VBU Manual U-37 Chapter 1-13 PDF

VBU Operating Manual
HALDIA REFINERY
CHAPTER - I
1.0. INTRODUCTION
Haldia Refinery was designed to produce various grades of Lube Oil Base Stocks
and Bitumen. Surplus distillates and heavy stocks when pooled together could not
meet FO specification. The feed stock therefore was designed to be visbroken in
a coil type Visbreaker Unit @ 462,000 TPA originally designed by M/s Romanian
State Institute for Oil Refinery Design.
This coil type Visbreaking Unit has been operating at Haldia Refinery since 1976
using a mixture of PDA asphalt, Vacuum Residue, Spindle distillates and Light Oil
as feed stock.
The existing coil type Visbreaker is switched over to a soaker type visbreaker
which result in
a) Reduction in fuel consumption due to low temperature operation
b) Less coke deposition in furnace tubes will at least double the the cycle length
c) Flexibility in operation with respect to processing of different feed stock
particularly that of having higher viscosity
d) Improvement of middle distillate yield by about 5.8% wt
e) Lesser probability of chokage of transfer line PRCV with coke
1.1 Function of Visbreaker Unit
Visbreaking or viscosity breaking is basically a mild thermal cracking process, a
common process wherein long chain hydrocarbon molecules in heavy feed stocks
are broken into small molecules having low viscosity, thereby leading to a viscosity
reduction of feed stock. This results in conserving valuable distillate products which
would otherwise be required to be used as cutter stock to produce fuel oil of required
specification.
There are two alternate processes for visbreaking:
Coil Visbreakinq
In this process, feed stock is cracked at high temperature (480-500 Deg C) in a
furnace with shorter residence time to achieve the required conversion.
Soaker Visbreakina
In this process feed stock is heated to relatively lower temperature (435-445 Deg
C) in a furnace and partly cracked VB charge is hold in a Soaker Drum for longer
residence times (25-30 min) to achieve the required conversion.
1.2 Visbreaking Chemistry
Visbreaking process reduces the viscosity as well pour point of the feed stock.
With the application of heat and temperature higher boiling hydrocarbons are
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decomposed and form lower boiling hydrocarbon molecules. Some of the reactive
molecules, however, combine with one and other to produce even higher boiling
molecules.
The process produces VB gasoline, gas oil and bottom residue (VB tar), basically
cracked and polymerised stock. The end product is essentially dependent on the
quality of feed stock, the temperature and pressure under which the stock is
cracked.
Cracked products are unstable and form gum. During the cracking some coke is
usually formed. Coke is the end product of polymerisation reaction in which two
large olefinic molecules combine to form an even larger olefinic molecule.
C10 H21 - CH = CH2 + CH2 = CH - C10 H21 ->
C10 H21 - CH =CH - CH2 - CH2-C10H21
When above reaction gets repeated several times, the end product is coke. This
usually found inside the walls of furnace tubes, soaker drum & other spots where
all may remain at high temperature and soak heat for sometimes.
Some of the typical reactions are given below:
C1O H22 ———> C8 H17 + C2 H5
C2 H5 + C6 H14 ———> C2 H6 + C6 H13
C13 H20 ———> C3 H10 + C5 H10
C15 H30, C7 H15 ———> C7 H16 + C14 H28 CH2 + C6 H12 CH2 C2 H6
+ C4 H8 CH2 + C8 H18 + C6 H12 + CH2
CH2 CH CH CH3 + C2 H4
1.3 Feed Stock
The original feed stock to VBU was a mixture of PDA Asphalt, Vacuum Residue,
Spindle Distillates and Light Oil. But considering the feed mix availability scenario,
the soaker is designed to process a feed stock consisting of PDA Asphalt and
Vacuum Residue in a proportion of 60 : 4 0 weight basis.
With mild cracking the feed stock is converted to gas, cracked naphtha, gas oil
and VB tar. The first three streams are separated in a fractionator and sent to
respective tanks while the bottom products i.e VB Tar is sent to FO pool, with or
without cutter stock.
1.4 Design Capacity
1.4.1 Presoaker
No. of stream days/year = 310
Design capacity = 462,000 TPA
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= 62.1 T/Hr
No of shutdown days/year = 55
- 4 shutdown of 6 days
1.4.2 Post Soaker
No. of stream days/Year = 330

Design capacity = 491,832 TPA
=62.1 T/Hr
Turndown = 90% of Normal capacity
No of shutdown days/year = 35
- 1 shutdown of 2 0 days for M&I shut down
- 5 shutdown of 2 days for short emergency shutdown.
- 1 shutdown of 5 days for long emergency shutdown
Note : However, all the key equipments and their-connections to the columns were
originally designed for 862,000 TPA with consideration of 310 stream days which
is equivalent to 917,613 TPA with 330 onstream days per year consideration.
Accordingly the new soaker drum has been designed to process 792, 000 TPA
(100 T/Hr) to cater the future needs.
1.5. Design Feed and Product Characteristics
1.5.1 Feed Characteristics
Feed : Asphalt : Short Residue 60:40
SNO CHARACTERISTCS FEED SAMPLE BLEND 1/3
1. Density at 15 Deg C 1.0399
2. Flash Point, Deg C 183.5
3. Viscosity, Cst
- at 135 Deg C 444.41
- at 100 Deg C 4301.3
4. Nitrogen, % wt 0.52
5. Pour Point, Deg d +72
6. Carbon Residue, % w
(Condradson) 22.84
7. Asphaltene Content, % wt 11.19
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SNO CHARACTERISTCS FEED SAMPLE BLEND 1/3

8. Penetration 4.7
9. Softening Point, Deg C 46.5
10. Sulphur, % wt 4.3
11. Wax content, % wt 1.2
12. C/H 7.6
1.5.2 Product Characteristics
Product : Gas
S NO CONSTITUENTS ANALYSIS
1 C1 44.5
2 C2 = 0.7
3 C2 20.7
4 C3 15.3
5 iC4 1.8
6 nC4 7.1
7 C4 = 1.7
C5+ 8.2
Product : Stabilised VB Gasoline : Fr IBP-150 Deg C
SNO CHARACTERISTCS IBP -150 Deg C
2. FIA, %
Aromatics 5.6
Olefins 50.8
Saturates 43.6
3. Sulphur, wt % 0.77
4. Bromine Number 54.5
5. C/H Ratio 5.68
6. RVP, Kg/Cm2 0.26
7. ASTM DISTILLATION Deq C
IBP 49.9
5% Vol 67.5
10% Vol 81.2
20% Vol 91.2
30% Vol 98.7
40% Vol 106.4
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SNO CHARACTERISTCS IBP -150 Deg C

50% Vol 113.3
60% Vol 120.3
70% Vol 127.7
80% Vol 136.4
90% Vol 144.3
95% Vol 150.2
FBP 164.0
Distillate % Vol 97.7
Residue % v 1.0
Loss % V 1.3
Product : VB GO : Fr 150-350 Deg C
SNO CHARACTERISTCS 150 - 350 Deg C
1. Density at 15 Deg C -
3. Nitrogen, ppm 302
4 Kinematic Viscosity, Cst
- at 40 Deg C 1.80
- at 50 Deg C 1.58
5. Diesel Index 67.7
6. Pour point, Deg C <-27
7 Anline Point, Deg C 57.1
8 Sulphur, wt % 1.98
9 Bromine Number -
10 C/H Ratio 6.39
11 RVP, Kg/Cm2 -
12 ASTM DISTILLATION Deg C
IBP 154 5
5% Vol. 166.4
10% Vol 178.5
2 0% Vol 196 .6
3 0% Vol 213.3
4 0% Vol 229.9
5 0% Vol 244.0
60% Vol 258.4
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SNO CHARACTERISTCS 150 - 350 Deg C

70% Vol 270.8
80% Vol 261.0
90% Vol 294.5
95% Vol 310.2
FBP 330.5
Distillate % Vol 96.9
Residue % V 1.6
Loss % V 1.5
Product : VB Tar R 150 Deg C +
SNO CHARACTERISTCS 150 Deg C +
2. Flash Point, Deg C 182.0.
3. Nitrogen, ppm 0.48
5. Kinematic Viscosity, Cst
- at 70 Deg C 4037.2
- at 100 Deg C 445.56.
6. Asphaltenes, % wt
7. Pour point, Deg C + 36
8. CCR, wt % 16.85
9. C/H Ratio 7.96
10. Merit Number 6.5
11. ASTM DISTILLATION Deg C
IBP 202
5% Vol 292
10% Vol 36S
2 0% Vol 48S
3 0% Vol 552 (27%)
4 0% Vol
50% Vol
50% Vol
70% Vol
80% Vol
90% Vol
95% Vol
FBP
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Product : VB Tar R 350 Deg C +

SNO CHARACTERISTCS 350 Deg C +
3. Nitrogen, ppm 0.58
5. Kinematic Viscosity, Cst
- at 70 Deg C -
- at 100 Deg C 2352.86
- at 135 Deg C 228.07
6. Asphaltenes, % wt -
7. Pour point, Deg C + 60
8. CCR, wt % 8 .29
9. C/H Ratio 8.29
10. Merit Number 6.5 (stable)
11. ASTM DISTILLATION Deg C
IBP 345
5% Vol 409
10% Vol 472
20% Vol 546 (20%)
30% Vol
4 0% Vol
50% Vol
60% Vol
70% Vol
80% Vol
90% Vol
95% Vol
FBP
1.6. MATERIAL BALANCE
1.6.1 Feed Stock
Constituent MT/Hr % WT
PDA Asphalt 37.26 60.0
Vacuum Residue 24.64 40.0
Total : 62.10 100.0
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1.6.2 Products
Case-A : Without Soaker
Product MT/Hr % WT
Gases 0.925 1.49
Stabilised Naphtha 1.428 2.3
Gas Oil 0.926 1.49
VB Tar (350 0C +) 58.82 94.72
Total 62.10 100.00
Case-B With Soaker
Product MT/Hr % WT
Gases 1.28 2.06
Stabilised Naphtha 1.53 2.47
Gas Oil 5.31 8.55
VB Tar (350 0C +) 53.98 86.92
1.7. Utilities & Chemicals
1.7.1 Utility Requirement
Utility Unit Consumption
Pre Soaker Post Soaker
1 Cooling Water MT/Hr 840 620
2. MP Steam MT/Hr 6.3 (*5) 3.06 (*4.5)
3. LP Steam MT/Hr -13 -9.76
4. Power KW 318 570
5. Instrument Air Nm3/Hr 120 180
6. Utility Air Nm3/Hr *500 *624
7. Fuel Gas T/Hr 2 0.973
8. DM Water M3/Hr 15 14
9. Service Water M3/Hr - 0.6 (**12)
(Blow Down)
* Intermitent Operational requirement.
Minus (-) Symbol indicates quantity is generated.
** Hose Station Requirement.
An additional rate of 6 T/Hr steam required by shoot blower for 12 minute, every 8
hours
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1.7.2 Chemicals
1. Corrosion Inhibitor : Approximately 1200 Kg/Hr
based on Ahuralan @ 5-6 ppm on 37C1 overhead vapour quantity
@ 3-4 ppm on 37C4 overhead vapour quantity
1.8. Battery Limit Conditions
1.8.1 Incoming Streams
Stream Temp (0C) Press (Kg/Cm2g)
Min Nor Max Min Nor Max
1. Feed Stock - 110 - - 2-9 -
2. MP Steam 230 290 310 13 14 15
3. Cooling Water - 33 - - 3.2 4.0
4. Instrument Air - 40 - 4.0 4.5 6.0
5. Plant air - 40 - 2.0 3.0 7.0.
6. Fuel Oil - 80-90 - - 8.0 10.0
7. Fuel Gas - 30 - - 2.7 4.0
8. LP Steam - 155-160 - 3.5 4 .0 5.0
9. Slop - 60 80 - 1.0 -
10. Spindle Oil - 5.0 70 - 4.0 -
11. Light Oil - 65 80 - 4.0 -
12 . Flushing Oil-I ** - 40 50 - 5.0 -
13. Flushing Oil-II*** - 50 70 - - -
** Gas Oil
*** Spindle Oil
1.8.2 Outgoing Streams
Streams Temp (0 C) Pressure (Kg/Cm2a)
1. VB Gas 45 5.0
2. VB Naphtha 45' 6.5
3. VB Gas Oil 45 7.0
4. VB Tar 80 4.5
5. LP Stream 155 - 160 5.0
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1.9 List of Equipments

1.9.1 COLUMNS
SNO TAG NUMBER SERVICE DATA SHEET
NUMBER
1 37-C-1 FRACTIONATOR 3592-37-2-DS-2.02/203
COLUMN
2 37-C-2 STRIPPER COLUMN 3592-37-2-DS-2 04/2 05
3 37-C-3 ABSORBER COLUMN 3592-37-2-DS-206/207
4 37-C-4 STABILISER COLUMN 3592-37-2-DS-2 08/209
5 37-C-105* SOAKER DRUM 3592-37-2-DS-201
* new equipment
1.9.2 VESSELS
NUMBER
1 37-B-1 CBD DRUM
2 37-B-2 FRACIONATOR
REFLUX DRUM
3 37-B-3 STABILISER REFLUX
DRUM
4 37-B-4 PURGE EXPANDER
5 37-B-5 WATER SEPARATOR
6 37-B-6 CONDENSATE DRUM
7 37-B-101 SLOP DRUM
8 37-B-102* FLUSHING OIL-1 3592-37-2-DS-210
DRUM
9 37-B-103* FLUSHING OIL-II 3592-37-DS-2-211
DRUM ,
10 37-B-104* STEAM DRUM 3592-37-2-DS-212
11 37-B-105* FEED SURGE DRUM 3592-37-2-DS-213
* New vessels
1.9.3 PUMPS
NUMBER
1 37-P-1/1R/1B FEED STOCK PUMPS 3592-37-2-DS-401
2 37-P-2/2R VB TAR PUMPS (OLD)
3 37-P-3/3R GAS OIL PUMP 3592-37-2-DS-403
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NUMBER
4 37-P-4/4R RECIRCULATED 3592-37-2-DS-404
REFLUX PUMP
5 37-P-5/3R RICH ABSORBENT 3592-37-2-DS-405
PUMP
6 37-P-6/6R UNSTABILISED 3592-37-2-DS-406
GASOLINE PUMP
7 37-P-8/8A WATER INJECTION
PUMP
8 37-P-9/9R LIGHT OIL PUMP
9 37-P-10/10R RECYCLE WATER 3592-37-2-DS-410
PUMP
10 37-P-11 SLOP PUMP
11 37-P-12 INHIBITOR INJEC-
TION PUMP
12 37-P-114A/B* FLUSHING OIL-II 3592-37-2-DS-415
PUMP
13 37-P-115A/B* FLUSHING OIL-I 3592-37-2-DS-416
PUMP
14 37-P-116* FLUSHING OIL RAM 3592-37-2-DS-417
PUMP
15 37-P-117A/B* STABILISER REFLUX 3592-37-2-DS-407
PUMP (In place of 37-P-7/7R)
16 37-P-119A/B* VB TAR PUMPS (NEW) 3592-37-2-DS-414
17 44-701-P-101 VB FEED BOOSTER 3592-37-2-DS-418
A/B@ PUMPS
18 37-P-120A/B* CUTTER STOCK PUMP 3592-37-2-DS-419
19 37-P-121A/B* SEAL OIL PUMPS 3592-37-2-DS-420
FOR P-119A/B
1.9.4 HEAT EXCHANGER
NUMBER
1 37-E-1 A/B/C/D RESIDUE FEEDSTOCK 3592-37-2-DS-301
HEAT EXCHANGER
2 37-E-2A/B FRACTIONATOR 3592-37-2-DS-302/
CONDENSOR 303.
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NUMBER
3 37-E-3 ABSORPTION GAS 3592-37-2-DS-304
OIL COOLER
4 37-E-4 STAB/UNSTAB 3592-37-2-DS-305
GASOLINE HEAT
EXCHANGER
5 37-E-5 STABILISER 3592-37-2-DS-306/307
REBOILER
6 37-E-6 STABILISER 3592-37-2-DS-308
CONDENSOR
7 37 - E - 7 STABILISED 3592-37-2-DS-309
GASOLINE COOLER
8 37-E-8A/B RESIDUE COOLER 3592-37-2-DS-310
9 37-E-9 SAMPLE WATER
COOLER
10 37-E-10 RESIDUE SAMPLE
COOLER
11 37-E-101 SLOP/VB TAR HEAT
EXCHANGER
12 37-E-111A/B* RICH OIL/LEAN 3592-37-2-DS-311
OIL HEAT
EXCHANGER
13 37-E-112 A/B* GAS OIL PRODUCT 3592-37-2-DS-313
COOLER
14 37-E-113 A/B* VBFO STEAM GENE- 3592-37-2-DS-314
RATOR
15 37-H-1 GAS OIL CR STEAM 3592-37-2-DS-312
GENERATOR
1) * Represents new exchangers
1.9.5 HEATER
NUMBER
1 37-F-1 VB FEED HEATER 3592-37-2-DS-1001
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1.9.6 FILTERS
NUMBER
1 37-GN-101 A/B* FLUSHING OIL 3592-37-2-DS-1401
2 37-GN-102 A/B* FLUSHING OIL 3592-37-2-DS-1402
3 37-GN-103 A/B* VB TAR 3592-37-2-DS-1403
4 37-GN-104 A/B* SOAKER LIQUID 3592-37-2-DS-1404
1) * New Filters
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CHAPTER - II
2.0 PROCESS DESCRIPTION
The Visbreaking Unit was designed to process a feed stock comprising of a blend
of Short Residue, Asphalt, Light Oil Distillate cut & slops etc to produce a stable
fuel oil component having a lower viscosity and pour point. However, soaker type
VBU is designed to process a feed stock comprising of a blend of Asphalt & SR
(60: 40 wt).
Two number rotary pumps (44-701 P101 A/B) have been installed in the 700 pump
house at the West side of the existing booster pump. The discharge pressure will
be maintained by local spill back controller (44PIC101).
Feed stock is charged into the Pump 37P-1/1R/1B at 80 to 110 Deg C via Feed
Surge Vessel 37B105. Feed surge drum pressure (1.8 kg/cm2.g) will be maintained
with inert gas by a split range pressure controller 37PIC1103. Level will be controlled
by 37LIC1101. For design feed stock, feed temp is to be maintained at 110 Deg
C.
Feed preheating is attained by heat exchange with fractionator bottom residue
(VB Tar) in heat exchanger 37-E-1 A/B/C/D. These four nos. of heat exchanging
units are placed in series. Feed is being preheated to 272 Deg C in this preheat
train and it enters Heater 37-F-1.
The Feed Stock enters the convection section of the heater in two passes. The
feed is split equally between the two heater streams. FRCAL-3702 and FRCAL-
3703 control the individual passflow. From the convection section the stock passes
into the radiation section of the Heater. The two outlet streams from Heater 37-F-1
are brought together in a header and passes into the soaker drum 37C105. From
Soaker drum it is entered into the Fractionator 37-C-1. Heater outlet temperature
is maintained at 430-445 Deg C. In order to prevent coke formation in the furnace
tubes, condensate water (hot well condensate) is injected into the last part of the
convection zone with the help of pump 37-P-8/8A. The effluent from the soaker
flows through a back pressure control valve PICV1301. Upstream of this valve the
stream is quenched with gas oil. The pressure at the outlet of the Soaker drum is
maintained 12-17 Kg/Cm (g) by PICV1301. The Heater is equipped with
combination burners which can operate either on Fuel Gas or Fuel Oil. Provision
has been kept to put quench gas oil to the outlet of furnace as and when it is required
through TRCV3702.
Before passing through PICV-1301, the outlet stream is quenched with gas oil
from P13/13R controlled by PIC1301 which is reset by TIC1307. To overcome
polymerisation and coking, Light Oil quench is given by 37-P-9/9R from VDU into
the Fractionator 37-C-1 between 4th & 5th tray of Distillation column.
To overcome the coke formation in 37C01 bottom, tar quench EX E01D is given
by FIC1401 cascaded with TIC1401 which maintains 37C01 bottom temp.
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The Column is provided with three sections. The bottom stripping section is
equipped with 4 trays, the middle section comprising of 9 trays and the top section
with 10 trays. One grid plate is existing between 4th & 5th tray. Gasoline vapours
leave column overhead at 13 0 Deg C. Gas oil is removed as a side cut from tray
10 and is fed into the stripping column 37-C-2. The bottom material of 37-C-l is
pumped out by 37-P-2/2R under level control (LIC-3703B) or by 37P119A/B under
level control (LIC-3703A). The temperature gradient of the column is controlled by
a gasoline reflux provided at the column top and a recirculating gas oil reflux
withdrawn from the draw-off tray 10, which is reintroduced into the column of tray
13 after being cooled in E-5, H-1 and a part in E-111A/B and in E-3. Steam is
introduced into the column bottom for stripping the tar from entrained light products.
Water vapours, gases and gasoline from the fractionator column overhead enters
the condenser E-2A/2B from where it is routed to the reflux accumulate or(37-B-
2). The separated gases from Vessel B-2 flows under pressure to the Absorber
37-C-3. The gasoline separated from water is pumped out by Pump P-6 and routed
partially as reflux to the Fractionator Column C-1, with the remainder flowing through
heat exchanger E-4 into the stabiliser column C-4. There is provision to draw off
water via 37B05 from top section (19th tray) of 37C01 to avoid accumulation of
water build up and the water is routed to 37B02 via 37E02.
In the Absorber column (37C03) the heavy hydrocarbons are recovered from rich
gases by gas oil absorption. The lean gases are -routed under pressure control
together with the stabiliser over head gases to the Fuel Oil.
Block as a source of fuel gas. The rich oil from the bottom of the Absorber C-3 is
reintroduced into the Fractionator column by pump P-5/3R for separation after
heating it in 37E111A/B.
Stabilized gasoline from 37-C-4 is routed under level control through 37-E-4
(stabilized gasoline vs. Unstabilized gasoline) and cooler 37-E-7 to storage. Heat
is supplied to the column bottom by reboiler 37-E-5, employing recirculating gas-
oil as the heating medium.. Gasoline flaw is recorded by FR3 713.
Gas-oil is obtained as a side stream fraction from column C-1 and after striping in
the stripper column C-2 it is routed by pump P-3/3R into the VB Tar Circuit at the
S/S inlet of E113 A/B or to the rundown after cooling it in 37E112 A/B. A part of
stripped gas oil after cooling in 37E112 is sent to 37B103 for flushing fluid. A
portion of the gas oil ex H-l is routed through 37-E-111A/B (Lean Vs Rich GO
exchanger) and then through cooler E03 in the Absorber column as absorbent.
Rich Gas oil Ex37C03 is sent to 37C01 via 37E111A/B.
VB Tar from the Fractionator bottom together with gas oil, exchanges heat with
the feed stock in exchanger E-1 A/B/C/D and thereafter passes through steam
generator E113A/B & cooled in cooler E-8 A/B before routing to storage. Provision
has been given to inject light oil or spindle oil as cutter stock at the upstream of
37E08, by 37P120 A/B. Provision exists to quench fractionation bottom by Light
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Oil (a cut of VDU) since there is possibility of further cracking at the bottom of
Fractionator (the product gets residence time-a certain minimum level is
maintained). Provision has been given for tar quenching at the bottom of 37C01
by FIC1401 which is reset by TIC1401 which maintains the column bottom
temperature within 350-355 Deg C. VB Tar to storage is recorded by FR-3714. A
slip stream of tar is. utilised to heat up slop in 37-E-101 during slop processing.
For obtaining an effective heat recovery in the unit, following Low Pressure Steam
Generation Systems are provided.
(a) STEAM GENERATOR H-1 : Employinq recirculated gas oil as che heating
medium, which after cooling is used as quench and recirculating reflux to the
Fractinator and absorbent to 37C03 via 37E111 and 37E3.
(b) STEAM GENERATION IN 37F01 : Steam also qenerates in furnace F-1 to
recover heat from the flue gases in conjunction with H-1. Water circualtion
through the furnace generator is ensured by Pump P-10/10R.
(c) STEAM GENERATOR 37-E-113A/B: Employing tar as the heating medium
ex 37E1D which after cooling in E08A/B goes to rundown.
In order to avoid corrosion of the overheat equipment of the Fractionator and
Stabiliser, facilities are provided for injection of inihibitor (AHURALAN) into
the column overhead lines.
The unit is provided with a blowdown system for emergencies and collection
of drainage/slops in 37-B-1 which can be pumped to slop tank by 37-P-11.
SOOT BLOWING SYSTEM : Heater is provided with soot blowing arrange-
ment at its convection bank.
Following provision is there to process slop continuously ex Tk-601/602. Slop
is received from Tank-601/602 [depending on amount of water < 1%] in 37-
B-101 & separation of water is done by maintaining interphase level (with
continuous water draining facility). Oil is the taken in P-9/9R to 37-C-01 bot-
tom via 37E101 where in slop is heated with a slip stream of VB tar. Amount
of slop processing regulated by controlling 37-C-01 bottom temperature 355
Deg C.
Flushing Oil System consists of the following.
1> Normal Flushing Oil (Gas Oil)
2> Medium Pressure Flushing Oil I (Gas oil)
3> Medium Pressure Flushing Oil - II (SO)
4> Medium Pressure Flushing Oil - III (Extract)
5> High Pressure Flushing Oil (Gas oil)
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Normal flushing oil is drawn from the Refinery flushing oil header and used for
normal flushing of various equipments like heat exchangers etc.
Medium Pressure Flushing Oil - I (Gas oil from U-37 or U-31) is used for in-
strument purging at the soaker drum instruments i.e. where ever I t is possible to
recover this oil products. Flushing Oil-I from 37B103 is pumped to medium pres-
sure header by 37P115 A/B. MP flushing oil is then filtered in Flushing Oil-I filters (3
7GN101 A/B) before it goes for flushing /purging. Level in 37B103 is maintained
by taking GO in the vessel under level control - Pressure on the discharge of the
Flushing Oil-I pumps is controlled by spill back controller (37PICV 2202). Gas oil
can be sent to 700' pump house for flushing of pumps (44-701 P101 A/B) casing.
Medium pressure flushing oil-II (SO) is used for instrument; purging (where the
stream is going to VB FO rundown), coarse and fine filters. Flushing oil-II (SO)
from flushing oil-II drum B102 is pumped by flushing oil-II pumps (37-P114 A/B) to
the flushing oil-II filters (37GN102 A/B) before using it far flushing/purging. It. is also
been utilised to flush the CBD. lines. Make up flushing oil-II (SO) enters the drum on
level control of the drum. Pressure on the discharge of 37P114 A/B is controlled by
spill back controller (37 PICV2201). Provision has been given to take spindle oil
either from flushing oil header near 37 P9/9R or light oil from 31 E127 outlet.
Flushing oil-III (EXTRACT EX U-33/38) is used exclusively for the seal flushing
of VB tar centrifugual pump 37P119 A/B. Make up flushing fluid-III(Heavy extract)
enters in 37B106 from either U-33 or U-38 on level control of the vessel. It is then
pumped by 37 P121 A/B with spill back control. Stand by pump P121 A or B will
start automatically on low header pressure of flushing fluid. For low low header
pressure of flushing fluid-Ill, 37P119 A/B shall trip. Provision has been given to
take light oil in 37B10S Ex U-31.
High pressure flushing oil connections are provided at the points where there is
possibility of choking because of congealing nature of VB tar/VB fuel oil. Flushing
oil-Ram pump (37P116) has been provided for ramming all such points. Flushing
oil required for ramming is taken from Flushing Oil-I vessel outlet. Pressure at the
outlet of this ram pump is again controlled by spill back control valve (37PICV2204).
During ramming care has to be taken so that the pressure should not be allowed to
increase the permissible limit with respect to that line/circuit (REF ANNEXURE-I
FOR RATING OF THE LINES AND MAXIMUM PRESSURE ALLOWED
DURING RAMMING).
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HALDIA REFINERY
CHAPTER - III
3.0 SUGGESTED NORMAL OPERATING CONDITIONS FOR DESIGN FEED
STOCKS
Following operating parameters are maintained during the normal running of the
Unit with design feed stock.
Feed Surge Drum (37-B-105)
Parameter Operating Value Design Value
Pressure, Kg/Cm2g 1.8 3.5
Temperature,0C 110 ISO
Feed Flow, MT/Hr 62
3.0.1 Heater (37-F-1)
Parameter Design Operation Value
Feed Rate, M3/Hr @15 Deg C 59.7
Turbulizing Water, T/Hr 0.621 (0.3105 in each pass)
Inlet Temp, 0C 272 0C
Outlet Temp, 0C 435 0C (445 Deg at 100 MT/hr)
Pressure Drop, Kg/Cm2g 9-15
Coil Outlet pressure Kg/Cm2g 13-19
Tube Skin Temp, 0C(Max) 650
Stack Temp, 0C 300
3.0.2 Soaker Drum (37-C-105)
Parameter Operating Value
Inlet Pressure 13-18 Kg/Cm2g
Outlet Pressure 12-17 Kg/Cm2g
Transfer line pressure (C105 to F01) 7 Kg/Cm2g .
Inlet Temperature 430-440 0C
Middle Temperature 428-430 0C
Outlet Temperature 426-436 0C
Quench Oil Flow 5 M3/Hr
Quench Oil Temperature 204 0C
Transfer Line Temperature (C105 to F01) 415 0c
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3.0.3 FRACTIONATOR 37C01

Flow (M3/Hr)
Feed - 59.71
Reflux - 9.55
Flow (M3/Hr)
VB Tar - 80
Gas Oil CR - 57.73
VB Tar quench - 28.57
Rich Oil to Col - 18.77
Stripping Steam (Kg/hr). - 160 0
Temperature (OC)
Feed - 415
Reflux: - 45
VB Tar - 356
GO CR Draw - 236
GO CR RTN - 200
VB Tar Quench - 252
Rich. Oil return - 140
C01 Furnace Zone - 408
C01 Top - 135
Stripping Steam - 280
Pressure (Kg/Cm2g)
Top - 5.3
Flash Zone - 5.5
3.0.4 GO STRIPPER 37C02
Flow (M3/Hr)
Feed - 8.34
Bottom - 6.25
Stripping Steam(Kg/Hr) - 150
Temperature ( OC )
Top - 232
Bottom - 226
Feed - 235
Stripping Steam - 280
Pressure (Kg/Cm2g)
Top - 5.40
Bottom - 5.45
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3.0.5 SPONGE ABSORBER 37C03

Flow (M3/Hr)
Lean Oil - 17.83
Rich Oil - 19.22
Temperature ( OC )
Top - 48
Bottom - 140
C1 OHD Vapors - 45
Pressure (Kg/Cm2g)
Top - 4.5
Bottom - 4.74
Gas production (kg/hr) - 575
3.0.6 STABILISER 37C04
Flow (M3/Hr)
Feed - 3.195
Bottom - 2.342
Reflux - 1.5
Temperature ( OC )
Feed - 100
Bottom - 155
Reflux - 53
Top - 70
Pressure (kg/Cm2g)
Top - 7 .21
Bottom - 7.30
Gas Production(Kg/hr) - 527
3.1 OPERATING VARIABLES
3.1.1 Feed Rate
Feed rate is determined keeping in view the overall requirement of the refinery but
it should not be less than the turndown ratio as specified. It is controlled by adjusting
flow controller 37-FIC-3702/3703. When feed rate is reduced, residence time in
furnace coil and 37C105 (Soaker) is increased and severity of cracking reaction
goes up resulting in lowering viscosity and pour point of VB tar and in turn more
coke lay down in furnace coils and soaker drum. This can partly be compensated
by increasing turbulising water flow through the furnace tubes and if required rest
by lowering coil outlet temperature by 10-15 Deg C. Increased severity may lead
to the instability problem of the fuel oil produced.
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When feed rate is increased, residence time in furnace coil and soaker drum
reduces causing reduction in severity of cracking reaction resulting in raising the
viscosity and pour point of VB Tar and in turn reduction of coke laydown in furnace
coils and soaker drum. This can partly be compensated by reducing the turbulising
water flow through furnace coils and rest by raising coil outlet temperature. The
normal turbulising water flow through each pass when feed rate is 100% i.e. 62
MT/hr is 310.50 kg/hr/pass and when feed rate is reduced to 90%, the turbulising
water flow is to be increased accordingly.
3.1.2 Furnace outlet transfer line temperature
At constant feed, if transfer temperature is raised the amount of cracking increases.
More gas, naphtha and gas oil are produced and the viscosity of VB Tar goes
down. Simultaneously, coke deposition in the furnace tubes increases resulting in
reduced run length of the unit. In addition, heat input to fractionator increases. This
calls for increase in CR and top reflux flow rates to maintain required product
specifications - When transfer temperature is reduced, the reverse takes place.
At design feed rate i.e. 62 MT/hr transfer temperature is 435 Deg C but transfer
temperatures are changed as per feed quantity or quality and VB FO viscosity/
pour requirements.
Indicative direction of T’put vis-a-vis coil outlet temperature for design feed case
is given below to achieve same conversion.
T’put MT/hr COT Deg C
62.1 435-440
56 (90% of 62.1) 432-438
75 (120% of 62.1). 437-442
100 441-445
3.1.3 VB GO quench to Soaker Outlet
The VB GO quench reduces the temperature at soaker drum outlet and stops
further cracking. This quench helps in reducing the tendency to laydown coke in
the transfer lines to column and column inside. Quench rate should be just sufficient
to avoid coking of transfer line. The quench flows to transfer line should be such
that the transfer line temperature should not exceed 415 Deg C. This flow will be
adjusted according to change in feed conditions and cracking severity. The quench
oil flow is controlled by 37FIC1301 which is reset by 37TIC1301.
3.1.4 Fractionator Pressure
The pressure on the fractionator is maintained by PIC-3703 which releases gas to
FG system. The HV1501 at the upstream of PICV3703 is provided to depressurise
the system to flare. A lower pressure causes more vaporisation resulting in heavier
naphtha and gas oil. Tar viscosity also goes high. Higher pressure makes naphtha
and gas oil lighter. VB tar viscosity also goes down. The normal pressure 5.3 kg/
cm2(g).
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3.1.5 Fractionator Top Temperature

The column top temperature is controlled by TIC3704 which adjusts reflux flow
through TV3704N to column 37C01.
Lowering the top temperature reduced initial boiling point and flash point of gas
oil. The yield of Naphtha comes down. Raising the top temperature will increase
the FBP of Naphtha and IBP and flash point of gas oil. The normal top temperature
is 135 Deg C.
3.1.6 Circulating Reflux Flow
The gas oil circulating reflux removes heat from the column and reduces vapor
load in the section above it. The C.R flow through steam generator circuit is
controlled by FIC3704 & FIC1301. The normal circulating flow is 72 M3/hr. A higher
C.R flow will lower the blind tray temperature and thus FBP of gas oil will come
down. Naphtha production will also reduce. Reduction in gas oil CR flow will result
in the reverse.
The return temperatures of the GO streams ex 37H-1 is 200 Deg C.
3.1.7 Gas Oil Stripper
Gas oil draw off from the blind tray to the stripper 37C02 is controlled by stripper
level controller LIC3704. From the stripper, gas oil is removed by FIC3707 A &
FIC3707B to VB Tar or GO R/D respectively. The flow of gas oil depends on the
amount of gas oil in the furnace effluent. Stripping steam is admitted into the gas
oil stripper to remove light ends. Increasing the stripping steam amount upto certain
level raises the IBP and flash point of gas oil. Lowering the steam flow will allow
lighter hydrocarbons in the gas oil making its IBP and flash point lower. Design
stripping steam rate is 150 kg/hr.
3.1.8 VB Tar Quench to Fractionator Bottom
In order to reduce coke formation in the fractionator bottom, cooled VB tar EX E01
at 252 Deg C is given as quench to its bottom. The normal flow rate is 28.6 M3/Hr.
Quench flow is controlled by 37FIC1401 which is reset by 37TIC1401 and bottom
temperature is maintained around 355 Deg C. Higher bottom temperature may
result in coking. The residence time of less than one minute will reduce the chances
of coking. Facility also exists for giving light oil quench to 37C01 bottom.
3.1.9 Stripping Steam to Fractionator
Stripping steam (VM) injected to 37C01 through FIC3706 to reduce the partial
pressure of Hydrocarbon as well as to strip off lighter material from tower bottom
product to get the desired flash point of tar.
3.1.10 Stabiliser Temperature and Pressure
The stabiliser removes most of butanes and lower hydrocarbons from unstabilised
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Naphtha. These are removed as gas from the stabiliser overhead. Higher top
temperature makes overhead gas heavier. On the other hand, lower top temperature
gives lighter gas. Design top temperature is 70 Deg C. Lower than design bottom
temperature of stabiliser will result in higher RVP of naphtha. The normal bottom
temperature is 115 Deg C.
Lower column pressure causes Heavier hydrocarbons to be carried into the fuel
gas system. Higher pressure increases RVP of bottom product. Normal top
pressure is 7.2 kg/cm2(g).
3.1.11 Soaker Pressure and Temperature
Normal operating pressure at the top of the soaker drum for design feed stock is
12 kg/cm2 (g). For lighter feeds, a higher operating pressure upto 17 kg/cm2 (g)
at the top of soaker drum can be used to obtain BUBBLE FLOW REGIME in the
soaker drum. To ensure bubble flow regime, the three TE’s - 1303/1304/1305
provided around the soaker drum, at the top should have readings close to each
other. If these readings are not close to each other, then this indicates that some
back mixing is taking place in the drum. Back mixing leads to undesirable cracking
reactions.
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HALDIA REFINERY
CHAPTER - IV
4.0 NORMAL START-UP PROCEDURE ;
Some of the checks to be carried out prior to actual commissioning of the unit are
indicated below.
ENSURE THAT :
01) Mechanical work has been completed as per P&ID
02) Hydraulic testing of various equipments/piping has been completed
03) Equipments, piping etc have been flushed and they are ready for use
04) Functional tests of rotary equipments and instruments checking/calibration
have been carried out
05) All safety valves are in position after setting and testing
06) Blinds are installed as per master blind list for start up and they are duly
recorded
07) Blinds from fuel oil lines at the battery limit have been removed
08) Flare, CBD and OWS systems, flushing oil facilities are in working condition
09) Safety and fire fighting equipments are in working condition
10) Unnecessary scaffoldings, wooden planks, cotton waste, nuts and bolts
etc are removed from the operating area
11) Power is available in all pumps and earthing of pump is O.K.
12) Utility headers are commissioned
13) Feed Stock is available and there is sufficient ullage in run down tanks
14) Ensure availability of chemicals and other consumables
15) Before start up of Unit inform the following; agencies :
a) RSM
b) OM & Sà for keeping feed TK ready and line up of rundown product and
slop tanks (i.e. circulation tank) and also to keep TK-715 ready
c) TPSà for power, VM steam & DM water consumption. CHECK THE
STATE GRID POWER SUPPLY STATUS.
d) FOBà for vaporizer pressure as FG will be required during FG back up
START UP OF THE UNIT AFTER M&I COMPRISES OF THE FOLLOWING
OPERATIONS :
1. Pressure testing of columns & Vessels
2. Pressure testing of Furnace Coils
3. Fuel Gas (FG) back up
4. Cold circulation
5. Hot circulation
6. On-stream of Unit
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1) Pressure testing of columns, Vessels :

PROCEDURE ACTION TAKEN BY
1) Open LP flare B/valve at battery limit. Field Operator
2) Pressure testing of columns & vessels is done by VM steam. Field Operator
Open the VM steam B/L valve on pipe rack and drain
condensate by opening the purging header VM I/L block valve
(crack open) and its condensate drain valve. Open other low
pt. drain valves in the unit
3) Pr. testing of 37C1, B2, C2, B5, C3, E3(S/S),E2 (S/S)
Get the steam out pts. SPB of column C3 reversed in open Field Operator
position and remove Tail Blind if any on stripping steam l/L
lines of columns C1 and C2. Pinch water of E2. Open the
vents of columns C1, B2, B5, C3. Drain steam condensate
from stripping steam inlet line bleeders of column C1 & C2.
Open suction valve (crack open) of pump P2/2R/ P119A/B
and its suction drain bleeders and pump chest bleeders for
draining condensate of column C1. During pr. testing, Column
C1 blow down valve to vessel B1 is opened crack. Open
suction valves of pumps P-3/3R and suction drain bleeders
fox draining condensate. of column C2. Open suction valves
and suction drain bleeders of pump P-5/3R for draining
condensate of column C3. Open suction valves and suction
drain bleeders of pump P6/6R for draining condensate of
vessel B5 thru’ B1.
4) Keep fully closed PICV1301 (Soaker BPC) , PICV03 Panel Operator
(37C03) & HV1501 (37C03 to flare)
5) Open FRCV-3706(Stripping steam to C-1) slowly. Gradually Panel Operator/
increase steam and check draining of condensate from all Field Operator
low pts and connected lines of C1. When steam appears
from the top vent of column increase steam further. After
purging all associated lines for few minutes open Stripping
Steam Block valve of C2 and Block valve of Steam out point
of C3 simultaneously
KEY POINTS :
# Open Control valve slowly and drain condensate on line
and then open b/v at the column I/L so that no hammering
takes place inside column. Drain condensate from all low
points of C1,B2,C2, C3 and B5. Open LPD’s of FICV-09
(Peed C04), TRCV-.08, C3LCV, E5 CT./S) , P-13/13.R
suction drain, P-4/4R suc/disch drain, TRCAH-3702, Drain
condensate from E112.
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# If hammering observed in E2 pinch water to E2
maximum.
At this time steam from B2, B5 and C3 vents will appear.
Open FRCV-3 708 and back up steam up to E111 via E3.
Drain condensate from E3 & E111 LPD’S.
6) Gradually close vents of Cl, B2, B-5 & C3 slowly and Field Operator
observe the columns and vessels pressure
KEY POINTS :
COLUMNS & VESSELS WILL BE PRESSURE TESTED
AT 5 KG/CM2
7) Check all manholes, PSV’s up stream flanges, connected Field Operator
flanges’ of columns, vessels including Level Gauge Level
Troll Flanges
8) If pressure holds i.e., no leak observed, gradually c l o s e Shift-in-Charge/
steam I/L valves but not fully so that some steam should Field Operator
come from the vents (i.e. columns, vessels are under
+ve pr.)
KEY POINTS :
# ALL LOW PT.DRAINS ARE TO BE KEPT OPENED FOR
DRAINING CONDENSATE
# Steam should appear from all connected lines
9) Pressure Testing of 37C4, B3, E4 (S/S) , E7, E6 (S/S.) Panel Operator/
Get the steam out point spectacle blind of C4 reversed in Field Operator
open position. Pinch water to E5, E7 Open the vents of,
C4, B3. Open all LPD valves of connected lines to C4, B3,
E6, E4, E7. Open the suc. valves of P-117/7R (crack open)
and sue. bleeders for draining cond.of B3. Open E-5 (S/S)
LPD and E4 LPD to drain cond. of C4. Keep PRCV-04
closed fully. Open FRCV-03 and FRCV-10 (crack) and
LPD’s of C/V’s.
10) Open S/0 pt. b/v very slowly and gradually increase steam Field Operator
till Steam appears from the vent of C-4
KEY POINTS :
#Open valve slowly so that hammering does not take
place inside column
#Check appearance of steam from all LPD’s of control/
v’s & exchangers, pumps
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11) When steam appears from all connected lines of C4 and B3, Shift-in-Charge/
increase steam further. Gradually pinch vent valves of G4 and Field Operator
B3. If pr. holds i.e. no leak observed, gradually close steam
to C4 but not fully so that some steam should come from
vents of C4 & B3 . Unit is ready for Fuel Gas back up
12) Go on draining cond. from E5 S/S drain pt. and other low pt. Field Operator
drains of B4. Check the column’s & vessels’s pr. so that it
should not exceed 5 Kg/ Crn2 (g)
13) Steam will also appear from B3 vent. Check all manhole Field Operator
flanges, connected flanges of columns, vessels, exchangers
and PSV u/s flanges, L.T L.G., P.G flanges
14) Open LPD’s of FICV-37(C4 reflux), LCV of C4, E7 sample Panel Operator/
pt Field Operator
15) Purging of Feed lines & Feed Surge Vessels Connect Shift-in-Charge/
VB steam hose to 37B105 & purge the Vessels including Field Operator
the feed line to vessel & line upto feed pumps 37P01/1B/1R.
Keep blind the nitrogen line to 37B105.
16) Pressure Testing of Furnace Coils
After decoking operation is over and Okayed by Inspection Shift-in-Charge
Section, fill up furnace coils with water by the following way.
Before filling water get all the thermocouple flanges of TI pts.
boxed up by Instrument Maint. (KEEP DECOKING ELBOWS
IN POSITION). Do the necessary blinding for pressure testing.
The Detail steps are given below
17) Get convection I/L flanges of both passes blinded by special Shift-in-Charge
type of blind provided with vent points so that during water
filling of coils air can be vented from the above high pt. Vents
18) Fill up water in coils thru’ decoking header in reverse direction Field Operator
till water comes out from convection I/L vents By This time
get hoses connected, at suction strainer flanges Of P8 and
P8A.
19) After filling up coils close HPV on special type of blind by Shift-in-Charge
cap or plug Reduce water flow so that a little quantity of water
comes out thru’ the vents and plug the vents.
20) Ask Instrument Dept. to install High Range PG’ s (0-100 Kg/ Shift-in-Charge
Cm2) at coil I/L’s P8, 8A discharge. Get P-8/8A motor
energised.
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21) Once coil filled, close decoking header water valve & go for Shift-in-Charge/
pressurization by the following way. Open fire hydrant valve Field Operator
and start P-8/8A high pressure side pump. Gradually increase
pr of coils in stages i.e. 20/40/ 60/80 kg/cm2 respectively
Close the suction and disch.valve of low pr.side of P8/8A
and keep stroke adjuster of low pr.side to “0” position. Coils
are normally pr. tested at 80 kg/cm2 (Insp Dept. will give the
exact rating of pr.)
KEY POINTS :
Before starting P-8/8A ensure that valves at coil I/L’s
are open. If leak starts at any stages then
depressurizing of coils to be done. Get leaks rectified
by Mechanical Maintenance. Again start pressurization
(Keep Inspection Dept. informed)
22) After coil pressure testing is over stop P8/8A and Field Operator
depressurize and drained water from Furnace Coils by
opening Radiation I/L P.G LPD’s.
23) Get blinds from Convection I/L, Radiation out let removed Shift-in-Charge/
and box up flanges after draining water from coils Field Operator
24) close hydrant water valves and get P8/8A-suction strainers Shift-in-Charge
flanges boxed up.
25) Open decoking air valve to both passes and admit air thru’ Shift-in-Charge
forward direction for blowing coils to decoking pots. KEEP
RSM & TPS INFORMED BEFORE TAKING AIR.
26) After blowing coils with air, get decoking elbows removed Shift-in-Charge
and connect spool pieces at Convection I/L’s & Radiation O/
L’s.
27) Now open PICV—1301 slowly and displace air of coils & Panel Operator/
soaker drum by steam from 37-C1 to 37B1. Bleed steam Field Operator
from 37B1 stack for sometimes to remove air from Soaker
& Furnace Coils. Keep U/S b/v of FRCAL-02/03 closed and
open d/s of C/V’s crack open. Open C/V’s and also open
LPD flanges for draining condensates of Furnace Coils.
Adjust steam rate so that steam should always come from
37B1 stack.
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28) Pressure testing of Furnace Outlet to Soaker BPC Shift-in-Charge/

Once steaming out of Soaker & Furnace coil is over, Panel Operator/
subsequent operation & action points are below Stop Field Operator
bleeding from Feed FRCV’s D/S and close PICV1301 (BPC).
Open emergency VM steam to each pass of the coils & build
up pr. to 14 Kg/Cm2g slowly. Check any flange/valve
leakages, if observed, rectify it and do the testing again
KEY POINTS :
#Prior to opening of emergency Steam C/V(V3738)
ensure draining of condensate
29) Once pressure testing is over, depressurize the system Shift-in-Charge/
keeping positive pressure. Drain the condensate from Field Operator
LPD’s.
30) Pressure Testing of 37-E-01A/B/C/D
Open both feed FRCV’s and purge the feed circuit up to Shift-in-Charge/
Feed Pump discharges Keep close PICV 3701 & purge Field Operator
from U/S & D/S. Bleed from E1A/B/C/D via slop header to
B1 also.
31) Charge steam in 32P2/ 2R, P119A/B discharge & bleed Field Operator
via 37E1A to D Drain condensate from LPD’s. Bleed steam
from Tar sample point.
32) Close Feed Bleeders that are opened & raise the pressure Shift-in-Charge/
to 14 Kg/Crn2g slowly. If no leak observes depressurize & Field Operator
keep under bleeding. Close bleeding in tar circuit &
increases pr. to 10 Kg/Cm2g. If no leak observes
depressurize & keep under bleeding.
33) Flushing Fluid Circuit
Connect steam (LP) hoses in 37B102/103/106 steam out Shift-in-Charge/
point and PICV 2201/ 2202/2203/2204 LPD’s. Do the Field Operator
steaming after condensate draining. After steaming,
pressurize all the flushing fluid network to cheek the
leakages. Carryout the steaming operation while steaming
of the end, point circuits.
34) FG back up in Unit.
After pr. testing of Columns, Vessels are over, get Fuel Gas Shift-in-Charge
0/L line SPB to open position at Unit B/L and remove blinds
(if any) at d/s of PRCV-03 & 04. Before admitting F.G to Unit,
keep all extinguishers ready in respective position. Check
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HALDIA REFINERY

and ensure the valves of fire hydrants and monitors are in
operable conditions. Inform RSM and Fuel Oil Block for
maintaining FG drum pr. Open B/L Fuel Gas valve fully.
KEY POINTS :
# KEEP UNIT U-31 OPERATOR INFORMED AS 31F1 IS
NEAR TO U-37
35) Now decrease steam to columns so that column’s pressures Shift-in-Charge/
are less than Fuel Gas drum pressure. Slowly open PRCV- Panel Operator/
03 and 04 and back up F.G to columns 37-C1 and 37-C4. Field Operator
Open LPD’s at different places i.e. 37-P-2/2R/P119 A/B suc/
disch 37-P-3/3R/5/6/6R/117/7R/13/13R/P4/4R suction and
discharge bleeders (keep warm up by pass valves of all
pumps open) and drain condensates. During back up of FG
lot of steam gets condensed and so adjust steam rate and
FG rate to keep columns under +ve pressure. When FG starts
coming from LPD’s, close LPD valves and fix caps. Keep a
note where LPD’s were opened. Drain condensates from all
C/V’s u/s bleeders also. Before closing steam to columns
close vent valves of all columns, vessels etc and get vent
valves d/s flanges blinded and also fix caps on vents of
vessels (B-2, B-3, B-5) . Now gradually open PICV-1301 to
back up FG in Soaker & furnace coils. Drain condensate
from FRCV-02/03 bleeders (keep u/s b/v of FRCV closed
and open d/s b/v only). When FG smells from bleeders close
LPD valves and put end blinds. Get SPB on steam out pots
of 37C3 & C4 reversed in close position. Open HV1301
(Soaker pump out) and drain condensate from filters 37-
GN-103 A/B and 37-P119 A/B suction LPD’ s.
36) Check up all LPD valves and close all. Field Operator
37) COLD CIRCULATION CHECK FOR BLINDING/

DEBLINDING & ANY LEFT OVER JOBS.
Before starting cold circulation open all steam tracers of lines Field Operator
and check. Steam Tracing is to be ensured for all diaphragm
type instruments.
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38) At B/L open C/W I/L and 0/L valves. Open water to E2, E3, Field Operator
EG, E7, E112 and ES A/B and purge air from all condensers
and coolers by opening HPV’s. Energise all solenoid valves
39) Get all Fuel Oil burners fixed back in position and keep torch Field Operator/
and safety match ready. Keeping individual valves of F.O Panel Operator
burners closed, start FO circulation. (By pass low feed flow
security to open SDVs in IFO lines. Once it gets pressurized
put the security in line).
40) Get all FG burners fixed back and drain condensate Panel Operator
(if any) from FG line at B/L.
41) Open purging steam to 37-F-1 after opening dampers. Get Panel Operator/
all motors of pumps energised and check the rotations. Start Field Operator
heating up of steam chests of P-2/2R. Inform OM&S to line
up Tk-703/704. Open cooling water to all pumps and check
the flows. Open suction valves of all pumps (be sure that
drain valves are closed). Check the opening of 37-PICV-01
at different values.
42) Line up the flushing, fluid circuits as follows :
Take GO from U-31 to 37B103, drain condensate. Again Field Operator
build up level. Start P115A/B and inject in all the points to
drive out the condensate. (Back up GO to U-37 and push it
to VB tar line U/S of E113 and drain condensate from D/S
LPD of FV 3707A).
KEY POINTS :
# KEEP SOAKER PUMP OUT LINE FILLED WITH LO.
ENSURE WATER IS REMOVED COMPLETED.
43) Take Extract from U-33/U-38 or LO from U-31 or OMS(Ex- Field Operator
Tk-761) in 37B-106. Drain condensate. Start 37-P121 A/B
and flush the line to 37P119 A/B,
44) Open suction valve and by-pass valve of P-1/ 1R /1B and Field Operator
inform OM&S to start booster pump. Two rotary boaster
pumps, 44-701P101A/B, with PIC for control discharge
pressure have been installed at the side of existing booster
pumps. Now open the suction and disch. drains of P1/1R/
1B and bleed for sometime. Take feed in 37-B-105. 37B105
is to be kept under nitrogen pressure(1.8-2 Kg/Cm2g). Check
from pump suction Pressure Gauge / B/Limit Pressure
Gauge whether OM&S has started booster pump or not.
Keep 44-PICV-101 set at 7-8 Kg/ Cm2(g) (By OM&S)
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HALDIA REFINERY

45) Keep 37PICV01 set at 18-20 kg/cm2g. Start 37-P-1 /1R/1B Field Operator
and open disch pt. by closing by-pass valve and bring up
37C1 level upto 40-50%. Stop P01/1R/1B and drain C1 level
to B1 till free water is present. Again start 37-P1/1R/1B and
build up level in 37-C-1 P-1/1R/1B disch pr to be maintained
10-15 Kg/Cm2g. Keep pass flows 25 M3/hr/pass
46) After circulating from TK-703/704 to TK-703/ 704 for 1/2 hour, Field Operator
stop circulation and allow materials in 37C-1 to settle for 1/2
hr Drain water from 37 C-1/37C105 and all low points.
47) Stop P1/1R/1B and P-2/2R/ P119A/B. Ask OMS to adjust Shift-in-Charge/
44PIC101 set point because booster pump in OM&S is Field Operator
running
48) When water is drained from all low pts. Again start Panel Operator/
circulation; and stop after 1/2 hr. Check all low pt drains a- Field Operator
nd 37C1 bottom from bottom try cock .and P2/2R/P119A/
B pump chest/casing drains, 37C105 pump .out drain line
and also from B-01 drain
49) Again start circulation from Tank to Tank and gradually Panel Operator/
close PICV1301 and build up pressure inside furnace coils Field Operator
upto 3 0 Kg/Cm2 and check all flanges connected to
transfer line upto 37-PICV-1301. Check all flanges
connected to line up. Check instrument tappings also for
any leak. Adjust 37PICV01 and set at 30 Kg/Cm2g. Adjust
Pump (F1/1R/1B) bypass valve to build up pressure .
50) If OK then gradually open PICV1301 and Release pressure Panel Operator/
to B1. Tk-703/704 -Tk-703/704 circulation continues Adjust Field Operator
P1/1R/1B pressure and set again PICV 01 at 20 Kg/ Cm2.
Adjust P2/2R for C1 level in case P2/2R is in line .
51) Take L.O. in 10th Tray by 37-P09/9R. Keep Tk.715 suction Panel Operator/
valve to P9/9R closed. Field Operator
52) Pump Out 37C2 to 37C3. Push 37C02 via E112 & drain Field Operator
condensate. Drain water from P5/3R suc. drains.
53) Again fill up 10th tray and pump out through P4/4R and Panel Operator/
P13/13R to C1 via C105 & PICV13 01. Open TRCAH-3702 Field Operator
and FICV1301 and start P4/4R and P13/13R. Push to C3
via E111.
If C2 level gets filled up that indicates 10th tray level is
full.
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HALDIA REFINERY
54) Open FRCV-04 and flush Circ. reflux line into 37C-1 Drain Panel Operator/
water through P4/4R/13/13R SUC. & disch. bleeders. When Field Operator
all lines will be water free, hot circulation can be started.
55) Keep level in 37C2 upto 50% and C3 upto 40%. Now stop Panel Operator/
P9/9R Drain water from 37C1, C2 & C3.During cold Field Operator
circulation slop gasoline Tk. to be made free of water and
line content to be drained of water thru’ P9/9R suction drain
points.
56) HOT CIRCULATION
After cold circulation is established and water from all
possible points is removed from the system, the unit
is considered ready for hot circulation, Step wise
operation for hot circulation is given below:
Unit is on cold circulation (30M3/Hr/pass i,e. Tk.703/704 Field Operator
To Tk-703/704 continues. Stop purging of 37-F-1 box. Open
Fuel Gas B/L Audco valve and line up FG upto Furnace.
57) Light up 4 pilot burners at different locations of 37-F-l and Panel Operator/
one FO main burner. Open PRCV-02 and keep close Field Operator
individual FG burner valves. Keep Fuel 0il pressure at 3.3-
3.5 kg/ cm2g by operating TRCAH-3703 C/V. Take DM
water in 37B104.
58) After 1/2 hr light up 2nd F.0. burner at the other end of 37F- Panel Operator/
1 and bring up transfer temp. @30 Deg C/hr. Field Operator
59) Start 37-P115 A/B and start Injecting flushing fluid in all Field Operator
locations.
60) Go on draining water from all low pts. till transfer temp, Field Operator
reaches 110 -12 0 Deg C. Do not raise temp, further till 37-
C-1 bottom materials is water free. Flush out Soaker pump
out line also with LO.
61) CHECK FURNACE INTERLOCK & ESD INTERLOCK. Shift-in-Charge/
in presence of Instrument Maintenance Personnel. Panel Operator
KEY POINTS:
# After Checking of Interlocks again isolate the main
oil burners individually and then reset the S/D Control
valve and then light up the burners.
#SOAKER BPCV to be checked for full opening and
then reset it for normal position
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HALDIA REFINERY

62) After 1/2 hr. light up 3rd burner and check the transfer temp. Panel Operator/
Total 3 to 4 oil burners will be sufficient at this stage. Field Operator
63) Check E-8A/B temperatures and adjust Cooling water Field Operator
accordingly to keep temp, (s/s) around 80-90 DegC
64) Light up 2 more burners and adjust FO pr to 4-5 Kg/Cm2 Panel Operator/
gradually to bring up coil outlet temp. Steam and Oil DP ~ Field Operator
1.9-2.1 Kg/Cm2 Raise temp, very slowly and drain water from
all low pt. drains of exchangers, pumps, columns, c/v’s etc.
KEY POINTS ;~
# DURING NORMAL OPERATION MINIMUM FLOW
SHALL NOT GO BELOW 28 M3/HR IN EACH PASS. TO
AVOID FREQUENT ALARM AND TRIPPING, LOW FLOW
ALARM AND FALCO HAVE BEEN PROVIDED AT 22 M3/
HR AND 15 M3/HR RESPECTIVELY
65) If no water is found bring up COT up to 250 Deg C @ 50 Deg Panel Operator
C/hr Keep COT steady at 250 Deg C.
66) If stack temp is more than 180 Deg C start P-10/10R. Field Operator
67) Line up DM water to 37-H1/ B104 and keep 37-H1/B104 Field Operator
vent open to atmosphere.
68) Give clearance to Mechanical Maintenance for HOT Shift-in-Charge
BOLTING of all flanges, manholes.
69) At 300 Deg C COT, Start 37-P-8/8A and inject turbo water Field Operator
@ 0.31 M3/ hr/pass.
KEY POINTS :
# Open Turbo water valves near 37-F-01 passes and
then start P8/8A and then adjust pump stroke
70) Check top temp of 37-C-1 and if it rises sharply then reduce Panel Operator/
COT and drain water from top reflux C/V bleeder, P-3/3R/5 Field Operator
suction bleeders. If top temp, is steadied out, line up TK-715
to P9R suction and if necessary. Check P9/9R suction
bleeders for any water
71) Drain condensate also from P4/4R suction/ discharge Field Operator
bleeders.
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HALDIA REFINERY

72) 37-P-9R to be run and reflux to be given via P6R discharge Panel Operator/
line (P9R Jump Over to P6R) and top TRCV of 37-C-1 Field Operator
KEY POINTS ;~
# At this stage 6 oil burners will be required. Keep the
block valve of interface. control valve of B2 closed.
Initially c/v may not work and gasoline may go to oily
water sewer. Watch and avoid the same.
73) At 330 Deg C COT introduce stripping steam to 37-C-1 @ Panel Operator/
300 kg/hr initially at very slowly after draining condensate Field Operator
from LPD at the U/S b/v of St. steam to C1. Check interface
level of B2 always and if OK, line up. Water to be checked/
drained from P3/3R/P5/P4/ 4R/P13/13R/P6/6R sue. &
discharge bleeders Check level of B5. If OK then line up
LCV of B5 (or line up B5 drain to B1 through P11 suction or
to u/s of E2)
74) If 37-H1/B104 pressure rises more than 3.5 kg/cm2 line Field Operator
up to VB header. Initially open VB header valve then
gradually close vent of H1/B104 and observe 37-H1/B104
pressure.
75) At 400 Deg C, gradually close PICV 1301 and increase Panel Operator/
back pr. of Soaker & 37-F-l. Start 37-P-4/4R and P13/13R Field Operator
for circulating reflux and after quench flows respectively.
Divert a stream of GO to 37-C-3.
78) Maintain after quench temperature 395 Deg C by opening Panel Operator/
PICV-1301. Maintain 25-30 M3/hr circulating reflux flow by Field Operator
FRCV-3704. In case quench flow is not available line up
SO from U-31 & run 37P13/13R for quenching. Drain
condensate from 37-P-5 suction bleeder & start 37-P-5.
79) If required, light oil from U-31 can be taken to 10th tray by Shift-in-Charge/
running P9/9R. Watch system pr. and maintain 5.0 kg/ cm2 Panel Operator/
by PRCV-03. In case 37-F01 COT increased beyond 435 Field Operator
Deg C, bring it down immediately by opening TRCV3702
to maintain the operating temp, as specified.
After establishing hot circulation the unit is now ready
to take feed and running down of product.
80) Increase COT to 420-425 Deg C and route VB Tar to storage Panel Operator/
tank. Gradually close PICV” 1301 and adjust back pr at 12 Field Operator
Kg/Cm2 (g). Gradually increase stripping steam of 37C1
and commission stripping steam to C-2. Ensure that all
35
HALDIA REFINERY

three TI’s(TII303/1304/ 1305) in Soaker drum are showing
same temp. Adjust soaker back pressure to have the same
value of TI1303/1304/1305.
81) Adjust E8A/B water flow to maintain R/D temperature 80-85 Panel Operator/
Deg C. Watch P2/2R discharge pressure & 37-E-1 A/B/C/D Field Operator
T/S pr. If any rise of pressure is noticed then open (crack) re-
circulation Valve and after sometime again try for closing the
valve. In case 37P119 A/B is in line, level of 37C01 will
increase. Do the same as stated above. If B2 level starts
rising, gradually reduce pumping gasoline to column from
Tk-715 and ultimately stop.
KEY POINTS :
# Before routing VB Tar to storage, OM&S to be
contacted for confirmation of R/D tank.
#First open R/D valve fully and then gradually close re-
circulation Valve.
#AT420 DegC COT, cracking will start for design feed
stock and B2 level will gradually build up. Before
starting P6/6R, check and drain if any water present in
sue. lines.
#During increasing back pr. of F01 check 37 P1/1R/1B
discharge pressure and adjust accordingly
82) If B2 level is more than 40%, commission 37-C-4. Maintain Panel Operator/
C4 bottom temp at 155-160 Deg C. Open FRCV-09 and Field Operator
start feeding C4 at slow rate. Check CW to E6 and if
required open. When level of C4 builds upto 30-40%, open
TRCV-3705 for heating/ increasing C4 bottom temp.
83) If B3 level appears check P117/7R suction bleeders and if Panel Operator/
no water found then start P7/ 7R and maintain 37-C-4 top Field Operator
temp at 60-65 Deg C by operating FRCV-3710.
84) Route Gasoline to slop Tk-715. Field Operator
85) Light up gas burners if gas production starts. Panel Operator/
Inform RSM before lighting gas burners. Field Operator
86) Increase C-4 pr by operating PRCV-04. Panel Operator
87) Check gasoline sample and if it is clear as well as if C4 Field Operator
condition is stabilized route gasoline to R/D Tank after
informing OM&S .
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HALDIA REFINERY

88) If C2 level is more than 80%, start P3/3R and divert VBGO to Field Operator
i)37B102, ii.) To R./D &/or VB Tar. Stripping steam to 37-C-
02 to be commissioned After draining condensate.
89) Before starting 37-P3/3R check suction bleeders and drain Field Operator
water, if any.
90) Increase P4/4R flows to maintain middle zone temp of 37-C- Panel Operator
1 and to reduce load on top zone of 37-C-1.
91) Gradually reduce light oil flow to 10th tray by pinching P9/9R Field Operator
discharge valve stop taking GO. from U-31.
92) When C3 level appears, start P5 and return back 37-C-3 Field Operator/
material via 37-E-111 to 10th tray maintaining 30-40% level Panel Operator
in 37-C-3. Normalize gas oil to 37-C-03.
93) Start P-12 and adjust inhibitor injection to 37-C-1 vapor Field Operator
outlet & 37-C-4 vapor outlet line as follows 37-C1 side 140-
150 cc/hr 37-C4 side 40 / 50 cc/hr
94) Adjust VB Tar visc. Panel Operator
→by transfer temp
→by Gas Oil withdrawal
STABILISE UNIT AND GRADUALLY INCREASE T’PUT
AS PER INSTRUCTION
KEY POINTS :
# With the increase of T’ put, adjust
(i) P-1/1R/1B pr
(ii) C-l level if P2/P2R in line,
(iii) adjust c/w to Coolers, condensers etc,
(iv) adjust P-8/ 8A flow,adjust circulating reflux flow
etc
37
HALDIA REFINERY
CHAPTER - V
5.0) SHUTDOWN PROCEDURE
Before shutting down the unit inform the following agencies
- RSM
- OM&S (700 P.H, 900 P.H & ETP)
- TPS - for reduction in consumption of utilities and also afterwards increase in
consumption of VM steam for steaming the columns, vessels etc
- Fire Station - to keep ready diesel pump for watering of columns, vessels etc. if
required
The Shutdown broadly consists of the following operations/steps
A. Reduction of feed rate and then C.O.T
B. Furnace cut off
C. Pumping out bottom products of Columns, Vessels
D. Depressurisation of Vessels, Columns
E. Steaming of Columns, Vessels, Exchangers
F. Watering and handing over the equipments etc to Maintenance
01) Start reducing T’ put gradually to 28M3/ hr/pass. Before Panel Operator
reducing T’ put reduce stabilizer feed to maintain B2 level
(60-70%)
02) Put off some burners if required. Adjust feed pump Field Operator
discharge pressure by operating bypass valve.
KEY POINTS :
# Keep watch on PICV-1301 opening. Adjustable
mechanical limit lock is provided to avoid full closing
of PICV-1301.
03) Reduce gas oil circ. reflux in steps to maintain 10th tray Panel Operator
temp & level.
04) Reduce stripping steam flow in steps. Panel Operator
05) Close gas oil to VB Tar & VB Gas Oil R/D valves. Switchover Field Operator
FLO from VBGO to GO ex U-31. Hold level in C02.
06) Stop stripping steam to C2 and isolate both b/v’ s & stop Field Operator
P3/P3R.
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HALDIA REFINERY

KEY POINTS :
# Keep 37-B01 empty
07) Reduce COT gradually to 425. De-cascade TRC- 01. Panel Operator
Preferably reduce gas firing.
08) At 415 COT stop pump 37P12 and isolate the pump. Field Operator
09) Reduce COT to 400 Deg C and put on hot circulation. Panel Operator/
Keep VB Tar R/D temp @ 75-80 DegC by adjusting CW to Field Operator
E8A/B.
KEY POINTS :
# Inform OM&S for change of line up of VB Tar.
# Open at first re-circulation valve and then close R/D
valves
# During changing-over keep watch on P2/2R/119A/B
discharge pressure and 37-C-1 level.
10) At 390 Deg C COT stop pump 37P13/13R Field Operator
11) Stop stripping steam to 37-C-1 by closing FRC-06 at a Panel Operator
COT of 350 Deg C.
12) Close the B/Valve D/Stream of 37-FV-06 (Stripping Steam Field Operator
to 37-C-01) and keep drain bleeder open.
13) Close Feed to Absorber 37-C-03. and Stop pump 37P5/ Panel Operator/
3R when 37-C-03 level comes down. Field Operator
14) Stop feeding to Column 37-C-04 if B2 Hydrocarbon side Panel Operator
level cornea down
15) Empty out 37B-03 and stop P-7/7R. Route gasoline R/D to Field Operator
slop Tk-715. (Inform OM&S prior to routing of Gasoline
R/D to Slop Tank-715)
16) Empty out Column 37C-04 to minimum level Panel Operator
KEY POINTS :
# Gas should not go to R/D or Slop TK-715 from 37-C-
04
17) Reduce COT to 300 Deg C. Fuel Oil/Gas burners to be Panel Operator/
reduced as per requirement and oil line to be purged by Field Operator
purging steam.
18) Stop 37P-8/8A and close the b/v’ s at the injection points Field Operator
of both passes of Furnace 37F-1 Close water I/L B/v’ s of
37B6
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HALDIA REFINERY

19) Reduce COT @ 30 Deg C/Hr. Put off all oil burners and close Panel Operator/
all FO isolation valves and open steam to clean FO burners. Field Operator
After isolation of all FO burner, give IFO circulation.
20) Put off fire in Furnace 37F1 (Gas burner). Close PRC-02 Panel Operator/
and its u/s Audco Valve. Open the pilot burner valves fully Field Operator
to depressurize the line. and then close the valves Open
the damper gradually.
21) Drain condensate of purging steam and start purging 37- Field Operator
F01 fire box.
22) Stop P-10/10R when stack temp comes down below 200 Field Operator
Deg C or when VB production Comes down. Open vent of
37H1, B104 and close VB 0/L valve of H-1/B104.
Inform TPS about reduction Of DM water consumption
in the unit.
23) At a COT of 150 Deg C stop pump 37P-01 and bring level Panel Operator/
of Column 37C01 up to 5%. Pump out the soaker content. Field Operator
Inform OM&S for stopping booster pump
KEY POINTS :
# Do not empty out 37-C01 completely otherwise gas
should pass through pumps P-2/2R/P119 A/B. Empty
out B105 to the minimum possible.
24) Take Light Oil in pump 37P-1/1R/1B suction through light Panel Operator/
Oil Line Ex. VDU (U-31). Close main feed valve at pump Field Operator
suction and open Lt. Oil suction valve and open by-pass
and disch. valve of P-1/1R/ 1B (Mech. seal may leak
because of low viscosity) Flush the feed line by LT oil after
informing OMS. Open PICV1301 fully (if not. done earlier).
KEY POINTS :
# During opening light oil valve in field ask Opt-A to
take care of Lt. Oil flow Ex-U-31.
25) Flush the feed C/V by-pass valves also inform to OM & S Field Operator
to flush offsite Booster pumps.
26) Take Light Oil in Column 37C-01 and continuously flush Field Operator
C-1, E-1,E113 A/B and E-8 till E-8 O/L sample is exclusively
Light Oil. During flushing with Lt. Oil open VB Tar R/D line
valve for sometime to flush the line so that the R/D valve
can be operated later on easily. Level of Column 37-C01
indication Will show less than actual with Light Oil. Flush
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HALDIA REFINERY

out the soaker pump out line also. Flush all the points where
flushing fluids connection are given.
27) Stop the flushing fluid pumps (P115A/B., P114A/B) Field Operator
28) Stop P121 A/B after stopping P119 A/B. Field Operator
Bottle up the unit in this conditions, wherever unit is
not to be prepared for M&I (Otherwise following steps
are to be adhered to).
29) Stop Light Oil flushing and close the b/v’ s. Pump out C-2 Panel Operator/
to VB Tar Line/TK-703/ 704 by opening Gas oil FRCV on Field Operator
VB tar line and opening B/V on 37-E-1’s. Pump out any left
over materials of C-3 in C-l and empty out C-l to min. level
possible. Pump out C105 also.
30) Inform TPS prior to starting of steaming of coils etc (approx. Shift-in-Charge
6-7 T/hr VM steam is required) .
31) Keeping PICV1301 open and after draining condensate Field Operator/
from steam line, open VM steam for flushing the furnace Panel Operator
coils. Check the VM flow/pass and adjust @2T/Hr.
32) Pump out soaker content. Keep watch on 37-C01 level & Field Operator/
empty out 37-C-01 up to min. level possible. Panel Operator
33) Stop steaming in forward direction and close PICV1301. Field Operator
Open steam in reverse direction and flush the F-1 coils to
B-1. Keep steam open to 37B-1 stack. Open the Blow down
valve to B1 a little to avoid carry over thru’ stack.
34) Close CW to E8 A/B and open CW drain pt. of E-8A/B. Field Operator
35) Drain water from 37B1 and pump out the material to Tk- Field Operator
703/ 704. Stop steam to stack of B-1
36) Hand over 37F1 to Maintenance for preparation of decoking Shift-in-Charge
operation i.e. reversing of elbows, putting blinds.
37) De-energise all motors of pumps Shift-in-Charge
38) Isolate 37F-1 positively from C105 & B-1. Put blind in, 37- Shift-in-Charge
C105(SOAKER) inlet line for steaming pf C105
39) Depressurisation of Vessels & Columns
Depressurise C-3, C-4 to FG header upto min. pressure Panel Operator
Possible. Open PRCV-03 & 04 fully
40) When C-3 & C-4 pr. equalizes with FG drum pressure close Field Operator
FG O/L valve at B/L
41
HALDIA REFINERY
KEY POINTS :
# Inform RSM before depressurising (Keep Mechanical
Maint. ready for reversing SPB ‘ s on S/O. pts of C-3,
C-4) .
41) Depressurise C-l, C-3 to flare through HV1501 and C04 by Field Operator
opening PSV by pass Block Valve
42) Drain B102/ B103/B105 B106 to 37B1 Field Operator
43) After depressurising, get SPB on F.G. 0/L at B/L blinded Shift-in-Charge
(U/S of b/v)
44) Get vent valve blinds on C-l, C-3, C-4 opened and vent Shift-in-Charge
caps of B-2 & C-2 also opened (Do not open the vent
valves).
45) Steaming of Column, Vessels etc
Start steaming C-1, C-3, C-4, C-105 after draining Field Operator
Condensate. Start steaming in B102/B103/B105/B106
through steam out point. Start steaming flushing fluid circuit.
Drain condensate from all low pts. of pumps, C/V bleeders.
Open HPV’ s.
KEY POINTS :
# Steaming of 37-C-01 to be done by operating FRCV
on Stripping Steam line.
# Open steam to C-2 by opening Stripping Steam block
valve and 37-C-03/ 37-C-04 are steamed by steam out
lines
46) Close C/W to E-2, E-3, E-7, E-112 Field Operator
47) Watering of Columns, Vessels etc
Connection to be made to 37-P6R/3R/7R for Watering of Shift-in-Charge
37-C-01/C-02/C-03/C-04
48) Start P-6/6R and open TRCV-04 (top reflux of 37C-01) and Field Operator
FRCV-09 for flushing 37C-01
49) Start P-3R and open PRCV-3708 for flushing 37C-03/37- Field Operator
C-03
50) Start P-7/7R and open FRCV 10 to flush 37C-04. Field Operator
KEY POINTS :
# DO WOT ALLOW COLUMN LEVELS TO RISE MORE
THAN 70% ON LEVEL INDICATION
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HALDIA REFINERY

51) Drain water from P-5, P-4/4R, P-13/13R, P-2/ 2R/P119A/B Field Operator
by opening it’s suction strainer and B/Valves. Keep 37-E-
05 S/S & T/S drains open.
(Suction Strainer to be opened by Mech. Maint.)
52) Keep E-03 S/S LPD open, keep E-04 S/S & T/S drain open Field Operator
and E-07 sampling point open.
53) Start P13/13R & open HV1301 to flush C105. (Connection Panel Operator/
to be made to P13R suction for watering SOAKER) Field Operator
54) PICV-13 01 to keep fully close by unlocking mechanical Shift-in-Charge/
lock. ( SOAKER BPC lock to be removed by Instrument Panel Operator
Maintenance)
55) Stop 37P-6/6R and open suction valve to back up water to Field Operator
B-2 and continue till water appears from vent of 37B-02.
Then close Suction valve and drain water from 37P-6/6R
which is idle. Repeat till 37B-02 water is clear and free of
any smell.
KEY POINTS:
# Close B/L valves of gasoline and gas oil. (If U-31 is
running then do not close B/L gas oil R/D valve. Keep
close isolation valves of FRCV-3707A.
56) Stop P-7/7R and open auction valve to back up water to B- Field Operator
03 and continue till water comes from B-03 vent and E-
6(S/S) LPD. Then open suction valve of P-7/7R which was,
idle and drain water from 37-B-03.
57) FLUSH ALL LINES CONNECTED TO COLUMNS, Field Operator
VESSELS EXCHANGERS BY USING P-3/3R, P-6/6R AND
P-7/ 7R. Flush flushing fluid circuits also.
KEY POINTS :
# Do watering B102/B103/B105 & Bl06 by connecting
hoses.
58) Stop P-3/3R and open suction valve to back up water to Field Operator
37C-02. 37C-02 can also be filled up from 10th tray. Back
up water from 13th tray to P-9/9R discharge line and drain
from 37-P-9/9R discharge drain lines (keep suction valves
closed)
KEY POINTS :
# WATERTING TO BE DONE FOR ATLEAST 16 HRS
43
HALDIA REFINERY

59) Stop P13/13R & drain water from 37-C-105 (SOAKER) Field Operator
completely
KEY POINTS :
# When watering will be over, drain water from all
columns vessels etc
# KEEP ALWAYS VENTS OPENED
60) Test gases inside vessels, columns etc by explosive-meter Shift-in-Charge
(O2% also to be meager before Man entry in Column/
Vessel/Furnace)
61) If gas test is OK (i.e there is no gas inside columns, vessels Shift-in-Charge
etc).Handover equipments to Mechanical Maintenance
after necessary blinding
Soaker Drum Cleaning
As in furnace tubes, coke gets deposited on the deposits on the walls of the
soaker drum over a time. The deposit found is of 1-2” thickness per cycle (total
coke about 1-2 m3). This coke as such is not detrimental to the visbreaking
operation but if not removed, becomes more and more hard and difficult to
remove ultimately. This also reduces the soaking volume. It is therefore
recommended that at the time of furnace tube decoking, soaker drum is also
cleaned of coke, if required.
Two methods are industrially employed for coke removal from soaker drum,
after the usual procedure of making it completely hydrocarbon free. After the
soaker becomes safe to enter, the top and the bottom manholes are opened
and the bottom distributor dismantled and taken out. Coke collection bins will
need to be placed beneath the bottom manhole to collect coke droppings. The
two methods of coke removal can be used separately/together.
Manual Coke Removal :
In this method the operator enters the soaker drum and manually chips off the
coke using chisel/hammer. It is not necessary that the soaker internal wall surface
is cleaned perfectly.
Hydro jetting Coke Removal :
In this method, hydrojetting unit is utilized to remove the coke and is quite
expensive as compared to manual coke removal. Coke collected can be
disposed off by incinerating or in land fills.
Transfer line (37F01 to 37C105) :
Although severity will be much less due to lower operating temperature and low
44
HALDIA REFINERY
residence time in the line, but coke deposition over a long time can not be ruled
out. Hence pressure drop in this line is to be monitored to decide whether cleaning
of this line is required or not. The line is to be cleaned manually by opening the
end blinds at different cross ends.
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HALDIA REFINERY
CHAPTER-VI
6.0) FURNACE DECOKING
During the period of operation coke slowly gets deposited on the internal surface
of the furnace tubes. This deposition increases with length of run and severity
of operation. Accumulation of coke deposits on the internal surface of furnace
tubes is detrimental because :
a) It increases the resistance to the Process flow i.e. the Delta P across the
furnace coils builds up and results in gradual T’ put limitation
b) It increases the resistance to heat transfer from the flue gases/flame to the
process fluid and in the process increases the tube metal skin temperature
which reduces the life span of tubes
c) The coke deposits get dislodged from the furnace tubes during some process
upsets end up in the fractionating column flash zone/bottom thus warranting
shutdown for cleaning
Hence it is required to clear the coke deposits from the tubes at regular intervals
and this is achieved by decoking operation. (Post soaker decoking operation
will be required almost once in 12 months in this unit). Decoking is achieved
in 2 stages.
Spalling : Steam is introduced in tubes with furnace on. This causes cooling
action of coke on hot tube surface causing the coke deposits to disintegrate.
The disintegrated coke gets entrained in the steam flow. This removes about
90% of coke deposition.
Burning with air : Introduction of air along with steam into the hot tubes burns
the residual coke deposits and products of combustion are removed by the
steam flow. Air introduction must be gradual and controlled. Otherwise the
resultant burning reaction may result in a run-away temperature of the tube
skin.
The unit is shutdown in the normal manner. It is steamed as per laid down
procedure and the furnace is handed over for necessary preparatory/
blinding/de-blinding jobs to undertake decoking.
6.1 BRIEF ON PAST OPERATIONS WITHOUT SOAKER
Normally the furnace tubes are de-coked when either Delta P across the furnace
or the tube skin temperature become a limitation, which ever may occur earlier.
Typical values for this end of run conditions on various. Occasions just before
going for decoking are listed below to describe the particulars conditions
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T’put COT FeedVisc Max Delta Max Skin

M3/Hr Deg C Cst @50O C Press. Kg/Cm Temp OC
2
Sept-82 70 470 400 + 11.0 630

April-83 70 473 500-1500 10.0 575
Nov.-83 70 475 500-1500 11.0 575
April-84 65 478 500-2000 11.5 625
The operating conditions keep changing (particularly the Delta P across the furnace
& tubes skin temperature) during the cycle and finally the limiting end of the run
conditions are reached. The following tables describes how the operating
conditions behaved during a particulars run.
T’put COT FeedVisc Max Delta Max Skin
M3/Hr Deg C Cst @50O C Press. Kg/Cm Temp OC
2
Dec-83 70 478 500-3500 8.0 550

Jan-84 70 480 1500-3500 8.5 550
Feb-84 70 480 1200-1500 9.5 555
Mar-84 70 478 1200-3000 10.5 590
Apr-84 65 478 1500-2000 11.5 625
If the upsets/emergencies during a run are more, the limiting conditions are
reached fast and length of run becomes short. With the implementation of soaker
technology, the COT will come down to 435 Deg C @ 62.1 MT/Hr T’ put level.
Hence coke deposition in furnace will take longer time to reach the limiting
value.
01) For decoking operation, line up the furnace to the decoking Shift-in-Charge
headers after dropping the spool pieces at the inlet and
outlet of the furnace (both passes) and connecting them
in the decoking headers. (Reverse the Elbow in Furnace I/
L and O/L lines)
02) Blind the open flanges of the furnace inlet & outlet Lines(tail Shift-in-Charge
blind) (100 mm dia) 4 Nos (pr. rating 65 kg/cm2).
03) Reserve the SPB on the vent line of the Economizer outlet Shift-in-Charge
line to open position
04) Blind the d/s flange of the block valve on the turbolisher Shift-in-Charge
water injection lines to the furnace coils (near furnace) (tail
blind (dia 25) - 2 Nos pr. rating 65 kg/cm2)
05) Indication to be checked by I/Maintenance at the following
points :
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37FI - 3706 VM steam to Left pass. 37FI- 3707 - Service air
to Left pass
37FI-3708 - VM steam to Right pass. 37FI-3709 Service
air to Right pass
Chromel - Alumel
37-TI-7321- 37-F-01 Box temperature
37-TI-3708- Skin temp. of Left. Pass 37th tube
37-TI-3719- Skin temp. of Right .Pass 37th tube
Iron - Constants
37-TI-3712-Left Pass Coil Outlet
37-TI-3723-Right Pass Coil Outlet
37-TI-3702-Left Pass Tube No. 1
37-TI-3722-Right Pass Tube No. 1
37-TI-3724- Flue gas after convection zone
37-TI-3725- Flue gas near Economizer coils
06) Inform RSM and TPS for supplying FO and uninterrupted Shift-in-Charge
service air at a steady pressure and higher consumption
of VM steam and DM water.
07) Inform Laboratory for arranging for the periodic testing of Shift-in-Charge
decoking exhaust gas samples.
08) Commission quench water to the scrubbers 37D-2 & 37D- Shift-in-Charge
3 and check for clear passage of the drain point and also
make temporary arrangements for directing the outlet water
to surface drain.
09) Inform Elect. Maintenance for providing flood lights near Shift-in-Charge
37D2 & D-3 to observe the colour of outlet water
10) Blinds from FG & FO to be reversed in open position (if Shift-in-Charge/
inserted already) and establish FO circulation through the Panel Operator
ring and ensure the closure of the individual valves of
burners (both FO & FG).
6.2 THE UNIT IS NOW CONSIDERED READY FOR
DECOKING OPERATION
1) Take DM water in 37H-1, line up 37H-1→37-P- Field Operator/
10→Economizer coils→ 37 H-1. Start circulation of water Panel Operator
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HALDIA REFINERY

Inform TPS to supply DM water. VB steam valve at 37H-1 to
be closed & vent on 3 7H-1 to be opened
2) Take FG up to the ring. Open snuffing steam to furnace fire Panel Operator/
box. Open atomising steam through 2-3 burners. Field Operator
Commissioning PDIC-3701. Introduce VM steam @1 MT/
hr /pass slowly. PDIC - 3401 pr. should be 2 kg/cm2
3) Light up 3-4 pilot burners and 2 FG burners on both sides Panel Operator/
with small flame, commission temperature recorder. Start Field Operator
noting down temp
4) Raise the fire box temp @ 50 Deg/hr up to 250 Deg C Panel Operator
5) Introduce water to furnace outlet lines from decoking header Field Operator
6) As steam pr. of 37H-1 builds up and equals to VB steam Field Operator
header pr., line up to VB steam network and close vent
valve of 37H-1
7) Raise the fire box temp @ 50 Deg C/hr and hold at 550 Deg Panel Operator/
C. Observe the colour of water at D-2/D-3,Black or qrey colour Field Operator
indicates spailing started. If heavy spailing noticed, reduce
box temp. by 50 Deg C
8) Allow the spailing to continue till the effluent water becomes
colourless
KEY POINTS :
# Box temp. & skin temp should not go beyond 600
Deg C
9) When spallirig is over in forward direction establish the steam Panel Operator/
flow in reverse. direction and hold the COT at 450 Deg C Field Operator
and box temp 600 Deg C
10) When there is no spalling in either direction of flow of steam, Panel Operator/
establish. steam flow in forward direction in each pass. Field Operator
Reduce the steam flow 0.6 to 0.7-T/hr and introduce air @
70-80 NM3/ hr/pass slowly and step by step
KEY POINTS :
# Decoking header pr should be less than air inlet
pressure
11) Check the temp rise (COT) for min 1/2 hrs. If the temp, rises, Panel Operator/
do not increase air further and if not increase air flow by Field Operator
20NM3/hr/pass
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KEY POINTS :
# Wait 1/2 hrs in each step before increasing air. Start
analyzing the effluent gasses for CO2, 02, CO
12) Continue to increase air flow by 20NM3/hr/pass up to a max Field Operator
of 400NM3/hr/ pass
13) COT - 465 - 470 Deg C Skin - 600 Deg C
Operation will be compleated when % of CO2 will be 0.1%. Shift-in-Charge/
If effluent gasses contain more than 18% CO2 coke burning Panel Operator
is taking place at higher rate and it is imperative to introduce
steam to prevent over heating
14) When there is no more CO2 in the effluent gasses, stop air Panel Operator/
injection. Reverse the direction of steam flow. Introduce air Field Operator
in steps up to 400 NM3/hr in each pass
15) When there is no more CO2 in the effluent gasses, stop air Panel Operator/
injection and increase steam flow to 2-3 T/hr. Increase fire Field Operator
box temp to 600 Deg C Note decoking header pressure
16) Introduce air in steps up to 40 NM3/hr/pass Max box temp. Field Operator
600 Deg C Max. COT 500 Deg C Max skin temp. 600 Deg
C Tube colour to be checked. If at the time of introducing
air, decoking header pr exceeds the air pr. reduce steam
to decrease the header pr. If COT rises, hold the air flow &
continue the operation
16) Get the Orsat analysis. If there is no CO2 in the sample up Shift-in-Charge
to 400 NM3/hr flow, reverse the direction of flow and repeat
the same
17) Bring down the fire box temp, at the rate of 50 Deg C and at Panel Operator/
250 Deg C of fire box, put off Gas burners. Open primary & Field Operator
secondary air-registers of burners. Open snuffing steam to
furnace and continue till steam conies from stack. Inform RSM
for low consumption of fuel gas
18) At 260 Deg C fire box, stop Steam in Furnace Coils. Panel Operator/
Shutdown 37P-10 and open the vent on 37H-1 after Field Operator
isolating it. Only air will flow through the coils to bring down
the temp of coils
19) Prior to cutting off steam inform TPS. After stopping 37 P- Shift-in-Charge
10 inform TPS/DM Plant to stop DM water pump.
20) Stop air when furnace box temp cools down and give Shift-in-Charge
clearance to Mechanical Maintenance to open return bend
plugs for inspection. Inform TPS for low consumption of
Service air
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HALDIA REFINERY
CHAPTER-VII
7.0 EMERGENCY HANDLING AND EMERGENCY SHUTDOWN PROCEDURE
There can be situations when the unit is to be shutdown on an emergency basis
consequent upon
→ Failure of feed to the unit
→ Leak in furnace tubes
→ Failure of steam (VM & VB)
→ Power failure
→ Cooling water failure
→ Instrument Air failure
→ Total utility failure
7.1 FAILURE OF FEED TO THE UNIT
There are three number pumps either in offsite or in the unit. In case one goes
under maintenance, two pumps will be available at site. Apparently feed failure
due to non-availability of pump either in offsite or in the unit is. remote.
HOWEVER IT IS TO BE REMEMBERED THAT DURING BOTH ROTARY
PUMPS (44-701-P-101 A/B) FAILURE AT OFFSITE, 37B105 LCV/37B105
NEEDS TO BE BYPASSED IMMEDIATELY TO HAVE SUPPLY FROM
OFFSITE CENTRIFUGAL PUMP.
Try to restart spare feed pump or booster pump as the ease may be. In case all
feed pumps fail or problem is with booster pump, Feed failure with unit will
automatically actuate the “I1” interlocks which will cut off FO & FG, open soaker
BPC, close LV3703B & trip 37P119 A/B. Proceed as follows :
DETAILS OF OPERATION/ACTIVITY OPERATION BY
01) Close stripping steam to 37-C-01 by C/Valve Panel Operator
02) Push emergency shutdown (ESD) switch at auxiliary panel. Panel Operator/
This will close both FO & FG shutdown valves. Open soaker Field Operator
outlet PICV 1301 and open soaker drum pump out C/V
HV1301. Close PIC1401 and LICV3703A in case P119A/B
in line or close LIC3703B in case P2/P2R in line.
03) Watch and verify security taking action in field at all 5 above Field Operator
mentioned control valves.
04)Close fuel oil, fuel gas main isolation valves. Field Operator
05)Close isolation valve of stripping steam to 37C02 Field Operator
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06) Close fuel oil and fuel gas control valves, manually and open Panel Operator
soaker outlet PRC on manual. Close quench control valve
on manual
07) Close stripping steam to 37C01 B/Valve Field Operator
08) Take SO from U-31 to 37P13/13R. Push the coil content in the Panel Operator/
forward direction to 37C01 via 37C105 by running 37P13/13R. Field Operator
Quench furnace 0/L as well as Soaker O/L by opening TRCV
3702 & FRCV 1301.
09)Keep open E1D feed side blow down valve to 37B01 with water Field Operator
quench to avoid pressurization in the feed side.
10)Run P-2/2R/P119A/B to pump out column bottom to run down. Panel Operator/
Keep C1/C2/C3 floating with FG pr. only. Watch coil inlet Field Operator
pressure near.
11) Close individual burner valves including pilots and purge Field Operator
furnace
12) Open H-1 & B104 vent to atmosphere after closing VB header Field Operator
valves
13) Stop P-8/8A & P-12. Keep P-10/10R running. Field Operator
14) Once hot heavy material displacement is over, empty out Panel Operator/
C105 & flush F01 coils with steam in forward direction. Hold Field Operator
the levels & pressures of columns/vessels.
15) Stop P13/13R, close E8 A/B water. Flush out E01 feed side Field Operator
with LO.
7.2 HEATER TUBE FAILURE
There are three sets of tubular coils in the furnace.
(i) Coils for superheating steam generated in the unit.
(ii) Coils for boiler feed water to generate steam.
(iii) Coil for hydrocarbon going to main fractionator.
Boiler feed water to superheating coils are located in the convection zone of the
furnace Chances of leak in these tubes are negligible. Small leak from these
tubes is not detectable as leaky water or steam gets mixed with flue gas and
moreover these tubes are covered with hydrocarbon coils in convection section.
However, big leak or rupture of the tube will affect tube will affect the flue gas
stack temperature.
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HALDIA REFINERY
Any leak from the hydrocarbon tube will catch fire and will be visible from furnace
peepholes. Small leak in the heater tube may eventually coke up and will not
warrant emergency shutdown. Operating personnel and supervisor have to
assess the extent of damage and take recourse to either normal or emergency
shutdown. In case of tube rupture, bridge wall temperature will start shooting
up. Smoke will be appearing at stack top. The smoke will go dense with increase
in leak, Sharp rise in stack temperature may also be observed
01) Push ESD push button in auxiliary panel Panel Operator
02) Stop feed pump and quench oil (P-13/13R) pump Field Operator
03) Close manually Fuel Gas, Fuel Oil and quench control valve Panel Operator
and open on manual soaker outlet PICV1301 in case if it is
not opened
04) Watch & verify all securities have taken action. Close isolation Field Operator
valve on fuel gas, fuel oil in and Pilot gas headers on the
furnace platform near soot blower panel
05) Watch coil inlet pressure near FRCAL’s and when it comes Field Operator
down to 10 kg/cm , close PICV1301, put steam at furnace
outlet and drain/ pump out C107 & C01 to 37B01/run down.
Quench the blow down with flushing fluid followed by water.
Purge the coils to blow down vessel B-1 with VM steam in
reverse direction. Stop flushing fluid injection.
06) Open fire box purging steam and close individual burner and Field Operator
pilot valves
07) Close stripping steam to 37- C-2 Field Operator
08) Close Stripping Steam to 37-C-1 Panel Operator
09) Open H-1/B104 vent to atmosphere after closing VB header Field Operator
valves
10) Stop P8/8A, P-12. Stop other pumps when they lose suction. Field Operator
Close E-8A/B water
11) Flush Feed and Tar circuits with LO from OM&S. Field Operator
Empty out columns, vessels, pippins etc and steam
purge/water wash the unit till all hydrocarbons are
removed from the system. Isolate the furnace (after
installing blinds etc) and hand it over for repairs once
tubes are free of hydrocarbon.
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HALDIA REFINERY
7.3 VM/VB STEAM FAILURE

Under normal operating conditions, the unit exports steam to refinery network after
meeting its own requirement. In case of refinery steam failure, the unit operation
can be managed by regulating steam export. However, it cannot be run for long.
Since Fire Fighting and steam to tracers will not be available as LP steam header
will have no pressure. The unit should be brought down as per normal shutdown
procedure till heavy oil is displaced with flushing oil and keep the unit bottled up.
Effects:
# Stripping steam to C-l & C-2 will stop (VM Steam)
# 37 P-2/2R will stop(VM Steam)
# Atomising steam to oil burners will stop and hence there will not be atomisation
of fuel oil and consequently no proper combustion.(VM Steam)
# Tracing steam will not be available and hence there is possibility of VB feed
and VB tar lines getting congealed.(VB Steam)
# Steam for fire fighting, furnace box purging, furnace coil flushing etc will not
be available.
# Steam will start condensing in steam headers resulting in accumulation of
condensate in lines. This will be dangerous, as on resumption of steam supply,
lines will start hammering if action for draining of condensate is not taken.
# Steam quenching to Pumps will loss
01) If P2/2R in line, switch over to P119A/B
Field Operator
02) Pull out fires both FO & FG fully. Close FG, FO C/V’s on
manual & open Soaker outlet PICV1301 on manual. Isolate Panel Operator
feed 37-FRCV 02/03
03) Isolate Fuel Oil Burners Block Valve Isolate Gas burner
audco valves Field Operator
04) Close Stripping Steam to 37-C-01 C/Valve
Panel Operator
05) Isolate Stripping Steam to 37-C-01/02 Block Valves and open
Up stream bleeder For draining condensate. Field Operator
06) Keep steam traps bypasses open on various steam headers,
manifolds, lines etc. Field Operator
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HALDIA REFINERY

KEY POINTS :
# When steam supply is resumed, commission the main
header slowly taking care to drain off all condensate
from lines. Hammering is to be avoided.
07) Cool the furnace outlet temp, by running feed and tar pumps. Panel Operator/
If require bypass 38E8A/B and close C/W valves Field Operator
08) Stop feed pump and inform OM&S to stop Booster pump Field Operator
09) Push ESD button on auxiliary panel Panel Operator
10) Stop 37-P8/8R, 37-P12 Field Operator
11) Check and verify the security has taken action. Pump out Field Operator
37C105 content. Open blow down valves of both coils very
gradually to B-1 and empty the coil contents into B-1. Give
fire water quench (CARRY OVER FROM B-1 TO BE
AVOIDED).
12) Drain 37-C01 content. Field Operator
13) Plush feed and tar circuits with LO from offsite. Field Operator
14) Stop flushing fluid injection. Field Operator
15) Hold pressure in C-3 & C-4. Hold levels in columns/vessels Panel Operator
16) Vent H-1 & B104 to atmosphere, after isolating from VB Field Operator
header
17) Close VM/VB steam block, valves at battery limit and open Field Operator
condensate drains in the Unit. Stabiliser section will remain
bottled up.
When steam is available proceed as per normal start-
up procedure
7.4 POWER FAILURE
On TPS power failure, all electric driven pumps will fail. Only 37-P-2/2R & 37-P-
119A/B,P1/1R/1B,P-13/13R may be available. However, Grid Power shall be
resumed immediately in substation for Offsite Booster pumps (44 -701-P101A/
B) and U-37 pumps. Hence these pumps as well as 31P7 can be taken in
service from state grid power.
The effects of total refinery power failure could be as follows: -
→There will be no light in the plant area. Emergency light will automatically
switch on in the control room.
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HALDIA REFINERY
→ TRC/TIC temperature indications may not fail, as there is arrangement of power

supply to instruments during power failure through inverter.
→ Emergency shutdown system will get activated. This will result in automatic
shutting of fuel oil and fuel gas to furnaces. ESD push button should be
operated in order to open emergency coil steam & depressurize the whole
system
→ All pumps will stop. This will result in
(a) No flow through heater coils.
(b) Stoppage of IFO circulation and hence no oil firing.
(c) No reflux to column top and thus top temperature will start shooting up
along with pressure.
(d) Exchangers will have thermal shock and thus increasing chances of fire
due to leaks from flanges glands, exchanger’s coveys etc.
(e) Thermal shock to refractory and hence higher chances of refractory failing
down.
(f) Fast filling of reflux drums and its safety popping, as column pressure will
be already high because of no reflux.
(g) Cooling water failure (as motors of cooling water pumps will stop). Column
pressure, product temperature etc will shoot up.
(h) Instrument Air may fail (If Instrument Air fail then Follow the Instrument
Failure procedure)
01) Close FG, FO Control Valves on manual and open Soaker Panel Operator
outlet PICV1301 on manual
02) Ask OM&S to start booster pump. Start feed pump & tar Panel Operator/
pump. Bring down the furnace temp. Switch from P-2/2R to Field Operator
37P119A/B & close its discharge valves, in case P-2/2R are
in line.
03) Check security has taken action at all the places. Close Field Operator
one block valve on FO, FG and Pilot gas
04) Close individual burner valves and purge furnace. Bypass Field Operator
E08A/B, if required and close CW valve.
05) Once furnace temp come down, stop feed and Tar pumps. Panel Operator/
Ask OM&S to stop booster pump Field Operator
06) Pump out C-1 & C-105 levels to VB Tar. Drain the coil Field Operator
contents to 37B01 slowly. Stop flushing fluid injection.
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HALDIA REFINERY
07) Hold levels in C-2, C-3 & C-4 and pressures by closing PRCV’s Panel Operator
08) Close stripping steam to 37-C-1 & 37-C-2 (Both Control Valve
and Block Valve) Panel Operator/
09) Open H-1 & B-104 vent & isolate from VB header Field Operator
Field Operator
10) Put VB steam through economizer coil and vent to
atmosphere Field Operator
Start unit as per normal procedure when power is
resumed. Otherwise flush feed and tar circuits with LO
from offsite.
KEY POINTS :
# Reset all solenoid valves before starting.
#Take clearance before starting the pumps
7.5 COOLING WATER FAILURE
This can happen when all the cooling water pumps fail simultaneously. It is quite
rare and is possible only during total power failure.
The overall effects of cooling water failure will be as follows:
→ There will be no water flow through condensers, coolers. Thus, in the absence
of cooling water, there will be no condensation of overhead vapors resulting
in shooting up of column top pressure. Column and reflux drum safety may
pop. (No water to Condensate E-2 A/B, E-6 and Coolers E-7, E-5, E-8 A/B
& E112 A/B)
→ Products going to storage will be at higher temperature, which is no
permissible.
→ Outlet lines of condenses and coolers will start vibrating.
→ No cooling water to pumps
01) Drastically rduce the unit throughput and bring down coil
outlet temperature to 200 °C. Panel Operator/
Field Operator
02) In case 37C01 pr. increases, HV1501 provided to reduce
the pressure. Panel Operator
03) Close steam to 37C-01 & 37C-02 (Close both C/V and B/V)
Panel Operator/
04) Isolate Fuel Gas and Fuel Oil burners individually and Control Field Operator
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HALDIA REFINERY

valves also. Then purge all Fuel Oil line by purging Steam. Panel Operator/
Field Operator
05) Cool down the furnace by running feed and VB tar pump.
Bypass E8A/B. Switch over unit to Circulation(Tank to Tank) Panel Operator/
provided rundown temperature does not exceed 150 Deg C Field Operator
Flushing Oil Injection to Feed to be started.
06) Open H-1 & B-104 vent to atmosphere. Stop P-8/8a P-12 and
others pumps except feed & tar Pumps Field Operator
07) Hold C-2, C-3 & C-4 levels. When cooling water is restored
start back the unit as per normal procedure Panel Operator
08) Try to maintain system pressures by opening the PRCV’s and
by passes as required Panel Operator/
09) Stop circulation and Pump out Soaker content & 37C01 to tar Field Operator
and blow down the coil content to 37B01 by VM steam. Panel Operator/
10) Stop flushing fluid injection. Field Operator
Operated ESD scheme if felt necessary.

7.6 INSTRUMENT AIR FAILURE
This occurs due to air compressor failure. If air supply is not resumed in short time
header pressure starts falling fast. Instrument air failure causes various control
valves to go to fail-safe position. The following are the general effects of instrument
air failure:
→ Fuel gas and fuel oil to Furnace will get cut of, as SDVs on these lines will get
closed. Pilots will remain on and atomising steam control valve will get closed.
→ Furnace flow FRCs control valves will get opened
→ VB tar rundown lines Control valve (37-C-03 LCV) will get opened.
→ Stabilised Naphtha; gas oil and VB tar run down control valves will get open.
→ Top reflux control valves for 37-C-1/C-4 will get opened.
→ Control valve on circulating reflux line (back to 10th tray) will also get opened.
→ BPC at soaker outlet will get opened.
→ 37-C-03/C-04 Pressure Control Valve will get closed.
→ Emergency Depressurization Control Valve will get closed
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HALDIA REFINERY

01) Ensure furnaces security shutdown system has been actuated, Panel Operator/
cutting of fuel to furnaces. Field Operator
02) Isolate B/V of FO and FG individual burner and open purging Field Operator
steam to FO burners.
03) Steam purge the furnace box Field Operator
04) Control furnace pass flows by pinching isolation valves of control Panel Operator/
valves(Pass Flow, 37-FC-02/03) Field Operator
05) When 37-C-01/C-04 level will comes to 30%, Then isolate U/S Panel Operator/
B/V 37-LC-03 (37-C-01 Level) And 37-LC-10(37-C-04 Level) Field Operator
06) Control circulating reflux flow by pinching isolation valve of 37- Field Operator
FC-04
07) 37-H-01 Steam to VB header to be isolated and Vent to be Field Operator
opened
08) DM Water to 37-H-01 & 37-B-06 to be isolated as it was full Field Operator
open (37-LV-01, B-06 Level) and (37-FV1601, DM water to
37-H-01)
09) If System pressure increases then pressure to be reduced by Panel Operator/
opening its bypass B/Valves. (37-PC-03(37-C-03 to FG) and Field Operator
37-PC-04 (37-C-04 to FG))
7.7 TOTAL UTILITIES FAILURE
Total power failure happens only due to Power Failure
01) Close FO, FG valves on manual and open PICV1301 to manual Panel Operator
02) Ask OM&S to start booster pump. Start feed pump & tar Panel Operator/
pump P119A/B(power resumes from state Grid). Field Operator
03) Close C-4 LCV block valve. Stop P-2/2R steam and close its Field Operator
disch. valve in case P-2/2R was on line
04) Check and verify all security valves have taken action and close Field Operator
one block valve each on FO, FG
05) Open purging steam to FO burners Field Operator
06) Bring down Furnace fluid temp & stop pumps. Then Ask OM&S Panel Operator/
to stop booster pump Field Operator
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HALDIA REFINERY

07) Pump out soaker & 37C01 content (low temp) & then blow Field Operator
down coil’s content to B-1 with quench water open to the inlet
line. Drain water from B-1. Close quench water & blow down
valves after completion of blow down. Stop flushing fluid
injection.
08) Close stripping steam to C-1 & C-2. Close individual burner Field Operator
valves
09) Close Gas Oil to VE Tar C/V on hand jack, Gas Oil to HSD Field Operator
pool C/V block valve, B-2 water boot drain block valves.
10) Vent H-1 & B-104 & close VB headers. Close 37E-8 A/B Field Operator
water valve
11) Close battery limit VM, VB Block Valves, product run down Field Operator
valves
12) Flush the feed and tar circuits by taking flushing fluid from
OM&S.
7.8 QUENCH FLOW FAILURE
In case of after quench flow failure the- following actions shall be taken
01) Stand by pump shall be started Field Operator
02) In case of starvation suction line up SO ex U-31 & start Panel Operator/
quenching, Field Operator
Failure of both the pumps will lead to coking of column
and colouring of gas oil/gasoline. Plant shall be brought
down as follows :
03) Start P9/P9R with LO and quench the column bottom. If Panel Operator/
required resume supply LO in 10th tray. Field Operator
04) Reduce COT to 400 Deg C immediately. Panel Operator
05) Follow the normal shut down procedure thereafter. Panel Operator/
Field Operator
7.9 PREHEAT EXCHANGERS LEAKAGE
In case of Preheat Exchangers E-1A/B/C/D leaks, resulting Tar Viscosity &
flash getting off, the folowing actions shall be taken :
01) The exchanger leak checking shall be arranged by sending Shift-in-Charge
samples from individual exchanger to laboratory
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02) On conforming the leak, the exchanger shall be by-passed, Shift-in-Charge
isolated, depressurised, steamed and handed over to
Mech.Maint for rectification
03) In case of any unforeseen process emergencies the first step Shift-in-Charge
to be adopted shall be to protect the quality of run-down product
already in the Intermediate/ Finished Product tanks, by routing
the off-spec product to slop tanks immediately
The next step shall consists of trouble shooting involving
DMPN/ PNM/SPNM and Tech Services if the problem
persist for long FACILITIES HAVE BEEN PROVIDED TO
STORE LO IN 31B01 AND INTERCONNECTION HAS
BEEN GIVEN TO 37 P13/13R VIA 31P7 WITH A JUMP
OVER CONNECTION FROM P13/13R DISCHARGE TO P9/
9R DISCHARGE. TO TACKLE THE EMERGENCY (TO
PUSH THE COILS AND SOAKER CONTENT) THE
STORED LO CAN BE UTILISED.
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CHAPTER - VIII
8.0 SAMPLES AND TESTS
The table gives the tentative Schedule of Laboratory tests to be performed
No Test Feed Gases STB VB Gas 37-B-2
Required Gas- Tar Oil
oline
1. Specific
Gravitity
2. Viscosity Once in Once in
Alternate a Shift
Day
3. Sulphur When When
Required Required
4. H2S
5. CCR When,
Required
6. Flash. Pt Daily
Once
7. Octane When
Number Required
8. pH Daily
Once
9. FO stability When
Required
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CHAPTER - IX
9.0 CONTROL LIMIT
In order to ensure agreed product specification, control limit shall be applied to
individual stream as described in 9.9 of Procedure Manual
VB TAR KV CST AT 50 DEG C 200 - 350 CST
VB TAR FLASH DEG C (MIN) 85 - PREFERABLE
IS 100 Deg C
VB PEED KV CST 800 - 2000 CST(4301
@ 50 Deg C CST @100 Deg C
design)
@ 110 Deg C
9.1 PROCEDURE/ACTIVITIES ACTION/FORM
9.1.1 Operating conditions to be adjusted & maintained within PANEL./
control limit as instructed by DMPN/S.PNE/PNE FIELD OPERATOR
9.1.2 VB gas oil/gasoline colour shall be checked twice in each FIELD OPERATOR
shift
9.1.3 Slop processing in Visbreaker in the flash zone to be
monitored as per the following : a> Flow indication in the
panel PANEL./OPERATOR
b> 37-C-1 bottom temperature PANEL./OPERATOR
c> 37-C-1 10th tray temperature PANEL./OPERATOR
d> 37-C-1 reflux load PANEL./OPERATOR
e> Colour of gas oil FIELD OPERATOR
f>37-B-5 draining FIELD OPERATOR
9.1.4 In case of VB Tar flash point being lower than the control
limit, the following actions shall be taken
a> stripping steam to 37-C-1 to be checked / increased PANEL./OPERATOR
b> Gas oil withdrawal to be increased watching 10th tray PANEL./OPERATOR
temperature
9.1.5 In case of TAR viscosity being higher than the control limit, the following actions
shall be taken:
PROCEDURE/ACTIVITIES ACTION/FORM
a> COT to be increased, within restricted operable limit PNE/SPNE/ DMPN
(435-445 Deg C) if feed viscosity is within the control limit
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PROCEDURE/ACTIVITIES ACTION/FORM
b> Drop gas oil inside the column taking into account flash PNE/SPNE/
point of VB Tar PANEL OPERATOR
c> Consult with Planning & Coor-dination for reduction of DMPN
feed viscosity within the Control Limit for checking the routing
Of VDU, PDA & BTU
d> Add cutter stock (LO/SO) after consulting with P&C DMPN
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CHAPTER - X
10.0 SAFETY
Visbreaking Unit (U-37) is an existing one where all safety protection facilities are
prevailing i.e. fire water net work, pill boxes, fire extinguishers etc. However to take
care of additional area (soaker area), Fire Water Network has been modified.
Extra pill box (fire alarm) has been installed. The general guidelines for fire fighting
procedures for different equipments and systems are provided in Annexure-1. To
take care of the plant operational safety additional interlocks and alarms etc. have
been provided. These are stated in the following paragraphs.
10.1 The following are the interlocks in U-37, the activities of which will force a unit
shutdown.
TAG NO. LOCATION SERVICE SET VALVE ACTION
FIC3702 F01 PASS #1 FEED 15 M3/HR FUEL SUPPLY
CUTOFF,
SOAKER
BPCV OPEN,
P119 A/B TRIP,
LV3703 B
CLOSE.
FIC3703 F01 PASS #1 FEED 15 M3/HR FUEL SUPPLY
CUTOFF,
SOAKER
BPCV OPEN,
P119 A/B TRIP,
LV3703 B
CLOSE.
ESD AUX CONSOLE MANUAL FUEL SUPPLY
(PUSH ACTIVATION CUT OFF,
BUTTON) SOAKER
BPCV OPEN,
P119 A/B TRIP,
LV3703 B
CLOSE, HV13
01 OPEN.
PIC 3701 FEED PUMP FEED 40.0 KG/ FEED PUMPS
DISCH- CM2G P1/P1R/ P1B
ARGE TRIPPED
10.2 The following are the interlocks in U-37. The activation of the same is accompanied
by a hardware alarm annunciator. Immediate operator intervention on activation of
these interlocks is required which otherwise may cause the unit shutdown.
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TAG NO. LOCATION SERVICE SET VALVE ACTION

PIC 3701 FEEDPUMP FEED 37.5 KG/CM2G PV3 701 OPEN
DISCHARGE
PSL1201 FO HEADER FUEL OIL 2.8 KG/CM2G ALARM
PSLL1202 FO HEADER FUEL OIL 2.6 KG/CM2G FUEL OIL TO F1
CUT OFF
TSH 13 08 SOAKER SOAKER 425 DEG C ALARM
OUTLET EFFLUENT
PV 1301 SOAKER SOAKER (%OPENING) ALARM
OUTLET EFFLUENT
FAL 13 03 P13/13R GAS OIL 8.0 M3/HR TRIP THE
SUCTION RUNNING
PUMP
LAH 3711 C1 BTM VB TAR % ALARM
LAL 3703 C1 BTM VB TAR % ALARM
PSLL-2206 P-121 A/B FLUSHING 13 KG/CM2G P119 A/B
DISCHARGE FLUID (EXT.) TRIPPED
LAH 3706 C3 BTM GAS OIL % FEED TO C3
CUT OFF
LAH 3 713 B101 SLOP % ALARM
PIC 3702 FG HEADER FUEL GAS <1.0 KG/CM2G FG TO F1 CUT
OFF
PSLL2205 P121A/B FL.OIL- II 10 KG/CM2G AUTO START
DISCHARGE (EXT) OF STANDBY
PUMP P121A/
B
LAL37l0 C04 BTM GASOLINE % R/D SDV
CLOSE
Logic has been built up so that in case of LV3703B (Steam to P2/2R) in line,
LV3703A (CV at Tar R/D) will get fully opened and locked. Similarly, in case of
LV3703A in line, LV3703B will get fully closed.
Push button in Aux console has been provided to open HV1501 to depressurise
the system if it calls for. Controlling depressurisation is also possible through HIC.
THE MIN PASS FLOW IK THE FURNACE( AT 90% TURNDOWN) ALLOWED
IS 2 8 M3/HR.HOWEVER THE SET VALUE FOR THE LOW PASS FLOW
ALRM AND LOW FLOW CUTOFF (FALCO) IK 37 FO1 HAS BEEN SET AT 22
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M3/HR AND 15 M3/HR RESPECTIVELY TO AVOID FREQUENT ALARM AND

NUISCENCE SHUTDOWN.BUT MIN PASS FLOW MAINTAINED AT ANY
TIME SHALL NOT BE LESS THAN 2 8 M3/HR.
10.3 The work permit system to be used is enclosed in Annexure-2
10.4 The various OISD standards followed/being followed is given in Ann.exure-3.
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CHAPTER - XI
U-37 (VBU) INTERLOCK
11.0 IN CASE OF LOW FEED IN EITHER PASS ( F02 & F03 )
• F.O. SUPPLY AND ON OFF VALVES CLOSE.
• SOAKER B.P.C. OPEN.
• 37 P-2/2R STEAM CLOSE (37 C-1 LCV-05)
• F.G. SUPPLY OFF.
• 37P119A AND P119B STOP.
IN CASE OF EMERGENCY SHUT DOWN BUTTON PRESS ( RED COLOUR)
ESD.
• F.O. SUPPLY AND RETURN ON/OFF VALVES CLOSE.
• SOAKER BPC OPEN (SOAKER TOP PC1301)
• 37 P-2/2R STEAM CLOSE (37 C-1 LCV-05)
• F.G. SUPPLY OFF.
• 37P-119A AND P-119B STOP.
• 37HV1301 OPEN (SOAKER BOTTOM)
37 P-13/13R INTERLOCK
37FX1303 FLOW COMES BELOW 8 M3/HR 37P-13/13R TRIP. (PLEASE
OPERATE THE BY-PASS SWITCH AND START THE PUMP THEN WITHDRAW
BY-PASS)
37 P-121A/121B INTERLOCK
37 P-121A OR 121B DISC. PRESSURE COMES BELOW 13 KG/CM2 OTHER
PUMP WILL TAKE AUTO START PROVIDED IT IS IN AUTO.
IF FURTHER DISC. PRESSURE COMES DOWN TO 10 KG/CM2 OR LESS 37
P-119A/119B WILL TRIP.
EMERGENCY DE-PRESSURISATION SYSTEM
SWITCH ON FOR OPENING 32HV1501 LOCATED IN AUXILARY CONSOLE.
FO PRESSURE LESS THAN 2.6 KG/CM FURNACE TRIP.
FEED PUMP P01A/B/R INTERLOCK
FEED PUMP PRESSURE MORE THAN 37 KG/CM2 BYPASS LINE CONTROL
VALVE FULL OPEN.
FEED PUMP PRESSURE MORE THAN 40 KG/CM2 FEED PUMP TRIP.
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CHAPTER - XII
SECTION - 1
12.0 EQUIPMENT HANDING OVER AND TAKING OVER

12.1 EQUIPMENT HANDING OVER TO MAINTENANCE:
Equipments are required to be handed over during shutdown/ normal operations
for maintenance purposes. Procedures given below should be followed to ensure
their safe release and safe maintenance work.
12.1.1 Pumps
A) For Electrical Maintenance
• Stop motor as per procedure
• De-energise the motor from substation
• If equipment is a HT motor, deenergising to be done from TPS
• Ensure that “DO NOT OPERATE, MEN AT WORK” board is put on the switch
• Give clearance to decouple the motor, if required.
B) For MECHANICAL MAINTENANCE:
a. Cold pumps:
• Stop the pump as per procedure
• Close cooling water
• Close suction and discharge b/vs
• Ensure that b/v’s are holding
• Depressurise/drain the pump gradually
• Depressurize pumps to flare, if connection is available
• If separate Seal Oil pumps are available, the same are to be stopped after
depressuring the casing by venting to compressor suction, or flare , as the case
may be. Casing to be finally drained to OWS before handing over the pump to
maintenance
• Chemical dosing pumps should be flushed with water if possible.
• Vacuum pumps should be depressurized to columns.
• Heavy material pumps should be flushed with FLO and then drained.
• Deenergise the motor from substation.
• Ensure that “DO NOT OPERATE, MEN AT WORK” board is put on switch.
• Give clearance for maintenance jobs.
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HOT PUMPS
• Stop the pump as per procedure
• Before depressurizing. Close warm up b/v
• Close gland sealing, flushing oil.
• Stop steam to mechanical seals
• Allow the pump to cool.
• Flush the pump with FLO, if material is heavy. Drain/depressurize the pump.
• Keep the water house running.
• Incase of high pour point materials like SR, RCO, VR, Wax, etc. open FLO to
suction and run the pump to displace heavy materials into discharge circuit
• If FLO is not available drain preferably through cooler or drain gradually.
12.1.2 HEAT EXCHANGER/CONDENSER/COOLER/ AIR FIN COOLER/
REBOILER:
• ISOLATE AND DECOMMISSION THE EXCHANGER/ CONDENSER/
COOLER/REBOILER AS PER THE PROCEDURE.
• Deenergise the motor of Air Fin Cooler/ Condenser. Ensure that “DO NOT
OPERATE, MEN AT WORK” board is put on the switch
• Flush the equipment handling heavy material with FLO/Steam
• Drain Hydrocarbons to CBD or, OWS. Open the vent valves to ensure the
complete draining
• Provide blinds/W.O towards the exchanger on both the side.
• Give steam connection on top nozzle. Drain water side (it need not be steamed)
• Steam for 4 hours
• Water flush condensers and coolers handling light hydrocarbons.
• Release the equipment for maintenance jobs.
12.1.3 FURNACE:
• Shut down the furnace as per procedure and blind fuel gas lines.
• Open the damper and air registers fully
• Isolate and flush fuel oil circuit and blind fuel oil lines.
• Steam purge the heater coils to displace oil contents to column. (Water washing
can follow for complete coil flushing if permissible, depending upon metallurgy
of coil).
• Passivate the coils wherever required
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• Carryout dechoking operation, wherever required.

• Open the manholes of furnace
• Isolate super heater coils and steam generating coils.
• Blind all steam and hydrocarbon lines.
• When the box cools down to around 50 degree C, check for presence of any
hydrocarbons.
• Give clearance for “MAN ENTRY” and maintenance jobs.
12.1.4 VESSELS:
• Pump out the vessel completely
• Drain out remaining portion of hydrocarbons to CBD/OWS.
• For heavy materials vessels, flush and then drain.
• For caustic chemical vessels, dilute the contents with water and then empty out.
• Close inlet and outlet valves, safety valves and any other connected lines.
• Keep the vent open.
• All outlet/inlet flanges should be blinded with wedge opening towards vessel
side.
• Give steam connection which are not having FRP lining.
• Thoroughly steam the vessel for 4 hrs. For vessels containing heavy hydrocarbon
more steaming will be needed.
• Keep the drains and vents of instrument taps open for flushing
• Ensure that steam comes out from all the wedge openings.
• Give a water hose connection and overflow water from the vessel for about 4
hrs.
• Drain water completely
• Blind water/steam lines
• Open manway cover.
• Test inside for presence of hydrocarbons with explosimeter
• If the above gas test is negative give ”ENTRY PERMIT” for maintenance job.
12.1.5 COLUMN:
• Pump out the oil in the column completely.
• Drain out remaining oil to CBD/OWS
• Deblind steam purging line.
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• Steam the system for 6 hrs. Steam will wet the entire column such that flange
opening for blinding and W.O. can be done safely.
• Install blinds on all inlet and outlet nozzles except steam and top reflux line.
• Keep the drains and vents of all instrument tapings open.
• Steam the column for 6-8 hrs.
• Ensure that sufficient steam issues from all the wedge openings, keep the vent
open
• Do not exceed working pressure of column while steaming
• Provide water connection to reflux line
• Keep the column drain fully open
• Stop steaming and water wash for above 4 hrs.
• Do not allow water level to build up in the column.
• Repeat steaming and water washing
• Open top manway cover
• Carry out gas test by explosimeter
• If gas test is positive, box up manway and repeat steaming and water washing.
• If gas test is negative, give clearance to open rest of the manholes.
• Get steam and top reflux lines blinded
• Ensure for proper ventilation in the column
• Provide air hose, if required.
• Give clearance for inspection/maintenance jobs.
12.1.6 FLARE HEADER:
• Ensure that all equipment connected with flare system are depressurized after
shut down.
• Close battery limit valve of flare header
• Provide steam connection if not there
• Introduce a small quantity of steam.
• Give clearance to provide blinds/wedge opening on the system wherever
required with steam on.
• Open the drains and vents of all instrument and of knock-out drum.
• Stop steaming
• Water wash the flare header upto battery limit/knock out drum.
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• Give clearance for maintenance jobs.

• If man entry in vessels is involved carry out water washing after steaming.
• The muck coming out from flare system should be separately disposed off as it
is likely to contain pyrophoric iron.
12.1.7 CONTROL VALVE:
• Bypass the control valve
• Close up-stream and down-stream b/vs
• Isolate gland seal oil/flushing oil
• Drain c/v loop. Ensure isolation valves are holding
• Give clearance for removing the c/v
• End blind the open flanges.
12.1.8 SAFETY VALVES:
a) SAFETY VALVES WITH ISOLATION VALVES:
• Take spare safety valve in line if provided.
• Isolate the safety valve
• Ensure that isolation valves are holding
• Give clearance to open the safety valve
• End blind the open flanges
• Safety valves without isolation B/Vs should not be removed.
b) SAFETY VALVES WITH NO ISOLATION VALVE ON FLARE SIDE:
• Take the spare safety valve on line, if provided. Isolate the one which is to be
removed.
• Give steam connection and open steam to the downstream bleeder, if available.
• Give clearance to remove safety valve on emergency basis
• Immediately end blind the open flanges.
• Keep water hose on the downstream flange while opening/blinding to avoid air
entry.
• Use non sparking tools.
12.1.9 INSTRUMENTS:
• Close the isolation valves
• Isolate flushing oil to the instruments
• Depressurize the instrument. Ensure isolation valves are holding
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• Remove the instrument. Cap or blind the open end.

• Give clearance for maintenance job.
12.2 Equipment taking over from maintenance:
If equipment are not properly checked while taking over from maintenance, it may
result in accident or give troubles during subsequent start ups. Check the following
items while taking over any equipment from maintenance.
12.2.1 PUMPS/MOTORS
• Check that electrical and earthing connections are complete
• Ensure the correct direction of rotation
• Ensure mechanical completion. See that coupling guard is in position.
• Ensure cooling water, quenching steam and flushing oil lines are clear.
• Pressure gauges should be in position
• Ensure that shift is free to rotate
• Check that lines are deblinded.
12.2.2 EXCHANGES/ CONDENSERS/ COOLERS/ FIN COOLERS/ REBOILERS/
STEAM GENERATORS:
Ensure the following:
• Tube and shell cleaning is proper
• Leaky tubes are plugged/replaced
• Shell is painted as per inspection
• Exchanger is properly boxed up with gaskets.
• Check for short bolting.
• Bull plugs, thermowells, pressure gauge assemblies, PST/TSV’s are in position.
• Fan belts and covers are in position incase of Fin coolers.
• Set is deblinded
• Electrical/earthing connections are complete.
• Before introducing Hydrocarbon fluid in the exchanger, vent off air from the
equipment by opening the inlet valve and opening the vent at the highest point.
The same is to be done for both Shell side and Tube side. Once hydrocarbon
starts coming out of the vent, the outlet valve is to be opened and the vent closed.
12.2.3 FURNACE :
Ensure the following:
• Heater tubes are cleaned
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• All foreign material is removed from the fire box

• Skin thermocouples/ oxygen analyzer and other instruments are in position
• Manway, explosion doors, peep holes, header box covers are boxed up.
• Stack damper operation is smooth and damper’s open/close position indicators
are correct.
• Operation of all burner valves is satisfactory.
• Check for evenness of the refractory surface especially around the base of the
burners and ensure that the burner alignment is done correctly.
• Blinding/deblinding is done as per the standard blind list
• Steam and oil connections to the individual burner gun are correct.
• Area around the furnace is clean.
12.2.4 VESSELS:
• While taking over vessel from maintenance check and ensure the following:
• Vessel is thoroughly cleaned.
• No foreign material is left inside
• Drain points and instrument tap are clear.
• Vessel’s internals including instruments are in their respective positions and
properly secured. Demister pads are in position.
• Vessel is coated/painted as per inspection report. Take clearance from
Inspection.
• No person is left behind in the vessel.
• If all the above things are satisfactory, give clearance to box up the manhole.
** Manhole should be boxed up on four bolts in present of production staff
• Remove the blinds are per master bind list.
• Connect all the instruments
• Line-up safety valves
• Vessel is ready for service
12.2.5 COLUMNS:
Check the following:
• Start boxing up from top
• The tray decks below the manhole are clean and free of foreign material
• Temporary connections are removed.
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• All instrument tappings drain points, distributors, downcomers, inlet and outlet
nozzles are clear
• All internals are fitted properly
• All inside fittings like distributors, thermowells flats of level indicators, etc are in
position.
• Tray manway covers are boxed up
• Manholes are boxed up on 4 bolts while ensuring that nobody is left inside.
• Tray manway and manholes should be boxed up in presence of production staff.
• All manway covers are boxed up as above.
• Blinding/deblinding is complete as per master blind list.
• NRV’s are installed in their proper direction
• Column bottom drains are connected properly.
• Safety valves are installed and lined up
• The instruments are in their respective position
• The column is ready for service
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CHAPTER - XII
SECTION - 2
12.0 EQUIPMENT HANDLING PROCEDURE:

12.1 PUMPS:
Pumps is used to transfer liquids from one place to other. There are three types of
Pumps.
a) Centrifugal
b) Reciprocating
c) Rotary/Gear
12.1.1 Centrifugal Pumps:
These are most widely used. A centrifugal pump consists of following parts: Motor,
bearing, housing, coupling, pump casing, impeller and shaft, mechanical seal/
gland packing, cooling/ quenching/ flushing system.
12.1.1.1 Start up Procedure:
a) Cold pumps
• Check for Mechanical/Electrical completion
• Check the quality and level of lube oil. Change/top up lube oil, if required. Also
check for oil in the bearing housing and top up the same by maintenance, if
required.
• Rotate the shaft by hand to ensure that it is free.
• Energise the motor
• Commission cooling water, if provided
• Commission quenching/flushing medium to seals/ gland packing. Adjust
pressure.
• Open suction vale and fill the causing with liquid. Bleed, if necessary
• Press/start button and check direction of rotation.
• Check the discharge pressure and open discharge valve gradually.
• Check the amperage of the motor. Adjust the load, if required.
• Check for any abnormal conditions like vibrations, abnormal sound, leakages,
bearing temperature etc.
2.1.1.2 HOT PUMPS START UP PROCEDURE:
The procedure is same as that for cold pump except for the following additional
points.
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• Open warm-up (across NRV of discharge line) to heat the pump before starting.
Ensure that while doing so, the dischrge pressure of the running pump does not
fall below operating pressure.
• Open suction valve very slowly for vacuum column pumps.
• Pinch/close the warm-up line valve after the pump is on full load.
• If external seal Oil pumps are provided, the same are to be started and after
adjusting for the rated discharge pressure in the presence of maintenance,
auto change over of the pumps are to be verified before putting one of them in
auto mode and the remaining in manual mode. The one in manual mode is to
be kept running. The casing is to pressurized slowly and after checking for
leaks, etc, main driver is to be started. Before operating the seal oil pumps,
check the seal oil tank level and top up the same , if required.
• If pump is run by a steam turbine, then VB is to be lined up first and then
condensate from VM line is to be drained before charging steam to turbine.
Governer Oil sump level to be checked and made up before starting turbine.
12.1.1.3 SHUT DOWN PROCEDURE:
• Close the discharge b/v fully
• Stop the motor
• Open ward up b/v for hot pump to keep it hot. Ensure that the pump does not
rotate.
• If main driver is a steam turbine, close Vm valve first and then close VB valve .
Close discharge valve of the pump first to stop it from anti-rotating(if control
valve is there at discharge, the same is to be closed prior to closing of steam
valve) and then, close suction valve. Keep seal Oil pumps running. If pump is to
be handed over to maintenance, start depressuring the casing by opening the
vent to compressor suction or, to flare, as is the case.
12.1.14 CHANGE OVER OF THE PUMPS
• Start the standby pump as per standard procedure
• Open the discharge valve gradually. Simultaneously close the discharge valve
of other pump keeping watch on the discharges pressure gauge/flow.
• Switch-off the originally running pump.
• Open warm-up valve of hot pump to keep it warm.
12.1.2 RECIPROCATING PUMPS:
This is a positive displacement pump. Hence an outlet must be available for the
liquid displaced otherwise the system will get over pressurized.
In reciprocating pump liquid is displaced from suction to discharge by the
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reciprocating movement of a piston or plunger in a cylinder. The pump consists of

following parts:
Motor, gear box, coupling, pump cylinder, piston/plunger, stroke adjuster, safety
valves, suction/ discharge valves.
• Check for mechanical completion
• Check the movement of the shaft
• Energise the motor
• Line-up suction and discharge system and open suction and discharge b/v.
Open steam tracers if any.
• Line-up the minimum flow circuit and discharge relief valve.
• Adjust the stroke length in case of dosing pumps.
• Start the motor by push button.
• Watch the discharge pressure
• If pressure continues to increase beyond normal pressure, stop the pump
immediately and check the line up.
• Check for unusual noise, vibrations and rise in bearing temperatures of motor
and pump.
• Discharge valve of reciprocating pump should never be closed/throttled while
the motor is running.
• Check and ensure that Gland flushing oil is lined up before starting pump.
12.1.2.2 SHUT DOWN PROCEDURE:
• Stop the motor
• Do not close suction/discharge valve unless it is to be handed over to
maintenance
• If pump is used for heavy Oil service, like asphalt or bitumen, etc, flush the pump
with FLO or heavy extract, in case of Bitumen , if possible
12.1.2.3 CHANGE OVER OF THE PUMPS:
• Start the stand by pump as per standard procedure
• Immediately switch-off originally running pump as soon as the pressure starts
increasing.
12.1.3 ROUTINE CHECKS:
Following checks should be carried out regularly:
• Quality and level of lube oil, bearing oil and Governer Oil and Seal Oil.
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• Pump and motor bearing temperatures

• Abnormal sound and vibrations.
• Leakages from Seal or pump casing.
• Pressure gauges
• Motor amperage
• Cooling water, quench steam and sealing liquid flows
• Warm-up condition of standby pump
• Functioning of safety valves of reciprocating pumps.
12.1.1TROUBESHOOTING
Sr. No. SYMNPTOM SEQUENCE OF ACTIONS TO BE
TAKEN
01. Not developing pressure Remove vapour locking, check suction
side line up and level in suction vessel,
blanketing header pressure in case of
blanketed vessels, check coupling and
direction of rotation, clean strainer,
consult maintenance. In case of
reciprocating pump, check the function
of safety valve also. Some pumps might
require priming before hand, the same
is to be taken care of before starting the
same.
02 Abnormal sound vibration Check for loose coupling guard, fan
cover, foundation bolts etc. Consult
electrical/mech. Technician. Change over
the pump if the sound/vibration is
excessive.
03 High Bearing Temperature Check lube oil level and quality. Adjust
cooling water, change over to spare
pump if the temp, is more than 80
Deg. C
04 Frequent Tripping of motor If the motor trips twice, don’t restart
unless cleared by electrical maintenance.
Check pump shaft for free rotation.If the
motor in question is a HT motor, do not
restart the same before taking clearance
from TPS.
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Sr. No. SYMNPTOM SEQUENCE OF ACTIONS TO BE

TAKEN
05 Hot Gland Check gland cooling water, arrange
external cooling till mechanical help is
available, get the gland nut loosened,
change over/stop the pump if temp. is very
high and hand over the same to M. Mech.
06 Motor not stopping with Throttle discharge valve (only for
stop switch centrifugal pumps) and trip the motor from
the substation.In case of HT motors, TPS
is to be requested to deenergise the
same from their end.
07 Excessive leakage Change over the pump, isolate and
depressurize
08 High discharge pressure Check the line up of discharge circuit. In
case of reciprocating pumps, stop the
pump immediately then check the line up
before restarting.
81
HALDIA REFINERY
CHAPTER - XIII
13.0 FIRE AND SAFETY
Visbreaking of atmospheric and vacuum residuum is carried out at high temperature
(460 0C) and elevated pressure of 12.0 kg/cm2 g. Thermal cracking produces large
amount of hydrocarbon gases, gasoline, gas oil and fuel oil. The presence of all
these products, high temperature and pressure, fired heaters make Visbreaking
an explosion and fire hazard process.
Thermal sulphur decomposition in the feed results in the formation of hydrogen
sulphide, which is characterised by specific toxicity when present in low
concentration. Due to corrosion and formation of pyrophoric ferrous compounds,
it should always be considered that pyrophoric ferrous compound will catch fire in
air whenever any equipment is opened for repair.
The most dangerous places in the unit are pump house area, sewerage manholes,
pits, hot piping, tube heaters, columns and heat exchangers. In all such places in
case of deviation from process conditions, wear or damage of equipment or piping
gas or oil release may occur which may cause an explosion, fire or injury to people.
Therefore, the operating personal should exercise special care in such dangerous
areas.
Self-ignition temperatures of products present in the units are:
Gasoline - 415-530 0C
Vacuum residues - 280-300 0C
Visbreaker tar - 270 0C
Petroleum coke - 185-200 0C
Gas oil - 300-350 0C
13.1 FIRE FIGHTING FACILITIES
The fire igniting/prevention facilities involve, fire hydrant system, fixed foam system,
fire extinguishers, fire fighting steam and fire alarms.
13.1.1 FIRE HYDRANT SYSTEM
An underground header of 8" size is laid between AVU & VBU with 5 numbers of
hydrant points. One jockey pump, 3 nos. of electrical pumps and 3 nos. of diesel
pumps are installed in water block to maintain ire hydrant pressure and for boosting
the pressure to deal with any emergency situation. Cooling water sprinkling system
on 16P2 is also provided.
13.1.2 FIRE EXTINGUISHERSThe use of fire extinguishers is limited to small fires
when the fire has not yet spread out. The fire extinguishers should always be easily
available in the unit so that small fire does not take the shape of a big fire.
Different types of extinguishers are used for different types of fires.
82
HALDIA REFINERY
(a) FOAM EXTINGUISHER

This type of extinguisher is suitable for liquid petroleum fires. It should not be
used directly on hot surfaces and electrical fires.
(b) DCP EXTINGUISHER
Dry chemical powder extinguisher is the most suitable extinguisher for any type
of fires including electrical fires.
(c) CO2 EXTINGUISHER
This extinguisher will be most suitable in enclosed space and with lot of
documents and papers are there. It can also be used in all types of fires.
13.1.3 FIRE FIGHTING STEAM
LP steam header having a number of steam hose points is laid in the unit area.
Steam will give immediate blanketing and vapours diluting effect. It is very useful in
small fires except electrical fires.
13.1.4 FIRE ALARMS
Fire alarm boxes are provided outside the unit battery areas. Fire alarm is also
provided in process electrical substation. By breaking the fire alarm box glass, the
alarm signal will go to fire station so that fire-fighting crew can reach the place of
fire without any loss of time.
13.2 UNIT SAFETY PROCEDURES
The section deals with basic guidelines for the safe operation of the Visbreaker
unit. These guidelines are applicable to all operating personnel to follow the
standard precautionary practices involved in various types of work and related
activities. These procedures alone, however well devised, will not ensure safety.
What is required is that all concerned must understand, accept and practice this in
day to day work.
13.2.1 GENERAL SAFETY RULES
1 All persons must be fully conversant with the plant operation and safety guidelines.
2 House keeping and safety go hand in hand. It is as much important as the
operation of the unit.
i) All stairways, platforms, approach paths must be kept clean. non-slippery
and free of obstructions all along.
ii) Oil soaked rags; rubbish, jute and waste paper are possible fire hazards.
iii) Hoses are to be racked neatly after use.
iv) Materials must not be placed where they may obstruct easy access to safety
appliances, such as safety showers, Fire extinguishers, fire hydrant, hose
boxes etc.
83
HALDIA REFINERY
3 Routine safety equipment inspection of the entire area should be conducted

regularly.
4 Safety valves visual inspection for proper seal, leakage or passing should be
regularly checked.
5 Barricade all dug out areas and leaks that cannot be immediately corrected.
6 Any smoking flange/valve land etc leaks should be immediately attended. If it is
not possible to attend, steam hose should be kept on it.
7 All manholes should always be covered. All temporary lines/tubing/wiring as
and when required should be laid so that it does not become a safety hazard.
8 Closed blow down tank should be kept empty as far as possible.
9 Proper safety precautions should be taken while taking samples, hydrocarbon
draining or commissioning of any equipment.
10 While lighting/shutting of the furnace burners, do not stand just below the burner
housing as it may back fire.
11 Drain condensate properly to a safer place before lighting up of gas burners.
12 Before lighting furnace purge the furnace box well with steam.
13 All safety wears kept in control room and in furnaces area should always be in
good condition.
SAFETY PROCEDURE FOR EQUIPMENT PREPARATION FOR
HANDING OVER TO MAINTENANCE
1 The equipment to be handed over to maintenance should be properly isolated
from the rest of the system. The draining of the material should be to close system
only and the draining should be under +ve pressure. Ensure no material comes
back to the equipment through any of the passing valves or from CBD line.
2 Steam flush and water wash the equipment (To be done for handing over column/
vessels).
3 Open the equipment vent to atmosphere once pressure in the equipments is
slight positive and keep it draining to CBD till draining is almost complete. Open
the outside drain and ensure complete draining.
4 Take electrical shut down of the equipment if having any electrical connections.
5 Before opening any column/vessel/line to atmosphere where pyrophoric ferrous
compounds are expected, extreme care must be taken to water wash/moisten
the compounds are expected, extreme care must be taken to water wash/moisten
the compound so that it does not catch fire in presence of air.
For handing over columns/vessels ensure gas test by explosive meter which
shows nil and there is no gas smell.
84
HALDIA REFINERY
13.2.3 HANDLING OF FLAMMABLE VAPOUR CLOUD

In case a vapour clouds release following actions to be taken immediately: -
(1) Inform control room of the nature of vapour cloud release.
(2) Inform fire station for bringing the fire engine and park it in the upwind direction.
(3) Form a water screen around furnace area.
(4) If the vapour cloud release is of minor nature put steam hose on the leak for
diluting the vapours.
(5) In case the vapor cloud is of major nature try to isolate the source and take
emergency shutdown of the furnace and plant as the situation calls for.
Sprinkle water on the vapour cloud using fire monitor, spray nozzle. Water should
not be sprayed directly on the hot surfaces. If the vapour cloud emerges from any
of the columns, sprinkling system of the column can also be used.
13.2.4 FIRE AND SAFETY PERMIT
Fire and safety permit is intended to protect personnel and equipment whenever
undertaken in a hazardous area involves welding, sparks, open flame, concrete
drilling or chipping. Before starting any work on equipment or using any tools which
might constitute filled in and signed permit is required. This permit will be required
to be prepared in triplicate and separate permit is required for each job. The
preparation procedure and its execution is as follows:
(1) Fire and safety permit is initiated by the maintenance personnel that will describe
work to be done, where it is to be done and the type of tools to be used.
(2) The gas safety inspector who is nominated by CPNM will specify the precaution
to be taken for the hot job. After he is satisfied with the permitee takes care of
the laid down conditions; he will sign the permit mentioning its validity period.
(3) Fire permit signature giver will recheck all the preparatory work specified in the
permit is complied with and will sign on the permit. This signed permit will be
then registered in fire and safety department. The job can only be started and
continued after taking clearance from shift engineer and satisfying the clearance
conditions.
The operating personnel and the permit signatories will keep a close watch of the
job in progress. In case any unsafe condition in the unit arises, the jobs will be
stopped and the fire and safety permit will be withdrawn till fresh clearances are
given.
13.2.5 SAFETY APPLIANCES
A number of safety appliances are available to be used for the unit personnel.
(a) Safety helmet: - To safeguard head against any injury due to material falling
85
HALDIA REFINERY
from height. Safety helmet must be worn in day to day plant movement and in
construction/shutdown activities in the unit,
(b) Safety glasses/goggles: -These are to protect eyes from any injury. Different
types of safety glasses are available to be used for chemical handling, furnace
operation welding, grinding etc.
(c) Safety face shield: - To protect eyes and face from any possible hazard due to
chemical/liquid hydrocarbon splash and backfires.
(d) Safety Gloves:
(1) Leather Gloves: -Must be used in day to day operational activities to safeguard
hands against injury due to rough surfaces.
(2) Asbestos Gloves:- To be used while working on hot surfaces.
(3) Rubber Gloves:- To be used in handling of corrosive chemicals.
(e) Safety Belts:- These are to protect against falls from height.
(f) Safety Shoes:- To be used for toe protection/liquid spills on foot.
(g) Safety suits and Aprons: - Asbestos suit to be used in case of a movement in
hot area for a very short time. PVC suit/apron must be used while handling
corrosive chemicals.
(h) Air Purifying Devices:
(1) Filters:- Mouth and nose filters are used in dusty atmosphere.
(2) Canister Masks:- Type CC to be used against toxic gas, petroleum vapours,
Cl2, SO2 etc. Type C.G. to be used against acidic gases.
These canister ,masks can only be used in low vapour concentration (less
than 1 % in atmosphere) and for a period of half an hour maximum.
(3) Breathing Air Apparatus:
(a) Blow Man Breathing Apparatus: These are externally supplied air type masks.
(b) Self contained breathing Apparatus: This type of mask has compressed air
cylinder, which can last for 30 minutes.
Both these masks are to be used against all types of toxic/acidic gases in high
concentrations.
86

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VBU Operating Manual

No. of stream days/Year = 330

SNO CHARACTERISTCS FEED SAMPLE BLEND 1/3

SNO CHARACTERISTCS IBP -150 Deg C

SNO CHARACTERISTCS 150 - 350 Deg C

Product : VB Tar R 350 Deg C +

1.9 List of Equipments

SNO TAG NUMBER SERVICE DATA SHEET

SNO TAG NUMBER SERVICE DATA SHEET

3.0.3 FRACTIONATOR 37C01

3.0.5 SPONGE ABSORBER 37C03

3.1.5 Fractionator Top Temperature

1) Pressure testing of columns, Vessels :

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

28) Pressure testing of Furnace Outlet to Soaker BPC Shift-in-Charge/

PROCEDURE ACTION TAKEN BY

37) COLD CIRCULATION CHECK FOR BLINDING/

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

T’put COT FeedVisc Max Delta Max Skin

Sept-82 70 470 400 + 11.0 630

Dec-83 70 478 500-3500 8.0 550

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

PROCEDURE ACTION TAKEN BY

DETAILS OF OPERATION/ACTIVITY OPERATION BY

7.3 VM/VB STEAM FAILURE

DETAILS OF OPERATION/ACTIVITY OPERATION BY

→ TRC/TIC temperature indications may not fail, as there is arrangement of power

DETAILS OF OPERATION/ACTIVITY OPERATION BY

DETAILS OF OPERATION/ACTIVITY OPERATION BY

Operated ESD scheme if felt necessary.

DETAILS OF OPERATION/ACTIVITY OPERATION BY

DETAILS OF OPERATION/ACTIVITY OPERATION BY

DETAILS OF OPERATION/ACTIVITY OPERATION BY

TAG NO. LOCATION SERVICE SET VALVE ACTION

M3/HR AND 15 M3/HR RESPECTIVELY TO AVOID FREQUENT ALARM AND

12.0 EQUIPMENT HANDING OVER AND TAKING OVER

• Carryout dechoking operation, wherever required.

• Give clearance for maintenance jobs.

• Remove the instrument. Cap or blind the open end.

• All foreign material is removed from the fire box

12.0 EQUIPMENT HANDLING PROCEDURE:

reciprocating movement of a piston or plunger in a cylinder. The pump consists of

• Pump and motor bearing temperatures

Sr. No. SYMNPTOM SEQUENCE OF ACTIONS TO BE

(a) FOAM EXTINGUISHER

3 Routine safety equipment inspection of the entire area should be conducted

13.2.3 HANDLING OF FLAMMABLE VAPOUR CLOUD