and secured properly. v. Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from the bleeder valve. vi. Energize the motor. Start the pump and check the direction of rotation. Rectify the direction of rotation if it is not right. vii. Check the discharge pressure. Bleed if necessary to avoid vapour locking. viii.Open the discharge valve slowly. Keep watch on the current drawn by the motor, if ammeter is provided. In other cases, check at motor control center. In some pumps a by-pass has been provided across the check valve and discharge valve to keep the idle pump hot. In such pumps, the by-pass valve should be closed before starting the pump. It should be ensured that casing of these pumps are heated up sufficiently prior to starting of the pump to guard against damage of the equipment and associated piping due to thermal shock. b) Shutdown i. Close discharge valve fully. ii. Stop the pump 1. If pump is to be prepared for maintenance, proceed as follows: Close suction and discharge valves. Close valve on check valve by-pass line, if provided.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 261 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023 Close cooling water to bearing, if provided. Also shut off steam for seal quenching, if provided. Slowly open pump bleeder and drain liquid from pump if the liquid is very hot allow sufficient time before draining is started. Ensure that there is no pressure in the pump. Also drain pump casing. Blind suction and discharge and check valve by-pass line and flare connection if any. Cut-off electrical supply to pump motor prior to handing over for maintenance. c) Trouble Shooting i. Pump not developing pressure Bleed to expel vapour/air Check the lining up in the suction side. Check the suction strainer. Check the liquid level from where the pump is taking suction. Check pump’s coupling and rotation. Get the pump checked by a technician. ii. Unusual Noise Check the coupling guard if it is touching. Check for proper fixing of fan and fan cover. Check for pump cavitation. Get the pump checked by a technician. iii. Rise of Bearing Temperature Generally the bearing oil temperature of up to 80°C or 50°C above ambient, whichever is lower, can be tolerated. Arrange lubrication if bearing is running dry or oil level is low. Adjust cooling water to the bearing housing, if there is such provision. Stop the pump, if temperature is too high, call the pump technician. iv. Hot Gland Adjust cooling water if facility exists. Slightly loosen the gland nut, if possible. Stop the pump and hand over to maintenance.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 262 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023 Arrange external cooling if pump has to be run for some time. v. Unusual Vibration Check the foundation bolts. Check the fan cover for looseness. Stop the pump and hand over to maintenance. vi. Leaky Gland Check the pump discharge pressure. Tighten the gland nut slowly, if possible. Prepare the pump for gland packing or adjustment/replacement of mechanical seal as the case may be. vii. Mechanical Seal Leak  Stop and isolate the pump and hand over to maintenance. 9.2 POSITIVE DISPLACEMENT PUMPS a) Start-up  Check if all mechanical jobs are completed.  Flush and renew oil in pump gear box.  Check whether suction strainer is installed.  Check for proper lining up including the pressure safety valve in the discharge. Open suction valve fully.  Check that the motor shaft is reasonably free and coupling secured. Coupling guard should be in position.  Energise motor. Open discharge valve. Start the motor and check direction of rotation. Stop and rectify if direction of rotation is wrong.  Adjust the pump stroke and run the pump at different settings. Watch discharge pressure and check the rate of pumping using the flow meter or by taking suction from the calibration pot.  In case the pumps are provided with a pressure controller adjust it to obtain the required discharge pressure.  Care should be taken to avoid dry running of pump and back flow of liquid. Bleed if necessary to expel vapour/air.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 263 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023  Check for unusual noise, vibrations, rise of temperature of both motor and gears. b) Shutdown 1) Stop the pump. 2) Close the suction and discharge valves. 3) Drain the liquid if maintenance jobs are to be carried out on the pump. c) Trouble Shooting i. Insufficient Discharge Pressure Check the lining up in the suction side. Check the functioning of the safety valve and pressure control valve on discharge to suction. Check the strainer on the suction side. Check for insufficient liquid level in the tank. Check the pump’s coupling and rotation. Get the pump checked by pump technician. ii. High Discharge Pressure Check the line up on the discharge side. Check pressure control valve opening. iii. Leak Gland Check for normal pump discharge pressure. Tighten the gland nut slowly if possible. Hand over the pump for replacing gland packing. iv. Unusual Vibrations Check the foundation bolts. Check motor fan cover for looseness. Stop the pump and hand over to maintenance. 9.3 RECIPROCATING COMPRESSORS a)Start-up  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 264 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023 i. Ensure all mechanical jobs have been completed on the compressor machine and auxiliary systems. Check if fine mesh strainer is installed as per vendor's recommendations. ii. No load run of the motor to be carried out before the compressor is coupled to the motor. De-energize electrical supply and couple the compressor with the motor. iii. Check oil level in frame sump and refill as required bringing the oil level to the high mark on the sight glass. Do not over fill. iv. Start the stand by motor operated frame oil pump keeping pressure regulator at a value given by vendor. Establish the required pressure of lubrication oil in bearings & crossheads. v. Bar the unit over once to be sure all moving parts are clear. vi. Open cooling water and ensure it is operative. Commission cooling water to frame oil cooler, cylinder jacket cooling and packing cooling as applicable. Remove the suction and discharge valve of the compressor if recommended by compressor vendor. Valve flanges should be covered to prevent entry of foreign material into casing. The machine has to be tried with the valves in removed condition. vii. Before running on no load, give a bump start. Time for which an unloaded machine continues to roll after driving power has been cut-off gives a fair indication of no load friction. viii. Start the motor and run the compressor with the suction and discharge valves in removed condition for about say 1 hour. After ensuring that the machine performance is okay, stop the compressor, isolate power and reinstall the valves. ix. Commission inert gas (IG) purge pressure controller to the packing and vent to safe height in atmosphere, as applicable (distance piece purging). It is assumed that compressor has been purged with IG while purging the system using IG. Compressor cylinder is to be purged with IG by temporary hose connection if for some reason compressors was under maintenance and cylinders are full of air. Steam purging of compressor should be avoided as it may lead to excessive rusting of parts afterwards. NOTE: The above is applicable when the gas handled is of explosive nature. x. The compressor should in manually unloaded condition. xi. Open suction valve/discharge valve and line up to the system. Open bypass valves/purge valve as applicable.  Doc. No.: OPT/01/KHDS/01 OPERATING MANUAL Page No. : 265 of 584 KEROSENE HYDRODESULPHURIZATION Issue No. : 02 UNIT Issue Date : 01.07.2022 GENERAL EQUIPMENT OPERATING Revision No.: 02 PROCEDURE Date of Rev. : 10.07.2023 xii. Before running on no load, give again a bump start. Time for which an unloaded machine continues to roll after driving power has been cut off gives a fair indication of no load friction. xiii. Start the motor and run the compressor on no load for 10 minutes until the frame oil warms to about 35°C. Watch compressor motor amperage. Listen for unusual noise during the warm up period. Periodically check any heating of bearing and other moving parts. If the compressor is operating satisfactorily, gradually start loading the compressor by manually operating the suction unloader/clearance pocket. xiv. Load the compressor to the required capacity in ascending sequence of steps. xv. Observe the discharge pressure, temperature and bearing temperatures when the machine is loaded step by step. b) Shut-Down i. Unload the compressor in descending sequence of steps and bring it to 0% capacity. ii. Stop the motor. iii. Close the discharge valve. iv. Close N2 purge to piston rod packing, if provided. v. Close suction valve. vi. Turn off cooling water to cylinders, packing and frame oil cooler. vii. If the compressor is to be given for maintenance, isolate, depressurise and purge with inert gas to make the compressor free of hydrocarbon gas, if handled. c) Normal Operation i. Check oil level in frame sump and add oil as required to maintain the proper level as indicated on sight glass. ii. Log all temperatures, pressures, levels and amperage. iii. Adjust cooling water flows to compensate for changes in inlet water temperature or ambient temperature and for change in compressor loading. iv. Listen for any unusual noise while the machine is