5

PREPARATION FOR START UP

The following preparations are meant for a unit start up after maintenance
turnaround activities. Some pieces of equipment were maintained, fixed,
replaced.
The unit is isolated at BL, with closed block valves and/or spectacle blinds, for
the process circuits and, possibly, for utility systems as well.
Before any activity can start it is necessary to close all work permits for
completion, remove from the unit all tools and materials used during
maintenance, send out of the area all maintenance and contractors workers.
5.1

Plant Check-Out
For a normal start-up any interdependent systems should be online or in the
appropriate state for this start-up procedure. For example, if a system being
started is part of a flow stream, the upstream and downstream systems should
be online or pressurized and ready to deliver or receive product.

Safety issues

Work plan

Valves line-up

De-isolation (blinds list)

Purge requirements

Personal Protective Equipment

Common Protective Equipment

Safety Equipment

Prerequisites for start-up

Inspection of the plant can be basically divided into the following areas:
1. Charge heater
2. Reactors
3. Vessels
4. Heat Exchangers
5. Pumps
6. Compressors
7. Piping

8. Instrumentation
9. Catalyst/Chemicals Inventory

On Charge Heater check that:

Radiant Section

Heater is clean and free from debris.

Refractory is in good condition before and after refractory dry-out. No

refractory is resting on tubes.

Heater shell is sealed to prevent escape of hot gases and entrance of

atmospheric moisture during shutdown.

Adequate space for tube expansion

Tubeskin thermocouples, are located properly and installed so that

they have good contact with the tubeskin.

Snuffing steam connections are not covered by refractory.

Valves on snuffing steam are located remote from the heater, with
drain valves and steam traps upstream of final block valve for
condensate removal.

Soot-blowers are installed and are out of heater.

Weep holes provided in snuffing steam lines at low points are clean.

Heater instrument connections and sampling connections are open not filled or covered with refractory.

Fuel gas, fuel oil and pilot burner tips are clean and oriented properly.

Burners are properly mounted with clearance for firing and removal.

Damper is free to move fully open and closed; its position indicator is
correct both at the stack and at the damper control.

Convection Section and Stack

If extended surface elements are allowed, the bottom three or more rows
of convection tubes must be bare.

No refractory is on the tubes.

External Inspection

Platforms for access to all observation ports, instrumentation, sample

connections, sootblowers, and damper connections.

Explosion doors located such that heater gases will not flow towards
process equipment and platforms.

Explosion doors located such that doors can open completely.

Instrumentation and sampling connections.

Damper position indicator visible from damper control; damper control

functioning properly.

Pocketed crossover connections have flanged drains.

Isolation valves on snuffing steam are located remote from the heater,
with drain valves and steam traps upstream of final block valve for
condensate removal. Weep holes provided in snuffing steam lines at low
points.

On Combustion Air Fans check that:

On/Off slide valves on suction lines are free to move fully open and
closed.

All instruments are installed (including auto starts).

Lube oil system is operable.

On Fuel Systems check that:

Fuel lines have battery limit block valves which are remote from the
heater and easily accessible.

Fuel oil piping and its steam tracing are correctly arranged.

Fuel lines to pilots and burners can be easily disconnected from

burners for burner removal.

Fuel oil lines at burner valves are correctly piped with steam
crossovers. All steam lines have adequate traps and condensate
drains.

Shutdown solenoids for fuel shutoff valves have been set properly.

On Reactor check that:

The reactor internals are exactly with the design specifications

The good distribution is to be attained and the catalyst migration is to

be avoided

Inlet distributors, quench distributors: metallurgy, type, size, opening

sizes, freedom to expand

Catalyst support grids: metallurgy, grid type and dimensions, screen

type and size, supports, welding.

The vessel has been hydrostatically tested.

Reactor skin thermocouples are located properly and installed so that

they have good contact with the wall.

Inlet and outlet lines are connected.

Flanges on catalyst withdrawal nozzles are installed.

Vessels

Vessel trays: spacing; levelness, orientation and dimensions of weirs,

downcomers, accumulators, drawoff and trap trays, seal pans,
distributors, baffles, nozzles, tray contact devices; metallurgy of trays,
contact devices, clips, bolts, nuts and gaskets; freedom of movement of
valve caps or other contact devices; number, size, and distribution of tray
contact devices or perforated plate holes; proper fit of all internals and
proper welding of support rings or other support devices; liquid tightness
of drawoff trays, seal pans and accumulators, all bolting and clips
tightened.

Mesh blankets and outlet screens: size, location, levelness, suitability of fit
(no bypassing allowed), metallurgy of blanket, support, tie wires, and
grids.

Vortex breakers: type, size, and orientation.

Baffles: type, orientation, levelness.

Instrument nozzles: location, orientation, cleanliness, thermowell length

and metallurgy, baffle size and type.

Inlet distributors: type, size, orientation, levelness, freedom to expand.

Internal ladders and other devices: location, size, orientation, properly

secured..

General

The vessel should be clean (free from trash) and should not have
excessive mill scale.

External Inspection

Manways and nozzles: location, size, flange rating and finish, metallurgy,
with proper gaskets, nuts and bolts.

Ladders and platforms: correctly positioned, secure and free to expand.

Insulation and steam tracing: provided as specified and has expansion

joints as required.

Vessel grounded correctly.

Correct vessel elevation.

Valves and instrumentation: easily accessible from grade or platform.

Piping:

Adequate supports and guides for all connecting lines.

Level and pressure instrument connections drain to a safe location.

Vents to atmosphere or blowdown provided as specified.

Relief valves have been bench tested.

Check valves exist on utility line connections where hydrocarbon backup

could occur.

Connections available for steaming/purging of the vessel.

Fireproofing of structure and supports is complete.

Filters
For filters, the same checking as for the vessels must be completed. In plus,
check if:
-

A complete set of filters cartridges and gaskets are purchased as

commissioning spare parts:

The isolation is in according with the project specification and with the
vendor requirements.

On Heat Exchangers check that:

Exchanger is free to expand. Slot length of sliding plates adequate for

expansion. Exchanger should not be tied down at both ends. Check
sliding ends of exchangers with regard to expansion of exchangers and
connecting pipe.

Vent and drain connections are installed.

Design temperature, pressure and pressure-drop ratings.

Nozzle size, flange type, rating, facing and metallurgy; vent and drain
connections.

On Air Cooled exchanger check that:

"Auto-variable" or "standard-pitch" fans, as specified.

Motor switches accessible from grade and located near the exchanger.

Fan pitch set correctly as determined by fan amperage draw.

Vibration switch on each fan.

Proper motor/fan rotation. Motors properly grounded.

Proper elevation and distances from connecting equipment.

Belt tension on motor drive pulleys is equal and correct.

Motor amperage can be easily checked.

Exchanger free to expand.

Manifold piping arrangements as shown on EFDs.

Split header design where specified.

Free draining requirements, as shown on EFDs.

Tube fin surfaces are in good condition with no construction debris on top
of the fins.

Pumps general checks. The following items should be checked for all
pumps:

Suction strainer easily removed for cleaning.

Discharge pressure gauge readable from discharge block valve.

Suction/discharge valves easily accessible and operable, and near to

the pump. Accessibility of auxiliary piping and controls.

Warm-up lines provided across discharge check valve when pumping

hot fluids.

Grounding devices.

Steam tracing and insulation provided on suction/discharge lines,

pump casing, and process seal flush lines.

Minimum flow lines (with restriction orifice), if required.

Adequate means for venting and draining the pump casing.

Rotating parts protections between pumps and drivers.

Check valves are installed in the correct direction.

All drains from pumps and associated piping and instrumentation

should be routed to a safe location.

On Centrifugal Pumps check that:

Sight flow indicators, inlet/outlet shutoff valves on cooling water lines

are installed.

Thermometers/pressure gauges for gland seal and flushing oil

manifolds are installed.

Restriction orifices (if required) present in seal flush manifold piping are
correctly installed.

Cooling water to mechanical seals on pumps operating at high

temperature is fitted.

Proper direction of rotation has been controlled.

Auxiliary lube oil system (if provided) is ready for operation.

Temporary strainer is installed.

On Reciprocating Pumps check that:

Cooling/lubrication systems are installed.

Pump stroke adjustment device is available.

Pulsation suppression devices, if required, are fitted.

Relief valves are installed.

Means for calibrating the pump flow rate are fitted.

Temporary strainer is installed.

On Reciprocating Compressors check that:

Acidizing requirements have been met and acidized piping is not in

contact with the atmosphere (under nitrogen blanket), includes both
process and lube oil piping. Mill scale must be removed from the
compressor section by Chemical Cleaning in order to reduce the
possibility of solids entering the compressors. The exact procedures to
be followed are supplied by the compressor vendor. The following
items must be chemical cleaned: all gas piping including spillback
lines, compressor suction drum gas coolers and intercoolers.

Field Inspection
The following items should be checked in the field:

Materials of construction; flange type, rating, finish, gasketing.

Instrumentation for conformity

operability and access.

Lube oil system/cooling water piping, including sight flow indicators.

Distance piece/packing vents piped correctly.

Adequate and accessible drains which are routed to a safe location.

Single strand steam tracing on the bottom of suction lines and snubbers,

to

project

specifications,

location,

as specified; insulation as specified for heat retention and personnel

protection.

Automatic suction valve unloader operation.

Two compartment distance pieces, if required (greater than 30 mol

percent hydrogen in process gas).

Acidizing requirements have been met and acidized piping is not in

contact with the atmosphere (under nitrogen blanket), includes both
process and lube oil piping.

Provision for suction strainers, if required.

Buffer gas lines are fitted

Instruments:
All instruments should be checked as soon as possible so that any malfunctions
or other faults can be detected early. The instrument checkout should include
the following items:

Pressure test of instrument air lines

Control valve action and calibration

Positioner calibration

Board calibration and loop check

Thermocouple calibration and identification

Level instrument calibration

Thermometers, pressure gauges, etc.

All orifice plate bores should be measured, recorded and compared with
required sizes. The orifice plates should also be checked to see if they were
counterbored wherever required. After hydrotesting and water flushing have
been completed, the orifice plates can be installed.
Piping

The unit must be constructed in accordance with Engineering Flow

Diagrams (EFDs), including all details, elevations, dimensions,
arrangements, and other notes on the EFDs. One must be able to
startup, shutdown and conduct normal operations on the unit as
envisioned in the project design. Also, piping for special procedures
such as dry-out, special materials preparation, regeneration and/or
alternative flow schemes may have been incorporated into the unit's
design, and the unit should be able to operate in all of these modes
with piping as designed and constructed.

For the connections to other process facilities, adequate means must

be provided to receive feed from or send products to these facilities

without contamination of these streams, and minimize as much as
possible the effects of upsets of other process units especially where
contamination of feed or product stream might occur. Check all
tankage interconnections to minimize the possibility of stream
contamination outside of the battery limits.

Check that adequate means of measuring flows, pressures, and

temperatures, and sampling of all process streams has been provided.

The following items must be checked to ensure conformity to the project design
specifications:

Flanges: rating, facing, and metallurgy; type (typically, 2" and smaller
are socket weld, 2%2" and larger are weld neck flanges).

Gaskets: type; metallurgy (materials of retainer, jackets, winding, filler,

etc.); thickness, ring size, etc.

Fittings, connections and couplings: rating and metallurgy.

Valves: rating and metallurgy (body, trim, seats, etc.); packing; seat
inserts; bonnet gaskets; grease seals; socket-weld or flange type,
rating and facing; installed in correct direction of flow; lubricant
provisions; gear operators; extended bonnets; stops; ease of
operation.

Bolting: stud or machine bolts; bolt and nut metallurgy; bolt size.

The hydrotest connections for process lines are seal welded.

Pipe: metallurgy, thickness; seamed or seamless; lining.

Tubing: size and thickness; metallurgy; seamed or seamless.

Gauge glasses:

Through-view types should have rear-mounted lights.

Design pressure and temperature.

Special materials of construction.

Drains to safe location.

Visible from grade (or platform, if required).

Pressure relief valves:

Size and style.

Lever requirement.

Inlet/outlet flange material, facing and rating.

Set pressure - must be bench tested.

Metallurgy of nozzle, disc, spring, etc.

Type (pilot operated, balanced, etc.).

Inlet/outlet block valves car-sealed open; valve stems installed

in horizontal or below.

General:

Utility systems within the battery limit should follow all relevant
pipe
class specifications in the same detail required for process
lines.

Package systems (modular units, etc.) shown on the EFDs

should follow all relevant pipe class specifications in the same
detail required for other process lines.

Expansion: review the physical installation to ensure that no

expansion problems will occur when the unit gets hot and that:

expand.

Column overhead, reflux, feed and other lines are free to

Rotating equipment will not be pulled out of alignment.

Sufficient expansion loops have been provided on long hot

Pipe shoes are free to move in one direction, and are

resting on supports of sufficient size that the shoe will not
fall off the support.

lines.

High point vents and low point drains should be installed where
necessary.

Spectacle blinds should be provided where required.

Car-sealed valves should be locked in proper position.

Spring hangers should have locking pins removed (after

hydrotesting) and necessary adjustments should be made for
hot/cold position after startup.

Catalyst/Chemical Inventory
Catalyst
It must be verified that sufficient quantities of catalyst, catalyst support material,
and other materials (such as ceramic fibre rope, etc.) are on site, in good

condition, and properly stored (for example, in drums, indoors, and on pallets to
prevent contact with moisture).
It must be verified that all equipment required to load the catalyst is on site and
in good condition.
Consider estimated quantities and detail spec
Chemicals
It must be verified that the proper type and quantity of chemicals (such as
inhibitors, sulfiding agent, soda ash, etc.) are on site and properly stored.

5.1.1

Operational Checks
The plant operator has to make several checks:

Action
1

Confirm that all construction and repair work on the system is completed.
Confirm that systems are isolated from any of the maintenance activities.

Confirm that all permits and maintenance checklists are closed out.

Confirm that the drain, vent, and bleed valves are in the closed position.

Confirm that the blinds and flanges are removed and documented.
Confirm that energy isolation has been removed. Follow the Safe Work
Procedures Manual (Lock Out / Tag Out)

5
6

Confirm that the safety and fire fighting equipment is in place, operational, and ready for use.

Confirm that the status of each temporary defeat is correct

Confirm that housekeeping has been properly carried out.

5.1.2

Maintenance Checks

Action
1

Confirm that control and shutdown loops are functional.

Ensure that the control valves, Blow Down Valves, Shut Down Valves and Emergency Shut Down
Valves are stroked to confirm that the valves are operating correctly.

Confirm that Restriction Orifices (RO), Non Return Valves (NRV), Spacers Rings (SR), Spectacle
Blinds (SB), Strainers and Spade points are correctly installed.

Confirm that all instruments are lined up and calibrated.

Confirm that electrical power is connected and tested for any necessary equipment.

Confirm that insulation is replaced on equipment where appropriate.

5.2

Establishment of Utility Services

After maintenance and before purging, all the utilities must be prepared, in
order to be available before starting up the process equipment.
The various utility lines should be tested and placed into service as soon as the
construction schedule allows. Pressure tests should be carried out on the
steam, condensate, air, fuel gas, fuel oil, flare, and nitrogen lines. The steam
lines should be warmed up gradually to prevent damage by water hammer. At
the same time, all steam traps and condensate lines should be placed into
service. Scale and construction debris can be conveniently removed from the
steam lines by blowing them as long as necessary with steam. The other utility
lines can be cleaned by blowing with steam or air, or by water flushing if
possible. All utility lines, with the exception of fuel and flare, can be put into
service as soon as the construction schedule allows.

5.2.1

Instrument Air
Most often, during maintenance activities, Instrument Air system is kept in
service with the specific instruments working.
Only in case of specific works on the system, it is necessary to put the header
in service as follows:
Action

5.2.2

Isolate all users turning closed the spectacle blinds or using removable blinds where
required

Remove FT-072 orifice plate. .(if some piping work has been done on the line upstream
FT)

Turn open BL spectacle blind and remove the final blind flange of the header

Inform Instrument Air Unit responsible of air usage

Open BL isolation valve

Blow the header until the air coming out from the end flange is clean

Reinstall FT-072 orifice plate and final blind flange of the header

Pressurize the system and check PG-400

Blow all branches to users before feeding them

Plant Air
Most often, during maintenance activities, Plat Air system is kept in service as it
might be useful for maintenance works.
Only in case of specific works on the system, it is necessary to put the header
in service as follows:
Action

5.2.3

Remove FT-071 orifice plate. (if some piping work has been done on the line upstream FT)

Turn open BL spectacle blind

Inform Plant Air Unit responsible of the air usage

Open BL isolation valve

Blow the system until the air coming out from hose connections is clean

Reinstall FT-071 orifice plate

Pressurize the system (check pressure via PG-414)

Nitrogen
Most often, during maintenance activities, nitrogen system is kept in service
even if isolated (blinded) at equipment connections.
Only in case of specific works on the system, it is necessary to put the header
in service as follows:

Action

5.2.4

Isolate all users turning closed the spectacle blinds or using removable blinds where required

Remove FT-065 orifice plate.(if some piping work has been done on the line upstream FT)

Turn open BL spectacle blind and remove the final blind flange of the header

Inform Nitrogen Production Unit responsible of nitrogen usage

Blow the header until the nitrogen coming out from the end flange is clean

Reinstall FT-065 orifice plate and final blind flange of the header

Pressurize the system and check PG-415

Blow all branches to users by disconnecting, if necessary, at the spectacle blinds before the
user connections

Utility Water
Utility water is very seldom put out of service as it may be functional to
maintenance activities. In case of isolation and maintenance act as follows:
Action

5.2.5

Remove FT-075 orifice plate (if some piping work has been done on the line upstream FT).

Turn open BL spectacle blind.

Wash header and lines from BL to all hose connections until water is clean

Reinstall FT-075 orifice plate

Pressurize the system

Drinking water
Drinking water should never be put out of service as it feeds safety showers
and eyebaths.
In case of isolation and maintenance act as follows:
Action
1

Remove FT-076 orifice plate (if some piping work has been done on the line upstream FT)

Turn open BL spectacle blind

Wash header and lines from BL to showers and eyebaths until water is clean

Reinstall FT-076 orifice plate

Pressurize the system

5.2.6

Cooling Water
Cooling water supply and return headers are seldom put out of service.
In case of isolation for maintenance act as follows:
Action

5.2.7

Remove FT-066 orifice plate .(if some piping work has been done on the line upstream FT)

Turn open CS and CR BL spectacle blinds.

Isolate all user inlets and outlets (coolers, pumps and compressors cooling systems)

Remove both headers (CS and CR) end blind flanges

Inform Cooling Water Unit responsible of the water usage

Wash headers from BL to their end flange until water is clean

Reinstall FT-066 orifice plate and headers terminal blind flanges

Wash lines to each user from the headers to drains

Establish circulation through users as needed

Boiler Feed Water

HP Boiler Feed Water
HP BFW header is normally put out of service just by closing isolation valve at
BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows:
Action
1

Turn open BL spectacle blind

Close user valves (line block valve upstream of 33-FV-042 and, 33-TV-143 assembly)

Inform BFW Unit responsible about water withdrawal

Slowly open BL valve and pressurize the system

Drain until water is clean

In case of cleanliness doubts sample BFW from TV upstream drains and check for iron
presence

In case of maintenance of the header itself, it is better to wash the system with
utility water, (through temporary connections) from BL to the end of the header
(removing FT orifice plate and the blind flange at the end) to minimize BFW
losses and safety problems (BFW is hot, at high pressure and more expensive
than UW).
MP Boiler Feed Water

MP BFW header is normally put out of service just by closing isolation valve at
BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows:
Action

5.2.8

Turn open BL spectacle blind

Close user valves (line block valve upstream of 33-TV-136 assembly)

Inform BFW Unit responsible about water withdrawal

Slowly open BL valve and pressurize the system

Drain until water is clean

In case of cleanliness doubts sample BFW from TV upstream drains and check for iron
presence

Demineralized Water
Demineralized water header is normally put out of service just by closing
isolation valve at BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows:
Action
1

Turn open BL spectacle blind

Close all user valves

Inform Demi Water Unit responsible about water withdrawal

Slowly open BL valve and pressurize the system

Drain until water is clean

In case of cleanliness doubts, sample DM and check for iron presence

In case of maintenance of the header itself, it is better to wash the system using
Utility Water (through temporary connections) from BL to the end of the header
(removing the FT orifice plate and blind flange at the end) in order to save Demi
Water wastage.

5.2.9

Low Pressure Steam

LP Steam system is normally put out of service just by closing isolation valve at
BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows.

Action
1

Turn open BL spectacle blind

Close all user valves

Open drain valves upstream of block valves to users

Open first the warming up bypass valve to warm-up slowly the header (if required after
long shutdown period). Keep it open for at least 2 hours

Slowly open BL valve and gradually warm up the system by draining condensate from low
points such as drains and hose connections

When condensate is clean and hot enough, close drain valves and check header steam traps
performance

Fully open BL valve and pressurize the system (check pressure via 33-PG-404)

Commission steam tracing system

In case of maintenance of the header itself, it is better to wash the system using
Utility Water, (through temporary connections) from BL to the end of the header
(removing FT orifice plate and the blind flange at the end) and then blow the
system with steam until everything is clean.

5.2.10

Low Pressure Steam Condensate

LP Steam Condensate system is normally put out of service just by closing
isolation valve at BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows:
Action

5.2.11

Turn open BL spectacle blind

Close all valves from users

Open drain valves

Crack open isolation valve at BL and pressurize the system (check pressure via 33-PG-403)

Close drain valves

Fully open BL valve after pressurization

Medium Pressure Steam

MP Steam system is normally put out of service just by closing isolation valve at
BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows:
Action
1

Turn open BL spectacle blind

Close all user valves (line block valve upstream of each control valve)

Open drain valves upstream of block valves to users

Open first the 1 warming up bypass valve to warm-up slowly the header (if required after
long shutdown period). Keep it open for at least 2 hours

Slowly open BL valve and gradually warm up the system by draining condensate

When condensate is clean and hot enough, close drain valves and check header steam traps
performance

Fully open BL valve and pressurize the system (check pressure via PG-402)

Close the warm-up bypass valve

In case of maintenance of the header itself it is better to wash the system with
utility water, (through temporary connections) from BL to the end of the header
(removing the FT orifice plate and blind flange at the end) and then blow the
system with steam until everything is clean.

5.2.12

High Pressure Steam

HP Steam system is normally put out of service just by closing isolation valve at
BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows.
HP Steam system is normally put out of service just by closing isolation valve at
BL and, if necessary, by turning closed the BL spectacle blind.
To put the system in service act as follows:
Action
1

Turn open BL spectacle blind

Close produced steam valve (downstream Steam Desuperheater)

Open drain valves upstream steam trap

Open first the 3/4 warming up bypass valve to warm-up slowly the header (if required after
long shutdown period). Keep it open for at least 2 hours

Slowly open BL valve and gradually warm up the system by draining condensate

When condensate is clean and hot enough, close drain valves and check header steam traps
performance

Fully open BL valve and pressurize the system (check pressure via PG-401)

Close the warm-up bypass valve

In case of maintenance of the header itself it is better to wash the system with
utility water, (through temporary connections) from BL to the end of the header
(removing the FT orifice plate and blind flange at the end) and then blow the
system with steam until everything is clean.

5.2.13

Amine Drain System

Amine Drain System is not normally put out of service.
In case of check for mechanical completion of AD network after specific
maintenance, the header can be disconnected at drum (33-V-201) inlet and
washed with Utility Water. The Amine Closed Drain Sump should be steamed
out separately and blanketed with Nitrogen.

5.2.14

Light HC Closed Drain System

Light HC Closed Drain System is not normally put out of service.
In case of check for mechanical completion of CD network after specific
maintenance, the header can be disconnected at drum (33-V-202) inlet and
washed with Utility Water. The HC Closed Drain Drum should be steamed out
separately and blanketed with Fuel Gas.