DOCUMENT No.

Operating Manual
FLARE UNIT ISSUE DATE REV. No. REV. DATE
HPCL MITTAL ENERGY Unit Number – 589 08/10/2010
LIMITED, BATHINDA

OPERATING MANUAL
FOR
FLARE UNIT
(UNIT No. 589)

GURU GOBIND SINGH REFINERY PROJECT

HPCL-MITTAL ENERGY LIMITED
BHATINDA, PUNJAB

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INDEX
CHAPTER - 1 GENERAL

1.1 SYSTEM INTRODUCTION

1.2 PLANT CAPACITY
1.2.1 LOAD CAPACITY DUE TO COOLING WATER FAILURE
1.2.2 UNIT POWER FAILURRE AND TOTAL POWER FAILURE
1.2.3 TOTAL COMPLEX POWER FAILURE LOAD (LP+HP)
1.2.4 ANY OTHER FAILURE
1.2.5 DESIGN HC FLARE LOAD
1.2.6 UNIT WISE FLARE LOAD SUMMARY
1.3 SOUR FLARE LOAD
1.3.1 COOLING WATER FAILURE
1.3.2 LOCAL POWER FAILURE IN SULPHUR BLOCK/REFLUX FLARE IN
ARU
1.3.3 SRU SHUTDOWN
1.3.4 DESIGN SOUR FLARE LOAD
1.3.5 UNIT WISE SOUR FLARE LOAD SUMMARY

CHAPTER - 2 PROCESS DESCRIPTION

2.1 INTRODUCTION
2.2 EQUIPMENT DESCRIPTION
2.2.1 FUS-64/24 CB MAIN FLARE TIP (589-LS-103)
2.2.2 BURN BACK SITUATION ON FLARE TIP & MEANS TO COUNTER
THE SAME
2.2.3 FLARE PILOT
2.2.4 AFS 76 MAIN FLARE MOLICULAR SEAL
2.2.5 COMMON FLAME FRON GENERATOR PANNEL
2.2.5.1 IGNITION PRINCIPLE
2.2.5.2 PILOT IGNITION
2.2.5.3 GAS & AIR SUPPLY
2.2.5.4 PILOT DETECTION AND INDICATION
2.2.5.5 VARIOUS ON-OFF INDICATION GENERATED AT FFG PANEL

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2.2.5.6 FUNCTION ON VARIOUS PUSH BUTTON & SWITCH MOUNTED

CHAPTER - 3 UTILITIES, CHEMICALS AND EFFLUENTS

3.1 UTILITIES

CHAPTER - 4 OPERATING VARIABLES

4.1 OPERATING CONDITIONS AND YIELDS

CHAPTER - 5 PREPARATIONS FOR START-UP

5.1 PLANT CHECKING

5.2 FLUSHING / STEAM BLOWING / AIR BLOWING
5.3 LEAK TESTS
5.4 UTILITIES COMMISSIONING
5.5 TEST RUN OF ROTATING MACHINERY
5.6 ELECTRIC AND INSTRUMENT SYSTEMS

CHAPTER - 6 COMMISSIONING & START-UP PROCEDURES

6.1 PRE COMMOSSIONING OF FLARE UNIT

6.2 FFG PANEL CONTROL LOGIC DESCRIPTION
6.3 COMMOSSIONING
6.4 FLRING PHILOSOPHY

CHAPTER - 7 NORMAL SHUTDOWN PROCEDURES

7.1 NORMAL SHUTDOWN

CHAPTER - 8 EMERGENCY SHUTDOWN PROCEDURES

8.1 EMERGENCY SHUTDOWN

CHAPTER – 9 NORMAL OPERATION OF THE UNIT

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9.1 PRE STARTUP OPERATIONS

CHAPTER – 10 PROCESS INTERLOCKS & PSV SCHEDULE

10.1 LIST OF INTERLOCKS

10.2 PSV SCHEDULE

CHAPTER – 11 HAZARDS, SAFETY & COMMUNICATION

11.1 INTRODUCTION
11.2 HAZARDS OF PETROLEUM PRODUCTS
11.3 SOURCE OF HEAT AND OPEN FIRE
11.3.1 AUTO IGNITION
11.3.2 SPARKS
11.3.3 LIGHTNING
11.3.4 STATIC ELECTRICAL CHARGES
11.4 POTENTIAL HAZARDS
11.4.1 TOXIC CHEMICALS
11.4.2 HIGH TEMPERATURE MEDIA
11.5 GENERAL SAFETY GUIDELINES
11.6 EQUIPMENT FOR PROTECTION OF PERSONNEL
11.7 SAFETY RULES FOR PARTICULAR OPERATIONS
11.7.1 SAMPLE AND PURGE COLLECTION
11.7.2 ISOLATION OF SAFETY VALVE
11.7.3 HIGH POINT VENT AND RELIEF VALVE DISCHARGE
11.8 HAZARDS DURING STARTUP AND SHUTDOWN AND PRECAUTION
11.9 PLANT MONITORING DEVICE
11.9.1 PROCESS CONTROL SYSTEM
11.9.2 INSTRUMENT SAFEGUARDING SYSTEM
11.9.3 MECHANICAL PROTECTION DEVICE
11.10 COMMUNICATION SYSTEM
11.11 ENVIRONMENTAL ASPECTS

CHAPTER – 12 CATALYST SPECIFICATION AND SPECIAL PROCEDURES

12.1 NOT APPLICABLE

CHAPTER – 13 MAJOR EQUIPMENTS AND THEIR OPERATION

13.1. INTRODUCTION
13.2. PUMPS

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CHAPTER – 14 MATERIAL SAFETY DATASHEETS

14.1 SAFETY DATA SHEET FOR HYDROGEN

14.2 SAFETY DATA SHEET FOR HYDROGEN SULPHIDE
14.3 SAFETY DATASHEET FOR LPG

CHAPTER – 15 FIRE FIGHTING FACILITIES

15.1 INTRODUCTION OF FIRE PROTECTION AND SAFETY MEASURE

15.2 FIRE PROTECTION
15.2.1 FIRE WATER SYSTEM
15.2.2 FOAM SYSTEM
15.2.3 POTABLE FIRE EXTINGUISHERS
15.2.4 FIRE SIGNAL
15.2.5 STEAM SMOTHERING
15.3 PROCESS UNIT FIRE FIGHTING PROCEDURE
15.3.1 GENERAL
15.3.2 RELIEF VALVE VVENT FIRE
15.3.3 EXCHANGER FIRES
15.3.4 ELECTRICAL MECHANERY FIRES
15.3.5 PUMP AND COMPRESSUERE FIRES
15.3.6 TRENCH AND PIT FIRE
15.3.7 FURNACE HEADER TO TUBE RUPTURE FIRES
15.3.8 SEWER FIRES
15.3.9 SPILL FIRE ABOVE GROUND LEVEL
15.3.10 SPILL FIRE AT GROUND LEVEL

CHAPTER – 16 CONSEQUENCES DUE TO UPSETS IN OUTGOING B/L STREAMS

16.1 CONSEQUENCES DUE TO UPSETS IN OUTGOING B/L STREAMS

CHAPTER – 17 EQUIPMENT DATASHEETS

17.1 FLARE HEADER

17.2 KNOCK OUT DRUM
17.3 HYDROCARBON FLARE
17.4 SOUR FLARE

CHAPTER – 18 EQUIPMENT HANDOVER PROCEDURES

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18.1 PUMPS
18.2 COLUMNS, VESSELS
18.3 L.T AND H.T. MOTORS
18.4 PROCEDURE FOR TAKING BACK AFTER MAINTENANCE
18.4.1 PUMPS
18.4.2 COLUMNS/VESSEL
18.4.3 L.T/H.T MOTORS

CHAPTER – 19 BLIND LIST

19.1 FLARE UNIT BLIND LIST

CHAPTER – 20 CHECK LIST

20.1 CHECK LIST FOR COLUMN, REACTORS AND VESSEL

20.2 CHECKLIST FOR PUMPS

20.3 CHECKLIST FOR VALVES AND RUPTURE DISC

20.4 PIPING

20.5 VALVES

20.6 STEAM TRAPS

CHAPTER – 21 ATTACHMENTS

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CHAPTER-1

GENERAL INTRODUCTION

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1.1 SYSTEM INTRODUCTION

The flare system will be provided for safe disposal of combustible, toxic gases which, are
relieved from process plants and off sites during start - up, shutdown, normal operation or in
case of an emergency such as:

* Cooling water failure

* General Power failure

* External fire case

* Any other operational failure

- Blocked outlet
- Reflux failure
- Local power failure
- Tube rupture

The refinery complex shall have two flare systems, one for Hydrocarbon flare for process
units & off-sites handling hydrocarbon and the other for the sulphur block handling sour
flare.

A) Hydrocarbon Flare System for refinery process units & Off-sites

HC Flare System shall be provided for safe disposal of hydrocarbons released from various process
units. The HC flare system shall have two independent flare headers.

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The process units having high operating pressure will be provided with LP & HP flare header. These
are:

- DHDT
- VGO-HDT
- HGU
- FCC – PC
- MS – Block
The balance units namely CDU/VDU, DCU and PP will be connected only to LP flare header. The LP &
HP flare headers will run independently in the OSBL area. These headers will join in the flare area
where a common flare KOD, Water seal drum and flare stack will be provided for the total load.

B) Sour Flare System for Sulphur block

Sour flare system shall be provided to handle sour flare relief from Sulphur block. The Sour flare
system shall comprise of a Sour flare knock out drum located within the HC flare area.

The sour vapors from the Knock-out drum will be burnt at the tip of HC flare stack flame by routing
these independently to the HC flare stack flame zone through riser. Thus no independent sour flare
stack is envisaged for the sour flare.

1.2 PLANT CAPACITY:

HC FLARE LOADS

The flare loads from individual units are segregated in two categories i.e. High pressure loads and
Low pressure loads.

The hydrocarbon loads from different units are summarized below for various failure cases separately
for HP flare load and LP flare loads:

HC Flare loads

1.2.1 Cooling water failure

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Two independent cooling towers are envisaged for the refinery project. Refinery cooling tower will
supply cooling water to all process units, utilities & off sites, except FCC-PC. The FCC-PC unit shall
have a dedicated cooling tower to meet the total cooling water demand of the unit. With the
segregation of cooling water supply source, the safety relief loads for cooling water failure of FCC-
PC unit shall not be additive to the cooling water failure load of rest of the refinery.

Following is the unit-wise flare load summary for the CW failure case:

A. LP FLARE LOAD
Refinery cooling water failure load – LP flare

Unit Flare Load (kg/hr) Mol.wt Temp. oC

CDU / VDU 94657 56.6 90.2

DCU 343700 56.4 132.0

MS NHT NIL - -
BLOCK
CCR 3227 13.3 93.6

ISOM NIL - -

VGOHDT NIL - -

DHDT NIL - -

PP 60000 42.0 86.0

HGU NIL - -

Total 501584 53.2 107.6

FCC-PC cooling water failure – LP flare

Unit Flare Load (kg/hr) Mol.wt Temp. oC

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FCC-PC 581417 49.0 152.1

Total 581417 49.0 152.1

B. HP FLARE LOAD
Refinery cooling water failure load – HP flare

Unit Flare Load (kg/hr) Mol.wt Temp. oC

CDU / VDU NIL - -

DCU NIL - -

MS NHT 1742 15.5 118.4

BLOCK
CCR 12146 27.0 83.8

ISOM 2301 53.45 107.7

VGOHDT 61652 16.3 89.9

DHDT 29855 15.2 103.4

PP NIL - -

HGU NIL - -

Total 107696 16.9 93.8

FCC-PC cooling water failure – HP flare

Unit Flare Load (kg/hr) Mol.wt Temp. oC

127400 (Note-1) 48.0 71.2

FCC-PC 384028 (Note-1)

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529373 (Note-2) 42.0 68.2

Total 656733 43.0 68.8

Notes:

1. Mitigated flare load.

2. Un-mitigated load considering one reboiler in operation.

C. TOTAL COOLING WATER FAILUER LOAD (LP + HP)

Cooling water failure load – LP + HP flare

Unit Flare Load (kg/hr) Mol.wt Temp. oC

FCC-PC CT failure load 1238190 45.7 107.9

Refinery CT failure load 609280 38.7 105.2

1.2.2 Unit Power failure and Total complex power failure

The power failure load for each unit is summarized in table below. During General power
failure, only the equipment which are connected with emergency power supply shall run.
So, individual unit power failure loads are additive.

Unit power failure load – LP flare

Unit Flare Load (kg/hr) Mol.wt Temp. oC

CDU / VDU - - -

DCU 579200 44.2 168 (hold)

MS NHT 132070 (Note-1) 78.6 111.3

BLOCK
CCR 21970 9.01 44.0

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ISOM 9468 (Note-1) 77.16 95.5

VGOHDT 218265 (Note-2,3) 60.3 160.8

DHDT 109177 (Note-1) 100.8 194.8

FCC-PC NIL - -

PP 60000 42.0 86.0

HGU NIL - -

Total 857465 47.2 154.4

Notes:
1. Not included in total due to flare load mitigation measures adopted.
2. Unmitigated LP power failure load. This being the single largest power failure load
(amongst mitigated loads), the same is included in the total considering the failure of
interlock logic system to act.
3. Deethaniser column is operating with hot VGO reboiler, 509-E-018. To mitigate this load,
pressure transmitters with 2 out of 3 voting logic to cut off Hot VGO to reboiler on high-
high column top pressure have been provided. Hence, flare load due to power failure
8178 kg/hr is not included in the total power failure.

Unit power failure load – HP flare

Unit Flare Load (kg/hr) Mol.wt Temp. oC

CDU / VDU NIL - -

DCU - - -

MS NHT 30000 (Note-1,2) 48.2 204.0

BLOCK
CCR 49458 40.4 91.8

ISOM 6000 (Note-2) 77.4 290.0

VGOHDT 171560 (Note-3) 12.2 306.2

DHDT 287814 27.6 265.9

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FCC_PC NIL - -

PP NIL - -

HGU NIL - -

Total 544832 20.6 240.2

Notes:

1. Load estimated based on the actual vapor load for PSV-1701(HDT separator drum load)
at the inlet of air cooler which is 30000 kg/hr. In case of power failure air cooler & CW
water exchanger will fail, hence the vapor load from HDT separator shall be total vapor.
2. Load due from stabilizer overhead 66563 kg/hr is not included in the total power failure
as flare load mitigation measures adopted for this column.
3. Load due from Debutaniser overhead 24359 kg/hr is not included in the total power
failure as flare load mitigation measures adopted for this column.

1.2.3 TOTAL COMPLEX POWER FAILUER LOAD (LP + HP)

Complex Power failure load – LP + HP flare

Unit Flare Load (kg/hr) Mol.wt Temp. oC

Complex power failure 1402297 31.5 187.8

1.2.4 Any other Failure

Any other failure – LP flare

Unit Failure Case Flare Load Mol.wt Temp. oC

(kg/hr)

CDU / VDU Reflux failure 421327 80.3 178

DCU Reflux failure 262500 59.9 153

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NHT Abnormal heat input 116207 78.46 110.8

ISOM Air cooler failure 318300 77.5 95.8

CCR Blocked outlet 21970 9.01 44.0

HGU Process vent 122422 2.03 40.0

DHDT Recycle gas reverse flow 48228 3.83 109.8

VGOHDT Gas blow by 68185 6.2 18.8

PP

FCC_PC Operational failure 252821 40.0 132.4

Any other failure – HP flare

Unit Failure Case Flare Load Mol.wt Temp. oC

(kg/hr)

NHT Blocked outlet 123439 46.89 296

ISOM Full open valve 223258 53.45 107.7

CCR Gas blow by 7457 3.48 26.3

HGU Blocked outlet 116416 12.9 305

DHDT Air cooler failure 58874 6.4 140.1

VGOHDT Air cooler failure 108602 4.6 121.6

PP

FCC-PC Operational failure 384028 42 59.2

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1.2.5 DESIGN HC FLARE LOAD

DESIGN HC FLARE LOAD

Load (kg/hr) Mol.wt Temp. oC

Complex power failure 1402297 31.5 187.8

FCC-PC cooling water 1238190 45.7 107.9

failure

1.2.6 UNITWISE FLARE LOAD SUMMARY

Unit wise governing flare load for individual unit header sizing is as given below:

Unit wise governing LP flare loads

Unit Governing load for individual unit Governing Case

flare header sizing

Load (kg/hr) Mol wt Temp. oC

CDU/VDU 421327 80.3 178 Reflux failure

DCU 579200 44.2 168 General power failure

(hold)

MS BLOCK 318300 77.5 95.8 Air cooler failure /reflux failure

HGU 122422 2.03 40.0 Process vent

DHDT 48228 3.83 109.8 Recycle gas reverse flow

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VGOHDT 68185 6.2 18.2 Gas blow by

FCC-PC 581417 49.0 152.1 Cooling water failure

PP 60000 42.0 86.0

Unit wise governing HP flare loads

Unit Governing load for individual unit Governing Case

flare header sizing

Load (kg/hr) Mol wt Temp. oC

MS BLOCK 223258 53.45 107.0 Full open valve

HGU 116416 12.9 305 Blocked outlet

DHDT 287814 27.6 265.9 General Power failure

VGOHDT 108602 4.6 121.6 Air cooler failure

FCC-PC 656733 43.0 68.8 Cooling water failure

1.3 SOUR FLARE LOAD

The flare loads from individual units (SRU/TGTU, SWS-1, SWS-2 AND ARU) for various cases
are listed under 9.3.1. The basis considered for sour flare system is summarized below

1.3.1 Cooling water failure

During cooling water failure, no relief load will come from:

 SWS-I/II: Overhead pump around circuit with air cooler

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 Amine section of TGTU: Overhead condenser is with air cooler

 Quench column of TGTU: With failure of CW cooler, the quench column and the
downstream amine absorber will operate at an elevated temperature. This will result in
increased flow of net gases to the incinerator. The relief load is not affected.

1.3.2 Local Power Failure in Sulphur block / Reflux failure in ARU

Local power failure in S-block may lead to failure of Feed pumps, reflux pumps, BFW pumps. S-block
generates its own steam for meeting part of the internal steam demand; additional steam (~ 75 TPH)
is imported from refinery. Thus in this case the sour and acid gases generated from ARU, SWS – I/II
will be routed to sour flare.

1.3.3 SRU shutdown

There shall be simultaneous release of acid and sour gases from ARU and SWS-I/II during SRU
shutdown. The relief load from these units is as follows:

Load MW Rel . Temp Remarks

T/hr Deg C

16.04 32.8 55 Amine Regeneration Reflux drum-I

16.04 32.8 55 Amine Regeneration Reflux drum-II

0.9 22.1 90 SWS-I

2.8 32.0 90 SWS-II ( First stage)

1.9 17.7 90 SWS (Second stage)

~37.7 31.0 60.2 TOTAL

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1.3.4 DESIGN SOUR FLARE LOAD

The design flare load for sour flare design is as follows :

Load (kg/hr) Mol.wt Temp. oC

Circulating Reflux failure 43893 18.4 123

1.3.5 UNITWISE SOUR FLARE LOAD SUMMARY

The governing sour flare load for individual units in the Sulphur block is as given below:

Unit Governing load for individual unit flare

header sizing

Load (TPH) Mol wt Temp.degC Contingency

SRU+ARU+SWS-I/II 37.7 31.0 60.2 SRU (both train)

down

Single stage sour water 43.9 18.4 123 Reflux failure

stripper

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Chapter-2
PROCESS DESCRIPTION

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2.1 INTRODUCTION

Flares are an integral part of the safety systems intended to prevent the risks of explosive,
accumulation of flammable, deleterious, toxic and polluting gases in the atmosphere. A flare
system is designed to dispose of the specified gas stream safely and efficiently by flaring.

Our plant consist of two flare systems –

1) Main HC (Hydrocarbon) Flare and

2) Sour (Acid) Flare

For safe disposal of combustible, toxic gases which are relieved from various process plants.

Proposed Flaring Systems (for Hydrocarbon & Sour Gas) are Elevated & provided with
Common Derrick Supporting Structure for this project. The HC flare is steam assisted
smokeless type where as the Sour flare is non-smokeless type. The flare system components
are sized for design flare load, so that specific conditions of velocity, Combustion & air
entrainment are met which in turn ensure flammability and flame stability. For details refer
the technical datasheet attached. The steam assisted Smokeless HC (Main) flare tip FUS
68/24 CB is provided with four pilot burners where as the non-smokeless Sour flare
tip FN 24/32 CB is fitted with three pilot burners, to maintain a constant source of ignition at
all times, and under all operating conditions. The flare tips are equipped with slated
windshields to prevent flame lick and help to cool the top of the flare tip closest to the flame
envelope. The tips are also provided with flame retention lugs to provide flame stability at
high flare gas discharge rates. The AFS 76 Main Flare (Molecular) Seal is located just below
the Main Flare tip. The Sour Flare tip is provided with Integral (velocity type)
Gaseel IGS 24, which is located integrally at the bottom of Flare tip. The seals have been
designed to prevent air ingress into the flare risers thus preventing the formation of an
explosion mixture in the systems. A small continuous bleed of purge gas at specified flow
must be maintained in order to ensure that the air does not penetrate in the seal & below.

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The Ignition system provided common for both the Flares is FD (forced draft) Auto/Manual
Flame Front Generator type to lit total seven pilots sequentially (four pilots of HC flare &
three pilots of sour flare). The pilot flame signals are generated by heat resisting K type
thermocouples fitted internally in the pilot nozzles. Temperature switches provided converts
the milli-volts signal to activate pilots on /off lamps.

2.2 EQUIPMENT DESCRIPTION

2.2.1 FUS 68/24 CB Main Flare Tip (589-LS-103):

(Drawing No. 5844-A3-002-G)

The flare tip is located at the top most portion of the flare where the flare gas is ignited &
destructed by means of combustion. The flare tips are available in many different types of
design & construction depending on the application requirement and suitability as per
composition of gases to be flared. An important criterion in the selection of the most
suitable design is whether smokeless combustion of the flare gas is required or not.
The Hydrocarbon (Main) flare system of GGSR project at HMEL consists of smokeless flaring
operation. The Main Flare Tip FUS 68/24 CB is smokeless type flare tip, which utilizes steam
to achieve smokeless flaring operation. External injection of steam on the flare tip increases
the air inspiration & provides intense mixing of the flare gas with air & steam this reduces
the smoke generation. The central steam injection also creates severe turbulence & mixing
of the steam with gas & results in reduction of the flame temperature, which avoids thermal
cracking of the heavy hydrocarbons, this assists in reduction of the smoke formation. Hence
to achieve efficient smokeless operation the Steam is injected externally as well as centrally.
The Central Steam injection is achieved through 1 no. Central steam nozzle. The external
steam is injected through 24 nos. of External steam nozzles, which are arranged peripheral
around the flare tip and connected through steam manifold. The specified steam
consumption of 1823 kg/hr centrally and 7923 kg/hr externally is based on steam pressure
3.5 Kg/cm2 g. Precautions should be taken to ensure that this pressure is not exceeded due
to mal-operation or failure of control valves.
While starting the flare, first drain the steam system and then slowly introduce steam to the
flare tip establishing a small bleed to the tip prior to ignition. This helps to reduce heating
shock on the steam manifold. Control of steam flow during operation can be manual or
automatic and is necessary to maintain a level sufficient to suppress the smoking. It has to
be noted that the steam injection will be required during flare operation where the flare gas
comprises of constituent, which produce smoke on flaring. However during the flare
operation where no much smoke is being generated, at that time the steam supply to the
system should be kept at minimum 2 kg/hr centrally & 48 kg/hr externally to help protect

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the steam nozzles of the flare tip from thermal radiation. The Main flare tip is supplied with
a slatted type Windshield to prevent flame lick, hold the flame above the tip and to help to
cool the top portion of the flare tip closer to the flame envelope. The flare tip is also
provided with flame retention lugs to provide flame stability at high flare gas discharge
rates. The top portion of 1500mm length of the flare tip main shell is provided refractory
lined to avoid deterioration of the shell material due to high temperature.

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2.2.2 Burn Back situation on Flare tip & means to counter the same:

Prolonged burning inside the tip could cause deterioration of the Flare Tip internals during
very low flare gas flow rate. The exit velocity of the flare gas at low flaring rates is so low
that the gas starts burning inside the tip shell rather than at the exit. This low burning inside
the body of the flare tip is termed as Burn-back. Apart from the low tip exit velocity, nature
of the flare gas also has great impact on the occurrence of burn back, e.g. hydrogen has
great affinity for oxygen & at low flaring rates hydrogen would pull the atmospheric air
inside the tip shell & establish flame much lower in the tip body causing burn back. It is
generally established that if the overall flare gas quantity is such that a visible flame is
observed on the exit of the flare tip, there shall be no burn back. To counter the burn back
the flare gas quantity should be sufficiently high so as to establish flame at the tip exit rather
than burning inside the flare tip body. On a flare system it is practically impossible to define
a precise gas rate, which would avoid the burn back for all operating conditions. This is true
since the flare system is subjected to vary wide range of operating situation in terms of flare
gas quantity & its nature.
If the refinery is operating normally no gas is expected to be flared in such case the purge
gas injection is generally supplied at rate specified to ensure the system is free air ingress
from the top. This rate of Fuel gas as purge gas is 31.6 m3/hr. However when the flare load
is low resulting from venting of various relief valves is such that the total flare gas flow going
to the flare system there is possibility that the flame may burn inside the tip body rather
than at the tip exit resulting in to Burn Back. To avoid this situation the flare tip has been
provided with burn back thermocouple to detect the low burning or lowering of the flame
inside the flare tip body, which give indication at FFG Panel.

2.2.3 FLARE PILOTS:

The Main Flare Tip FUS 68/24 CB is provided with 04 nos. pilot burners, which maintain a
constant source of ignition at all time and under all operating conditions.
The Flare pilots are of self-inspiriting type and utilize a gas pressure in the venturi to entrain
combustion air. Sufficient combustion air is entrained to ensure the pilots remain lit even
when blanketed by inert gas. The pilot nozzles have built-in flame retention and include a
shield to ensure a stable flame and enable positive re-ignition even in condition
of high winds. Ignition of the pilot is via a flame front generated at a remote panel and fed
to the pilot nozzle via a 1” igniter tube. (The pilot gas is supplied via a ½” inlet to the venturi
with an air adjuster). The air is pre-mixed with gas in a 2” gas tube and is ignited at the pilot

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nozzle by the flame front. For flame indication, or flame failure, a thermocouple is fitted
internally in the nozzle and the gas mixture tube where it is protected from the main flame
and cooled by the flow of gas passing over the thermocouple. The pilot venturi, for
entrainment of air, is located at the lower end of the assembly to ensure that gas free air is
inspirited. Air adjuster should be set approximately at 4 mm open. Refer Appendix 1
attached for details on the correct location of the thermocouple & venturi settings.
Note: Do not open the air adjuster too much since a highly inspirited flame can flash back
into the pilot tube.

2.2.3 AFS 76 Main Flare (Molecular) Seal (589-LS-102):

(Drawing No. 5844-A3-003-G)

The AFS 76 Main Flare (Molecular) Seal is located just below the Main Flare tip and has been
designed to prevent air ingress into the flare riser thus preventing the formation of an
explosion mixture in the system. The Molecular seal is basically a gas inversion device
causing the gas normally flowing in an upward direction to be turned to 180 degrees
and flow downward for a short length before being redirected through 180 degrees back in
the original direction of flow. In a static condition, gases lighter than air will tend to collect
in the upper bend, sealing off the stack against the back flow of air. Heavier gases will tend
to settle in the lower bend with the same effect. Some wind and atmospheric action will
affect these interfaces slightly and also molecular diffusion of the two gases will take place
at the interface. In order to counteract these effects, a small continuous bleed of purge gas
at specified flow must be maintained in order to ensure that the air does not penetrate
in the seal. The seal only is not meant for reducing oxygen concentration in the flare tip or
any part effectively downstream from it. The presence of Flare seal results in significant
savings in purge gas consumption.

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2.2.4 FN 24/32 CB Sour Flare Tip with Sour Flare Seal

Integral Gaseel (IGS 24) (589-LS-105):
(Drawing No. 5844-A3-004-G)

The FN 24/32 CB Sour Flare tip is Non-smokeless type Flare tip. The tip is provided with an
Integral gas seal IGS 24, which is located integrally at the base of the flare tip and prevents
air ingress into the flare system by presenting a smaller cross sectional area of the
stack to the rising gases, thereby reducing the volume of gas needed to maintain a fixed
purge velocity. It also prevents the passage of air currents down the stack riser section.
The Sour flare tip is supplied with a slatted type Windshield to prevent flame lick, hold the
flame above the tip and to help to cool the top portion of the flare tip closer to the flame
envelope. The flare tip is also provided with flame retention lugs to provide flame stability at
high flare gas discharge rates. The top portion of 1060mm length of the flare tip main shell is
provided refractory lined to avoid deterioration of the shell material due to high
temperature. The Sour Flare Tip FN 24/32 CB is provided with 03 nos. pilot burners,
which maintain a constant source of ignition at all time and under all operating conditions.

2.2.5 Common Flame Front Generator Panel (589-LS-104):

(Drawing No. 5844-A2-005-G)

The common Flame Front Generator panel provided is suitable for total 7 nos. pilot burners
(4 of Main flare & 3 of Sour flare).

2.2.5.1 IGNITION PRINCIPLE

The ignition system provided by Airoil-Flaregas is forced draught, electric type,

Auto/manually operated system, which is designed to use the flame front generator
principle. If a tube is filled with a static mixture of fuel gas and air, within the fuel’s
combustibility limits and an ignition source is supplied to one end, a crescent shaped flame
front will travel along the full length of the tube, at or about the burning velocity. The
emergence of this flame front at the flare tip, adjacent to the pilot gas tip, will thus provide
a reliable ignition source to the pilots. The well-proven principle of traveling flame front
generation is employed for flare pilot ignition. Basically the ignition piping system (1” Pipe)
is filled with a flammable mixture of gas and air, which is ignited at source. The resulting
flame burns through the entrained mixture to the pilot nozzles, where it provides an ignition
source for the main gas/air mixture to the pilot burner.

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2.2.5.2 PILOT IGNITION

The ignition system is designed to ignite one pilot at a time. As the panel is mounted remote
from the flare, the gas and air pressure are required to be regulated suitably to create a
flammable mixture in the 1” ignition pipe. Minor pressure adjustment required can be done
by the needle valves provided on the panel. Flame front is distributed by means of the flame
front diverter and thus all pilots are lighted up sequentially. The ignition source at panel
comprises of Ignition Transformer and Spark Plug. The Ignition Transformer steps up voltage
to 7.5 KV (normal). This voltage is discharged as a spark gap. Earth the ignition chamber to
the backing frame (earth bolt) and earth the backing frame to site earth.

2.2.5.3 GAS & AIR SUPPLY

The pilot gas and ignition gas are supplied at 1.4 Kg / Cm2 (g) pressure and around 0.1 to 0.2
Kg / Cm2 (g) pressure respectively from the panel while the ignition air is supplied at 1.4 Kg /
Cm2 (g). The pressures are indicated individually by locally mounted pressure gauges .
Actual pressure of air & ignition gas should be adjusted
at site during commissioning.

2.2.5.4 PILOT DETECTION & INDICATION

The milli-Volt (mV) signals for pilot flame detection are generated by thermocouples fitted
internally in the pilot nozzles. These signals are carried through Thermocouple cables up to
the panel, where Temperature switches provided on the ignition panel converts the mV
signals to mA signals and suitably activate the pilots on / off indication lamps.

2.2.5.5 Various ON-OFF Indications generated at FFG Panel

(Pilot monitoring box):

WHEN

Main Pilot – 1 is ON : Indicating Lamp L1 [GREEN] is ON.

Main Pilot – 2 is ON : Indicating Lamp L3 [GREEN] is ON.
Main Pilot – 3 is ON : Indicating Lamp L5 [GREEN] is ON.
Main Pilot – 4 is ON : Indicating Lamp L7 [GREEN] is ON.
Sour Pilot – 5 is ON : Indicating Lamp L9 [GREEN] is ON.
Sour Pilot – 6 is ON : Indicating Lamp L11 [GREEN] is ON.
Sour Pilot – 7 is ON : Indicating Lamp L13 [GREEN] is ON.

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WHEN

Main Pilot – 1 Flame Fails : Indicating Lamp L2 [RED] is ON.

Main Pilot – 2 Flame Fails : Indicating Lamp L4 [RED] is ON.
Main Pilot – 3 Flame Fails : Indicating Lamp L6 [RED] is ON.
Main Pilot – 4 Flame Fails : Indicating Lamp L8 [RED] is ON.
Sour Pilot – 5 Flame Fails : Indicating Lamp L10 [RED] is ON.
Sour Pilot – 6 Flame Fails : Indicating Lamp L12 [RED] is ON.
Sour Pilot – 7 Flame Fails : Indicating Lamp L14 [RED] is ON.

WHEN

HC BURNBACK occurs : Indicating Lamp L15 [RED] is ON.

System Lockout occurs : Indicating Lamp L16 [RED] is ON.
Power Supply to Panel is ON : Indicating Lamp L18 [RED] is ON

Lamps L17, L19, and L20 & L21 are spare.

Potential Free contacts are provided in our FFG Panel so that Flame on off
monitoring is done at Control Room.

2.2.5.6 Function of Various Push Buttons & Switches mounted on FFG

Panel (Pilot Monitoring box):

Push Button PB1 : Manual Ignition Start

Push Button PB2 : Auto Sequence Start
Push Button PB3 : System Reset
Push Button PB4 : Spare
Push Button PB5 : Lamp Test
Push Button PB6 : Spare
Selector Switch SW1 : Main Supply ON/OFF switch
Selector Switch SW2 : Auto/Manual/Off selector switch
Selector Switch SW3 : Ignition Transformer ON/OFF switch

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Chapter-3
UTILITIES, CHEMICALS AND EFFLUENTS

3.1 UTILITIES:

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SL Battery Limit Condition Utility Required

N SERVICE Pressure Temperature Consumption Remarks
O kg/cm2 g Deg.C
A FUEL GAS
1 For Pilot burners MIN: 2.5 MIN: AMB
(Continuous) NOR: 3.0 NOR: AMB
MAX: 7.0 MAX: AMB Please refer below Table-
2 For FFG ignition
DES: 9.0 DES: 65 A
Panel
(during start up)
3 For Purging

B INST. AIR
MIN: 4.5 MIN: AMB @ 1.4
For FFG Ignition
NOR: 6.0 NOR: AMB kg/cm2 g
Panel
MAX: 6.0 MAX: 50 50 Nm3/hr after PCV-
(During start up)
DES: 9.0 DES: 65 1001

C MP STEAM (*)
1 Primary Steam Ring MIN: 9.0 MIN: Satd 7923 kg/hr
-
(External) NOR: 10.0 NOR: 220
2 Secondary Steam MAX: 11.0 MAX: 245 1823 kg/hr
-
Ring(Central) DES: 12.5 DES: 300

D POWER
For Ignition 240V A.C./ 1 φ / 50 Hz 700 VA
Transformer
For FFG Panel 110V A.C. (UPS) / 1 φ / 50 300 VA
Hz

(*) To provide sufficient protection to the steam parts at the top from high heat
radiation, minimum
steam supply of 2 kg/hr for central steam line & 48 kg/hr for external steam line are
necessary.

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TABLE – A
FUEL GAS CONSUMPTION

Normal Case Start up Case

(MW: 19.74) (MW: 52.64)
FOR MAIN HC FLARE
Pilot gas per pilot, Nm3/hr (Continuous) 2.1 0.8
Pilot gas pressure, kg/cm2 g 1.4 after PCV-1701
Fuel gas for FFG, Nm3/hr (During start
5.3 2.0
up)
Fuel gas pressure for FFG, kg/cm2 g 1.4 after PCV-1002
Fuel gas for Purging, m3/hr 31.6 (for Molecular seal to avoid air ingress)
Fuel gas pressure for purging, kg/cm2 g 0.5 to 1.0

FOR SOUR FLARE

Pilot gas per pilot, Nm3/hr (Continuous) 2.1 0.8
Pilot gas pressure, kg/cm2 g 1.4 after PCV-1702
Fuel gas for Purging, m3/hr 37 (for Integral Gaseel to avoid air ingress)
Fuel gas pressure for purging, kg/cm2 g 0.5 to 1.0

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Chapter-4
OPERATING VARIABLES

4.1 OPERATING CONDITIONS AND YIELDS:

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Description Units MAIN FLARE SOUR FLARE

Gas to be Flared Hydrocarbon Acid/Sour Gas

Peak Flare Load kg/hr 1381034 43893

Minimum Flare Load kg/hr 460 -
Average Molecular 36.4 18.4
Weight
Gas Temperature °C AMB. – 160 123
Smokeless Flare kg/hr 28000 -
Load
Calculated Pressure Mm WC
Drop
Flare Tip 1400 Less than 300
Seal 500
Total 1900
Allowable Pressure Mm WC 2000
Drop 300

Tip Exit Velocity m/sec 162.1 (0.47 77 (0.16 Mach)

Mach)
Stack Diameter 76 Inches 32 Inches
Stack Height M 140

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Chapter-5
PREPARATION FOR START-UP

PREPARATION OF START UP/ PRECOMMISSIONING

5.1 PLANT CHECKING

Pre-commissioning is the period when conformity, non-operating checks and

verifications that the installation conforms to plans, specifications, and drawings,

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are carried out. It includes the calibration of instruments, cold-alignment checks,

testing of safety devices, etc. This phase leads to the mechanical completion or
ready for commissioning. These activities are carried out after the completion
of erection and other nonoperational activities. A planned check of the unit forms
the first steps for a smooth start-up.

These activities are normally the CUSTOMER’S responsibility (where only

commissioning assistance is by EIL), unless the contract specifically provides
otherwise (like turnkey commissioning by EIL).

This section details out the pre-commissioning procedures and general

guidelines for preparing a unit for start-up. Some of the pre-commissioning works
can be carried out simultaneously along with construction. But, care in the

organization of this work is required so as to ensure that it does not interfere with
the construction work. It is most important to plan schedule and record with
checklists and test schedules all the preliminary operation and to co-ordinate the
construction program.

Some sections need to be expanded to give specific directions (water flushing

procedure, inertising procedure for example); this shall be prepared by
commissioning personnel prior to start of the pre-commissioning/start-up.

PRECOMMISSIONING ACTIVITIES
Pre-commissioning activities include, but are not limited to, the following:

 Inspection of Tanks / Vessels / Columns etc. for cleanliness and any

construction debris.

 Isolation / removal of inline components / instruments for flushing operation

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and re-install them on the completion of these operations with assistance

from construction.

 Commissioning of utilities and other auxiliary systems.

 Flushing & Cleaning of pipes / vessels / equipment by air blowing/water

flushing/hydro jetting / steam blowing/oil flushing/decreasing etc.

 Cleaning and flushing of sewer systems and blow down systems.

 Carry out chemical cleaning for pipes / vessels as per guideline provided by
specialist group.

 Passivation of lines/vessel/equipment as required.

 Reviewing of compressor, special pumps/rotating equipment as per

manufacturer’s instructions including preparations of lubrication system for
these equipments.
 Testing of safety valves and other safety devices.

 Testing of heat exchangers for leaks.

 Testing of plant communication system.

 Functional test of rotating equipment with a suitable medium

(nitrogen/air/water etc.) as the case may be.

 Checking out interlocks systems and emergency shutdown systems.

 Installation of temporary blinds/spools etc. to enable isolation of systems

during pre-commissioning stag.

 Removal of temporary blinds just prior to commissioning.

 Water run / dry run for process systems to check the functioning of control
systems (both software and hardware) including tuning of controllers.

 Installation of permanent packing/gaskets, if permanent packing/gasket is not

suitable for initial run up purposes. Otherwise this activity will be part of

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construction activity.

 Leak testing of vessels / piping / equipments etc.

 Drying of columns / equipment with dry air / nitrogen as required.

 De-airing of the systems by nitrogen purging / steaming as required.

 Nitrogen padding/fuel gas backing of the piping / vessels / equipment as

required.

Inspection of Vessels.

Inspection of the interior of the vessels, columns, and other vessels not normally
accessible during operation should be made to ensure that they are complete,
clean and correctly installed. The actual installations must be compared against
the drawings to assure that the vessels will function as intended. The reactor
internals must conform exactly to the design specifications if good distribution is to
be attained and catalyst migration is to be avoided. Particular attention must be
paid to the following details:

Specification Check

a. Review design specifications with the vendor drawings to verify agreement on:

1. Pressure, temperature, and vacuum ratings.

2. Shell metallurgy, thickness, and corrosion allowance

3. Vessel elevation, Nozzle size and orientation; flange rating, type and finish.

4. Type of lining, thickness and material.

5. Stress relieving and/or heat treatment.

6. Foundation design for full water weight.

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b. Confirm that the vessel has been hydrostatically tested.

c. Verify that all code plate information on the vessel is correct.

Internal Inspection
Vessels

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

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

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

I. Vortex breakers: type, size, and orientation.

II. Baffles: type, orientation, levelness.

III. Instrument nozzles: location, orientation, cleanliness, thermowell length and

metallurgy, baffle size and type.

IV. Packing: type, size, support, installation.

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

VI. Internal ladders and other devices: location, size, orientation, properly
secured.

Lining and refractory:

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Hex-steel for concrete lining: clean and properly secured. Lumnite or other
specified cement applied according to the specifications, with no holes or gaps
in the applications.

Metal linings in good condition. Weld overlays have no gaps or holes in the
application.

Lining is of the proper thickness and covers the required portion of the vessel.

Other refractory installed correctly with no gaps or holes in the application.

General

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

External Inspection

I. Man-ways and nozzles: location, size, flange rating and finish, metallurgy,
with proper gaskets, nuts and bolts.
II. Ladders and platforms: correctly positioned, secure and free to expand.

III. Vessel grounded correctly

IV. Correct vessel elevation.

V. Valves and instrumentation: easily accessible from grade or platform.

VI. Fireproofing of structure and supports is complete.

VII. Piping

- Adequate supports and guides for all connecting lines.

- Level and pressure instrument connections drain to a safe location.

- Vents to atmosphere or blow down provided as specified.

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- Relief valves have been bench tested.

- Check valves exist on utility line connections where hydrocarbon backup

could occur.

- Connections available for steaming/purging of the vessel.

VIII. Insulation and steam tracing: provided as specified and has expansion joints
as required.

Instrumentation:

- Level glass floats center positioned correctly with respect to vessel tangent
line, and are readable from grade or platform.
- Through-view level glasses have rear light for illumination.
- Flange ratings, metallurgy, size, etc. are all correct.

- Thermocouples are located properly and installed so that they have good
contact with the wall.

Field Inspection

In the field the following items should be checked:-

1. Name plate verifies specifications.

2. Flange size, rating, facing and gaskets.
3. Insulation for heat retention and personnel protection.
4. Exchanger properly grounded.
5. Tubular exchangers:

a) Elevation

b) Slot length of sliding plates adequate for expansion. Exchanger should not be
tied down at both ends. Check that sliding ends of multi-shell exchangers
make sense with regard to expansion of exchangers and connecting pipe.

c) Piping symmetry for parallel exchangers.

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d) Non-condensable vents in steam service or in totally condensing systems.

e) Water coolers; inlet at bottom of exchangers; inlet/outlet block valves with

a thermal relief valve inside the outlet block valve; vent and drain connections inside
the block valves.

f) Witness a shell/tube differential pressure test, if possible (especially

important in feed/effluent exchangers). When leak testing piping and
equipment, ensure that the design shell/tube differential pressure is not exceeded.

Inspection of Piping and Accessories

The unit must be constructed in accordance with Piping and Instrumentation

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

Piping support and hangers will be inspected to ensure that all anchorages are
firm. Valves will be checked for proper packing and mounting direction and
accessibility for operation and maintenance. Spring supports, if any, to be
checked for the cold setting and later for hot settings while plant is in operation.
Check for completion of welding work, especially on small bore piping and socket
weld valves

If the unit is connected to other process facilities, adequate means must be

provided to receive feed from or send products to these facilities without

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contamination of these streams, and minimize as much as possible the effects of

upsets of other process units especially where contamination of feed or product
stream might occur. Check all tankage interconnections to minimize the
possibility of stream contamination outside of the battery limits. Check that
adequate means of measuring flows, pressures, and temperatures, and sampling
of all process streams has been provided. The following items must be checked
to ensure conformity to the design specifications:
1. Flanges: rating, facing, and metallurgy; type (typically, 2" and smaller are socket
weld, 2½" and larger are weld neck flanges).

2. Gaskets: type; metallurgy (materials of retainer, jackets, winding, filler, etc.);

thickness, ring size, etc.

3. Fittings, connections and couplings: rating and metallurgy.

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

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

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

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

8. Gauge glasses:

− Through-view types should have rear-mounted lights.

− Design pressure and temperature.

− Special materials of construction.

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− Drains to safe location.

− Visible from grade (or platform, if required).

9. General:

a. Utility systems within the battery limit should follow all relevant pipe class
specifications in the same detail required for process lines.
b) Package systems (modular units, etc.) shown on the P&ID should follow
all relevant pipe class specifications in the same detail required for other
process lines.

c) Expansion: review the physical installation to ensure that no expansion

problems will occur when the unit gets hot and that:

− Column overhead, reflux, feed and other lines are free to expand.

− Sufficient expansion loops have been provided on long hot lines.

− Pipe shoes are free to move in one direction, and are resting on
supports of sufficient size that the shoe will not fall off the support.

d) High point vents and low point drains should be installed where
necessary

e) Spectacle blinds should be provided where required.

f) Car-sealed valves should be locked in proper position.

g) Spring hangers should have locking pins removed (after hydro testing) and
necessary adjustments should be made for hot /cold position after startup.

Inspection of Instrumentation

All personnel on site should check to ensure that the instrumentation is provided

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as specified; that it is functional; and that a minimum of instrumentation

problems will occur when the unit is commissioned.

All instrument tapings for pressure, level and flow should be clear and
thermowells should not foul with the internals. These should be checked prior to
box up of the equipment. Instruments starting from the controller and proceeding
logically through the control loop will be checked. Cascade control system will
be checked from the impulse point of primary loop. Operating crew should check
proper mounting of control valves. Control valves responses should be checked
for controller outputs. The shutdown systems of the equipments should be
checked by simulating the various conditions in the control circuits.

Some of the basic items which must be checked include the following:

1. Instrument type, range, and size.

2. Instrument tagging is proper.

3. Materials of construction and rating of instrument, accessories, and connecting

piping, flanges, and valves.

4. Accessibility of instrument for routine checks and maintenance; rigidly mounted.

5. Installation according to correct Licensor’s drawing details, if any.

6. Accessories (pulsation dampeners, filter/regulators, diaphragm seals, excess

flow checks, seal pots).

7. Location of local indicators so they are readable from grade platform or controller
assembly, as required.

8. Operating range is consistent with the operating parameters prevailing at the

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location.

9. Process requirements of flow, temperature, pressure, differential pressure,

specific gravity, etc. and location as per process requirements are met.

10. Controller type, number of modes, chart type, range, cascades.

11. Power requirements of voltage, frequency; emergency power supply and

connections.

12. Calibration of controllers, transmitters, analyzers, special instrumentation.

13. Flow orifice coefficients must be checked and recorded.

14. Level instruments shall be calibrated using the most likely liquid density.

15. Control valve, block and bypass valve sizes for control valve assemblies.

16. Alarm/ light are actuated in the control room by their corresponding mechanism.

Inspection of Control valves

The control valves are removed during washing operations. They will be checked
for cleanness of the seats and free movement of the plug or ball. Check the
valves motion and their response to the controller signal. When all the single
instruments have been individually checked, when all their addresses have been
verified in the D.C.S., then the loop checking can take place for each loop or
group of control loops. Each automatic action, either linked to the process or to
equipment shall also be individually tested.
Inspection of Relief Valves

Relief valves will be set in the shop and mounted before the system pressure
test. Block valves ahead and after relief valves will be checked for lock open or
lock close position as per P&ID. Relief valves will be checked against

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specifications and some of the items to be checked which ensure conformity with
these specifications are as follows:

− Size and style.

− Lever requirement.

− Inlet/outlet flange material, facing and rating.

− Set pressure - must be bench tested.

− Metallurgy of nozzle, disc, spring, etc.

− Type (pilot operated, balanced, etc.).

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

horizontal or below.

Inspection of Safety devices

The process includes a number of specific safety devices referred to Interlocks

Safety (IS) which, are implemented in the Emergency Shutdown System (ESD).
These devices are designed either to protect the unit against any improper
operations or to fulfill safety actions.

The Interlocks Safety (IS) is composed of independent systems which in the

occurrence of pre-defined potentially harmful events, initialize various actions such
as:

Valve(s) are set to their failure position (FC, FO or FL).

Shutdown of equipment (pumps, compressors, furnace, electrical heater, etc...) to
alleviate the risk.

The details of the Interlocks Safety are separately shown in the P&ID. The tests of
these devices must be witnessed by Licensor’s representatives and remedial work
must be carried out until the operation is fully satisfactory.
The principles of these checks are as follows:

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 A simulated default signal from the primary sensor will be fed into the system
and the resulting signal output to valves or equipment will be checked.

 Whenever possible, the end result of the signal output such as actual valve
failure or machine shutdown will be observed.

 Ultimately, a real test which requires running machines must be performed

during the forthcoming operation procedures.

Throughout this exercise, the actual physical position of the valves or status of
machines will be checked against the indications shown in the control room.

The check of the motorized valves is part of the same task. It includes:

 A site test of the opening / closing of the valve upon the input signal.

 A check of the reported information in the control room and a check of the
control room command.

Inspection of Drainage System

Check the OWS and blow down system against drawings. Check for free flow.

UNIT INSPECTION ACTIVITIES

i. Check the unit for completion of mechanical work against P&ID.

ii. Check list points are liquidated. Any pending point should not affect pre-
commissioning operation.

iii. Remove all construction debris lying around in the unit and clean up the area.
iv. Install blinds as per master blind list as detailed out in section -

v. Safety valves should be kept blinded during flushing and re-installed afterwards.
These should be shop tested and set at the stipulated values.

vi. Ensure that underground sewerage system is in working condition. Clear

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plugging, if any. Check by flushing with water.

vii. Check that communication between units, control room, offsites and utilities are
complete and in working condition.

viii. Ensure that the required lube oil, grease and other consumable are available in
the unit.

5 Preparation of the unit/blinding

Prior to the commissioning of the plant there are several pre-commissioning

operations that must be conducted to prepare the plant for the actual start-up;
these are:

1. Commissioning of utilities

2. Final inspection of vessels

3. Pressure test equipment

4. Wash out lines and equipment

5. Service and calibrate instruments

6. Purge and gas blanketing

7. Tightness test
It is important that these operations should be carried out as thoroughly and as
well as possible to help achieve a smooth and trouble-free start-up and later
steady normal operation.

A discussion detailing the major items to monitor in each of these operations

follows.

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5.2 FLUSHING/ STEAM BLOWING/ AIR BLOWING

All piping must be thoroughly cleaned of debris and scale. This may be done
after hydrostatic testing, before the test water is drained. Generally, liquid lines
are flushed with water and thoroughly drained. Gas lines may be either water
flushed or air blown, but water should be blown from gas lines if water flushed.
Gas lines to compressors must be free of water. It should be noted that no matter
what the flushing medium – steam, air, or water – maximum volume and velocity
should be used for thorough cleaning. The flushing medium should be regulated
at its source. For example, water from a tower should be regulated at the tower;
and steam, at the valve in the supply to the line being blown.

Flush or blow, the main header, from source to end, then, each lateral header,
from the main to end, and each branch line, from the lateral header to end.
Always flush through a piece of equipment's bypass to an open end before
flushing through the equipment.

An effort should be made to run as many of the pumps and use as many of the
lines as possible to collect and remove all trash, solids, slag, etc. left over from
construction.

Remember, when pumping water with centrifugal pumps intended for

hydrocarbon service, the suction valve must be fully open and the discharge
throttled to avoid overloading the motor. All pumps and drivers must be properly
aligned by qualified personnel, and the lubrication and cooling systems placed in
service before any attempt is made to run them. It is recommended that
whenever possible the drivers are run prior to being coupled to the pumps.

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While running the pumps, the bearing should be checked often for signs of
overheating and vibration. An operator should be nearby to shut down a pump at
the first indications of cavitations. Suction strainers should be pulled and cleaned
as often as needed until no more dirt accumulates in them. In flushing through a
reboiler is sure to do so one passes at a time to ascertain that the tubes are clear.
Do not flush into any exchanger until the lines leading to them have been flushed
clean.

The reactor section requires special attention since it will not be possible to use
any pumps to flush the combined feed exchanger, heaters, etc. The water left
after hydro testing can be drained out under pressure, and this will remove most
of the foreign material. High pressure steam can also be used to blow through

the lines. This procedure is especially recommended for the charge heaters and
effluent condensers to assure that all passes are clear. Advantage should also
be taken of the compressor run-in period when the air pumped by the
compressors can be used effectively to blow through the heater tubes and
exchangers.

Upon completion of line flushing of any system, carefully check that all temporary
breaks are reconnected, control valves are replaced, and pump alignments are
normal. Also, see that all possible water has been drained.

NOTE: ALL THE FLUSHING AND CLEANING LOOPS ARE TENTATIVE, IF

ANY MODIFICATIONS ARE REQUIRED, ACCORDINGLY WILL BE DONE AT
THE SITE.

Considering the type of fluid handled, pipe material and internal wall conditions,
pipe cleaning method shall be selected from following alternatives:

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a) Cleaning by water

b) Air Flushing

c) Steam Flushing

d) Chemical cleaning

e) Oil flushing

a) Cleaning By Water or Water Flushing

As a rule, water flushing shall be done for pipes in liquid service. If cleaning by
water is unsuitable, other methods will be used. Wherever practical, care should
be taken that clean water supplied to the vessels and contiguous lines should be
flushed away from the vessel and should never flush into the equipment.

Following procedure shall be adopted for water flushing.

 Low point drains and high point vents should be opened.

 Low point flanges should be opened during initial flushing, wherever possible.

 All instrument connections should be isolated, orifice plates removed, control

valves dropped or isolated and by passed. In case there is no bypass facility
provided, remove control valves and flush the line. The valve will be installed
after clear water starts coming out and further flushing may be continued.
Relief valves should be blinded if they have been returned to service after
hydro testing. Orifice plate can be installed only after the total flushing of the
loop is over. Instrument lines should be flushed with the transmitter removed.

 For pumps in line, suction and discharge piping should be disconnected.

Temporary fine mesh screens should be placed on the suction strainers of all

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pumps.

 If there is any heat exchanger in the line, flushing should be done up to the
inlet of heat exchanger and around the exchanger using bypass line. It should
be ensured that dirty water from initial flushing does not get into the
exchanger. Wherever by-passes are not available, the flanged joint at the
inlet of heat exchanger should be first opened (the exchanger nozzle should
be covered thereby isolating the exchanger internals) and the line flushed till
clear water starts coming out. Then reconnect flange and flush through the
exchanger.

 At each opening of the flanged joint, a thin metallic sheet should be inserted
to prevent dirty water from entering the equipment or piping.

 The flow of water should preferably be from top to bottom for flushing of heat
exchangers / coolers. The bottom flange of the equipment should be opened
to permit proper flushing. Where possible, flush downward or horizontally.

 Flushing should be carried out with maximum possible flow of water till clear
water starts coming out.

 Vertical lines which are long and rather big (say over 100 mm diameter)
should preferably be flushed from top to bottom. This will ensure better
flushing. Filling the lines and releasing from bottom is also helpful. Temporary
water connection at suitable points can be made to carry out flushing
operation. The run down lines should be flushed from the unit to the
respective tanks or tanks to unit.

 It should be ensured in all flushing operations that design pressure of lines

and equipment are never exceeded. After flushing of lines and equipment,
water should be thoroughly drained from all low points. Lines and equipment

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containing pockets of water should not be left idle for a long time; it is
preferable to dry these lines and equipment with air after water flushing.
During water flushing wherever applicable for the equipment having
demisters, the demisters are to be removed and shall be installed only after
flushing and subsequent drying with air is completed.

 For flushing of stainless steel lines and equipment, DM water shall be used.

 In case the piping which is used in gas service is being cleaned by water,
temporary pipe supports may have to be installed. Confirmation from
engineering departments should be obtained regarding weight carrying
capability of these lines, prior to introducing water.

Where low chloride test water is required to prevent the potential of chloride stress corrosion
cracking of austenitic stainless steel, it is especially important that all water from low points is
removed by being purged with nitrogen. Otherwise, as the remaining water evaporates, the
chloride concentration that started at lower concentration will concentrate to levels that can
(and will) crack or cause pitting of the austenitic stainless steel. If pitting occurs, it may be
discovered during a final equipment inspection (for example, at the bottom of a fractionation
column), allowing time for repairs. On the other hand, if stress corrosion cracking occurs it
will probably not be discovered until the equipment temperature is increased for the first time,
causing a delay in the startup schedule.

Systems that have been water flushed or steam flushed may require complete drying
before hydrocarbon can be taken in. This operation becomes critical when the plant
is dealing with refrigerated systems operating at low temperatures (e.g. LPG, LNG,
C2/C3 recovery etc.) or systems handling chemicals like SO 2 which will lead to
profuse corrosion.

If slugs of water are to be removed, the system is initially blown hard with a strong
flow of plant air. Necessary temporary connections for air inlet and outlet are to be
made. Since plant air can give rise to about 7 Kg/cm 2g pressure on blocked out
conditions, care should be taken to ensure that line design conditions are not
exceeded. Ensure that there is no inadvertent closing of valves during air blowing &
adequate venting is available. When major portion of water has been removed, the

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air drying can be continued with compressed utility air to make the system
completely dry. For pre-specified critical services, the plant air is to be heated up to
80°C and blown through the system followed by instrument air or Nitrogen.
Alternatively the line can be blown through by N2 from Nitrogen Cylinders. Portable
dew point instrument is to be used to measure the dew point of exit air. Normal
recommended value is - 40°C at atm. pressure.

It is advisable to take up small systems at a time for drying. After drying these are to
be isolated and kept sealed with Nitrogen. While blowing with hot air, precautions are
to be taken to take care of thermal expansion of pipes.

b) Air Blowing or Air flushing

Air flushing is done for pipes in gas service or low temperature service. If sufficient
air is not available, pipes can be cleaned by pressurizing and depressurizing by
bursting disc of cardboard or gasket material. Pressure should not increase beyond
design pressure. Larger diameter pipe- lines also which cannot be water flushed
properly, shall be air blow completely with strong flow of air to clean and dry the
lines. The instruments and control valves shall be isolated / removed from the
system before flushing. Equipment shall be disconnected to prevent entry of flushed
material. Safety valves and rupture discs are to be isolated or removed during the
flushing.
Strainer elements to be kept removed during the flushing operation.

c) Steam Flushing

Steam flushing shall be done mainly for steam lines. It is preferable that insulation
should be complete; otherwise when steam is opened lot of condensate formation
will take place. Hot un insulated pipes may cause injury to personnel. When cleaning
by steam is performed thermal expansion of pipe should be taken into consideration.
Following procedure should be followed.

 Remove orifice plates and control valves.

 Spool piece to be put in place of control valves, flow meters etc. In case the
above instruments have been provided with a bypass, isolate the instrument
and open bypass.

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 Disconnect equipment to avoid entry of flushed material.

 If necessary make temporary arrangement for steam blowing at open end of

the pipe.

 Systems should be flushed through the dirt leg drains. Open steam trap
bypass valves, and isolate steam traps.

 Slowly allow steam to heat the pipe and then flush thoroughly with a strong
flow of steam. Avoid steam hammering by draining condensate properly.
Repeat this operation after allowing the line to cool for effective flushing.

 Check pipe line supports and loops for expansion.

 After blowing is over, allow the pipe to cool, with vent open to prevent vacuum
pulling. Open drip leg flanges and remove accumulated muck. Then box up
the line. Install the control valves and orifice plates.

Safety measures for flushing activities

All necessary safety precautions given below are to be followed during flushing
activities:

 Proper drainage arrangement

 Flushing area cordoning off.

 For air blowing or steam blowing, blowing pipe surrounding 3-4 meter area
should be cordoned off.

 Covering electrical equipments like motors, switch board panel, etc.

 Covering instruments like transmitters, diaphragm gauges, control valves,

temperature gauges, flow meters, etc.

 Provide tags like ‘DO NOT OPEN’, ‘FLUSHING UNDER PROGRESS’, ‘DO
NOT REMOVE BLINDS’; ‘DO NOT OPERATE THE PUMP’ etc.

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 Cover critical equipment nozzles with tags

 PSV’s to be handled with care and inlet/outlet to be covered

 Wearing apron, safety goggles, face shield, etc.

 Proper communication arrangement to be made

Service and Calibrate Instruments

Normally, instrument lead lines will be tested hydrostatically up to block valves when
the balance of the unit is tested. Hydrostatic test pressure will not be made on
instruments which normally handle gas and no pressure-measuring element should
be subjected to test pressures above its range. Also, never pull a vacuum on a
pressure instrument or gauge unless it is specifically designed for it.

All instruments should be checked as soon as possible so that any malfunctions or

other faults can be detected early. The instrument checkout should include the
following items:

 Pressure test of instrument air lines

 Control valve action and calibration

 Positioner calibration

 Board calibration and loop check

 Thermocouple calibration and identification

 Level instrument calibration

 Thermometers, pressure gauges, etc.

All instrument air piping should be tested at 7 kg/cm2 g (100 psig) with compressed

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air. Soap should be used on all joints to check for leakage. Care should be taken to
ensure that this high air pressure is not put on any instruments or control valve
diaphragms. Likewise, care should be taken that the fuel gas pressure balance
valves are blinded off to keep high pressure off the diaphragm while pressure testing
the unit. Before starting up, all instruments should be serviced and calibrated. This
includes carefully measuring all orifice plate bores with a micrometer. The following
guidelines may be adopted for checking and calibration of all instruments.

1. Orifice Plates

Before each orifice plate is installed the orifice taps should be blown clear. The
orifice plate should be callipered to check, if the correct size orifice plate is installed.
All orifice plate bores should be measured, recorded and compared with required
sizes. The orifice plates should also be checked to see if they were counter-bored
wherever required. After hydro testing and water flushing have been completed, the
orifice plates should then be installed after checking for the correct direction.

2. Differential pressure Transmitters and Receivers

Ordinarily these should be calibrated locally against a manometer. The calibration

should be checked at the receiver (which may be board or locally mounted) recorder
or indicator.

3. Pressure Transmitters and Receivers

These should be checked in place. The calibration of the receiver should be checked
at the same time.

4. Alarms

All alarms, auto start and cut off systems should be checked by simulating the
conditions.

Purge and gas blanketing

Before feeding any hydrocarbon to the plant all piping and vessels are to be purged

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out free of air. If air is allowed to remain it will form an explosive mixture with the
hydrocarbon. It can become potential hazard for explosion. Hence it is imperative
any air to remove any air in the system. To remove air (oxygen) from the system, a
normal criterion is to bring down oxygen content to less than 0.5%.
This can be achieved as follows:

a) Nitrogen purging followed by hydrocarbon feed.

The second method, where N2 or inert gas is available, is fairly simple and straight
forward. The system is flow purged continuously from one end to the other with
unidirectional flow than can sweep off all the air in the system. Normal requirement
of N2 for flow purge is of the order of 3 to 5 times the system volume. If the system is
designed for higher pressure it can also be pressure purged by pressurizing it with
N2 and releasing through a top vent that will establish a unidirectional flow.

If the system can operate under vacuum, it is advisable to pull vacuum and refill with
N2. In this way N2 consumption can be reduced to a maximum of 3 times the system
volume. HC is taken while the system is still under slight positive N2 pressure.

5.3 LEAK TEST:

A hydrostatic pressure test must be carried out in order to assure that the unit will be
able to withstand the normal operating pressures and temperatures. One exception
to this rule is the reactor, which can be excluded since it has already been shop
tested. Special metallurgical considerations must be taken into account whenever
such a vessel is pressured at low temperatures.

It is normally the mechanical contractor’s responsibility to hydrostatically pressures

test the unit during construction.

Before any vessel is filled with water, the foundation design must be checked to see
if it is rated for this load. Screens should be placed in the lines before the unit is
pressure tested so that the test water can be pumped through the lines for the
purpose of washing them.

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Screens should be placed in a flange between the suction valve and the pump so
that the screen may be removed without de-pressuring any vessels. The flow
through the screen should preferably be downward or horizontal. Precautions should
be taken to place the screen in a location where the dirt particles will not drop into an
inaccessible place in the line when the flow through the pump stops. If this happens,
it would not be possible to remove the dirt upon removal of the screen.

An air pressure test can be carried out on the sections of the unit prior to water test
so that any open lines or flanges may be discovered and taken care of before liquid
is admitted. It should be remembered that in pressure testing vessels, the test gauge
should be placed at the bottom of the vessel so that the liquid head will be taken into
account. Before draining any liquid from a vessel, a vent must be opened on top of
the vessel to prevent a vacuum from pulling in the vessel sides. In pressure testing
equipment, particularly in cold weather, care should be taken that the testing of the
vessels is not carried out at temperature levels so low that the metal becomes brittle.
As metal temperatures decrease, the tendency for brittleness increases.
Temperatures above 17°C (60°F) are considered satisfactory for testing to eliminate
the possibility of cold fracturing of equipment. Such temperatures can be attained by
warming the testing medium.

If the unit contains any austenitic stainless steel, the chloride content of the test
water must be less than 50 ppmw. If this is not possible, a maximum of 0.5 wt%
sodium nitrate should be added to the test water.

It will not be practical to test all of the equipment together. Thus, the unit can be
divided into sections based on the location of the various items of equipment and the
test pressures to which each item will be subjected to. Suitable blanks must be made
up for insertion on nozzles and between flanges to isolate the various sections of
equipment as required.

Normally, the exchangers, receivers, etc., for the various towers will be tested
together with the main vessels. Test pressures will be determined from the pressure
vessel summary for the unit. In any given section, the pressure test applied should
be equal to the allowable test pressure of the lowest rate equipment in the circuit.

During pressure testing, all safety valves must be blinded off, since their normal
relieving pressure will be exceeded. Care should be taken to remove all orifice plates
from the lines prior to hydro testing.

A temporary connection may have to be installed to assure that both sides of the

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exchanger are pressured to the same level if the reactor is not included in the test.
Before the pressure test is concluded, the effluent exchangers must be tested at the
design differential pressure to assure that no cross leakage exists.

The test pressure must be held until it is assured that the unit is tight and all leaks
have been eliminated. In addition to process lines, utility lines (steam, air, etc.)
should also be tested.

At the completion of the hydrostatic test, all water should be removed from the
equipment. Where necessary, flanges can be broken to drain low points and the
equipment air blown to remove as much water as possible before flanging up.

After hydrostatic pressure testing, a tightness test must be conducted to check all
flanges and fittings, especially the ones opened during hydro testing. This final
tightness test must be witnessed by EIL representatives and is normally done just
prior to start-up.

5.4 UTILITY COMMISSIONING:

The various utility lines should be tested and placed into service as soon as the
construction schedule allows. Pressure tests should be carried out on all steam
condensate, air, fuel gas, flare, and nitrogen lines as is done for all process lines.
These utility systems commissioning are detailed out below.

I. Steam Network

The steam network shall be blown through completely from battery limit with a strong
steam flow in order to clean the lines. The following steps are recommended:

1. Check network, all equipment will be disconnected to avoid entry of flushed

material

2. Drain all the low points. If necessary open steam trap inlet flanges.

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3. Open slowly battery limit valve and let the temperature rise in the header, slowly
and steadily.

4. Check support of fixed points and expansion loops.

5. When line is hot, blow it through completely with a strong steam flow.

6. Close battery limit valve and prepare another network. When the blowing is
satisfactory, reconnect all equipment and remount steam traps. Recharge header as
above.

7. To gauge the effectiveness of the steam blowing (and the amount of scale left in
the lines), target plates should be installed at the blow down points. The lines should
be repeatedly blown down until virtually unmarked target plates are obtained.
Condensate lines should be continually checked and traps removed and cleaned if
plugged.

Note: The following precautions to be taken while blowing / commissioning steam

header:

 To drain the low points of the lines before and during heating period in order
to avoid water accumulation, this causes hammering.

 To open drain / vent during cooling period to prevent vacuum formation

 To isolate the instruments, remove orifice plates and control valves; to re-
install the orifice plates and control valves after blowing is over.
II) Cooling Water and Service Water

The cooling water network shall be cleaned from battery limit with a strong water
flow. All equipment will be disconnected at the inlet and reconnected when lines are
cleaned. Control valves and orifice plates will be removed and re-installed, after the
lines become clean. When system has been flushed, charge the lines to the
operating pressure. The following precautions to be taken:

 To open vents at high points in order to expel air from equipment and piping.

 To open the battery limit valve, slowly and steadily.

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IV) Instrument and Plant Air

The instrument and plant air network shall be blown through completely from battery
limit with strong flow of air in order to clean and dry the lines. All joints and
connections shall be checked for tightness with soap solution. Header and branch
lines will be blown through with a high flow rate of air. During all tests, the
instruments and control valve shall be carefully isolated from the system.

V) Fuel Gas Networks

The fuel gas networks shall be blown through from battery limit with a strong air flow
in order to clean the lines. During the operations, orifice plates and control valves
shall be removed. Special care shall be taken to prevent water from entering the
furnace. The fuel oil and fuel gas headers will be commissioned before firing the
Heaters.
Commissioning of Flare Headers (LP Flare)

 Ensure that the LP Flare headers are under 0.5 kg nitrogen pressure and
oxygen is < 0.3%.
 Ensure that line up for all flare connections is done as per P & ID.

 Ensure that all LPD end blinds are provided & valves are closed.

 Slowly commission the flare header by opening the butterfly valve at the B/L.
While opening use online BA set first time. Ensure that it is “Locked Open.”

 Ensure that the N2 is available for purging the header.

 Ensure the continuous nitrogen gas purges at header extremities have been
brought into operation.

 Obtain clearance from the Utility for charging the LPF header with N 2 purge.

 Open the N2 supply isolation valve through PCV and establish N2 supply
purge to the header, if required. Keep N2 supply through ISBL.

 Check once again with the checklist about all branches isolation valve

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condition as locked open. Now the flare header is ready to receive the
process relief.

 Check out connecting lines for any leakage as per P&IDs.

Commissioning of Fire Water System

 Ensure that all the pre-commissioning points are liquidated.

 Ensure that all valves are lined up as per Fire Water P&ID and OSBL
connecting header I/Vs are open.

 Slowly line up Fire water to the header, watching the pressure.

 Charge the header and open one by one Fire Hydrant valve and fixed
Monitors and allow water to flush out for about ½ hr. Mark up P&ID for each
hydrant flushing.

Commissioning of Oily Water Sewer (OWS)

 Ensure all blinding positions of all connecting pipelines and manholes are
provided as per P&IDs. Ensure that OWS OSBL system is completed and
sign off dossier is available.

 Ensure pressure test and hold up test is completed for the U/G lines. Mark up
to be done on U/G P&ID. Ensure that system is flushed as per P&ID.

 Put water in each OWS Funnel and check that water is coming out in OWS
Manhole. For each Funnel the above activity is to be carried out.

 Ensure that ETP Unit is ready to receive Oily Water into their unit.

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Final Inspection of Vessels

All vessels should be inspected before final closing and any loose scale, dirt, etc.,
should be removed. Any line coming directly off of the bottom of a dirty vessel should
be removed.

5.5 TEST RUN OF ROTATING MACHINERY:

All the rotating equipment no load trial to be conducted in presence of both mechanical and
electrical persons. Also checked equipment rotating direction.

5.6 Electrical

Verify that all circuit breakers are properly labeled and that they control the proper equipment. Test
each breaker to ensure that it is functioning. Verify that all lock out procedures are being followed
and that any maintenance and construction tags have been cleared prior to energizing any circuit.

Verify that the backup and/or UPS is functional. Check that all control circuits have power of the
correct voltage. Verify that the ground fault system is functioning properly.

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Chapter-6
COMMISSIONING & START-UP
PROCEDURES

6.1 PRECOMMOSSIONING OF FLARE UNIT:

It is recommended that the following pre-commissioning instructions be carried out

before any attempt is made to put the flare into service. The complete flare system
should be checked to ensure that it is gas tight and that drain valves are installed at
all low points. The flare pilots incorporate small diameter orifices, which are located
at the pilot venturies. It is essential therefore that these systems are thoroughly
cleaned to avoid the possible blockage of the orifices by pipe scale and debris, which
would otherwise render the system inoperative. The following procedure should be
implemented:

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a) Open the drain valves at all low points in the system to remove any accumulated
water condensate. All lines should be self drainage back to the drain valves.

b) Blind off the flare header at the inlet to the KO Drum.

c) Check that the pilot venturi, air adjusters are set 4 mm open and locked in this
position. This may be suitably adjusted to a maximum of 6 mm based on the actual
requirement.

d) Set the temperature alarm unit in P.M.Box for pilot on/off indication at around
150 0C to 250 0c.

e) Set the timer for ignition spark at around 3 to 4 seconds only.

f) Check the proper functioning of the Ignition Transformer and Spark Plug before
going to final operation. Press the Ignition push button and observe spark formation
through the viewing port. If the spark is not produced adjust the spark gap as
follows: Release the lock nut, securing the electrode adjustment bolt. Screw-in the
adjusting screw until the two spark electrodes touch, then unscrew the adjusting
bolt 1.5 – 2.0 mm and tighten the lock nut. With pilot / ignition gas isolation, switch
on the power to the panel and operate the ignition push button. A strong spark
should be produced.

g) Initiate a supply of ignition and pilot gas and set pressure to 0.2 Kg/cm 2g & 1.4
Kg/cm2g respectively. Similarly set air pressure to 1.4 Kg/cm 2 g. Allow sufficient time
for the gas to pass through the venturies to inspirate air for ignition and to fill the
ignition and pilot tubes.

h) Press ignition push button for 1 or 2 seconds and release immediately, a flame
front should be produced which will travel through the ignition / flame front piping
system and ignite the pilot. A loud pop should be heard as the flame front leaves the
igniter tube at the pilot. The forward flame front will ignite the fuel gas at the pilot
nozzle.
i) Under certain conditions the gas / air mixture will explode with a loud bang when
the igniter is operated. If this happens it can be reduced by slightly reducing the air
pressure.

j) If the igniter fails to create flame front, then the air pressure should be slightly
reduced and another attempt should be made. This should be repeated until the
ignition is successful.

k) When ignition of the pilot is successful, turn off the igniter / flame front gas
supply to the igniter.

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l) The pilot flame on the forced draught pilot should be stable and about 0.6 meters
in length.

m) Having satisfactorily proved the ignition system, isolate the ignition gas and pilot
gas at the inlet block bleeds to extinguish all points.

Note:
If there is any tendency of burning back in the pilot ventury throat, close the pilot
venturi air adjuster in stages until this condition is eliminated.

6.2 FFG PANEL CONTROL LOGIC DESCRIPTION:

Ignition Principle:

The Auto/Manual flare ignition panel (Pilot Monitoring Box) is used to ignite the pilot
burners. A combustible mixture of gas and air flows from the FFG Panel and fills the
FFG line up to the pilot burners. A flame front generated by a spark from the ignition
transformer travels up to the ignition/flame front generation line & emerges at the
pilot burner nozzle, thus igniting the pilot gas at the top of pilot burner. Pilot burners
flame status is constantly monitored with the use of thermocouples fitted in the pilot
tips. The pilot monitoring panel (local panel) will have indication of pilot flames `On’
or `Off’ for remote/control room indication. Pilot burners of flare system can light up
in auto or manual mode.

A) Auto Mode

Following are sequence of operations under auto mode:

When the ignition panel selector switch (SS2) is switched to auto mode & auto
sequence start push button PB2 pressed from local panel ignition, air solenoid valve
and ignition gas solenoid valve will be energized to open.

a) If Pilot `1’ is unlit, flame front line of pilot –1 will filled up as all the solenoid
valves of 3-way flame diverter valves POV-001, POV-002, POV-003, POV-004, POV-
005 & POV-006 with de-energized condition allow combustible mixture of air & gas
to pilot –1 FFG Line.

b) 0-60 second flame front line fill up time delay (Ignition on delay timer) is
operated.

c) On expiry of the time delay the ignition transformer is operated for 2 to 3

seconds (adjustable). Spark time will be controlled by ignition timer (0-60 Sec).

d) A 0-90 Sec flame propagation timer is actuated to give time for the pilot to

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light-up & signal to control room/local panel.

e) Now, if pilot burner-2 is unlit, the solenoid valve of corresponding flame diverter
valve (POV-003) will be energized & operation (b) to (d) will be repeated. Please
refer Pilot burner selection table given in Wiring Diagram for solenoid valve
energized & de-energized condition, reproduced below for ready reference:

Pilot Burner Selection Chart

Pilot
Condition of SOV to Flame Diverter Valve
Burner
POV-001 POV-002 POV-003 POV-004 POV-005 POV-006
Pilot-1 OFF OFF OFF OFF OFF OFF
Pilot-2 OFF OFF ON OFF OFF OFF
Pilot-3 OFF ON OFF OFF OFF OFF
Pilot-4 OFF ON OFF ON OFF OFF
Pilot-5 ON OFF OFF OFF OFF OFF
Pilot-6 ON OFF OFF OFF ON OFF
Pilot-7 ON OFF OFF OFF ON ON

f) Similar sequence will be repeated for remaining pilots (pilot-3 to pilot 7).

g) If, all the pilot burners are lighted up, the sequence will not be repeated.

h) If any of the pilots are not lighted up during one attempt as mentioned above,
the sequence for lighting up that particular pilots or pilot shall be repeated
automatically. If even after three such attempts, any pilot burner is not lighted up,
then the system will lock-out and lock-out indicating lamp will glow on the local
panel. System can be reset with the use of count reset push button mounted at local
panel (field mounted).

i) After light up of all pilot burners, if any pilot is extinguished during operation & if
Auto/Manual switch (SS2) is in auto mode, pilot light up sequence will be repeated
automatically for extinguished pilot burner.

B) Manual Mode

a) When the ignition panel selector switch (SS2) is switched to manual mode [select
the pilot to attempt ignition], Ignition gas & Instrument air solenoid valves SOV-001
& SOV-002 will be energized to open.

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b) Select the pilot burner to be lit up by turning the selector switch (SS2) as per
table shown in wiring diagram to pilot-1, pilot-2, pilot-3, pilot-4, pilot- 5, pilot-6 or
pilot-7.

c) Allow a one or two-minute flame front lines fill up time.

d) Press the ignition push button (PBI) mounted at local panel and initiates a spark
through ignition transformer. Duration of spark will be controlled by timer T1 (0-60)
adjustable in the local control panel.

e) The flame thus created will travel up to the ignition/flame frontline and will
emerge at the pilot nozzle thus lighting the pilot, which is selected.

f) The pilot ON/OFF status is indicated in pilot monitoring box. Steps (c) to (e) are to
be repeated till that particular pilot is light up.

g) The above sequence is to be repeated for other pilot burners.

Note: Switching the selector switch to either ‘Auto’ or ‘Manual’ will not extinguished
the pilots once lighted up. The pilots can only be extinguished by shutting the
manual isolating valve on the pilot gas line.

6.3 COMMISSIONING:

True relief system cannot be considered commissioned until a relief situation is

initiated by the upstream, process system, which is designed to protect the flare.
The entire relief system must therefore be purged of to eliminate air before the
process plant approaches an operating condition where a relief situation may occur.

The purging sequence should be achieved as follows:

a) Check the pre-commissioning procedures have been carried out.

b) Ensure that the stack area is cleared of personnel and that the necessary
authority has been obtained to commission the flare.

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c) Remove the blind from the flare header at the inlet to the KO Drum.

d) Introduce suitable oxygen free purge at a point in the relief system farthest from
the flare stack to ensure that all air is swept away from the system.

e) The system should be thoroughly purged for extended period to ensure that the
system is free of oxygen. When this point is reached, introduce the permanent purge
gas supply.
Having satisfactorily completed the purging sequences following activity should be
carried out.

1. It is extremely important that the steam system is thoroughly cleared prior to its
connection with flare tip.

2. Clean the steam piping by repeated blowing with live steam.

3. Blow down of steam line is also required to allow clean dry saturated steam.

4. Draining of all condensate from the line is to be done. Before starting flare,
ensure that all pilots are lighted up. Procedure for lighting up the pilot is explained
under section 7.0 (Pre-Commissioning)

Note:
Before leaving, ensure that all personnel are aware that the unit is alive and take all
necessary precautions to prevent personnel climbing the stack.

6.4 FLARING PHILOSOPHY

6.4.1 All hydrocarbon bearing discharges of varying molecular weights from pressure relief/

pressure control devices shall be discharged to closed flare system.

6.4.2 The individual unit flare header sizing shall be done considering the controlling flare

load from all the significant flare load cases.

6.4.3 A maximum allowable back pressure of 1.4 Kg/cm 2g at unit battery limit shall be
considered for sizing the LP hydrocarbon flare header. However, a maximum allowable
built-up back pressure of 1.7 Kg/cm2g shall be considered at PSV outlet.

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A maximum allowable back pressure of 5.3 Kg/cm 2g at unit battery limit shall be
considered for sizing the HP hydrocarbon flare header. However, a maximum allowable
built-up back pressure of 5.5 Kg/cm2g shall be considered at PSV outlet.

VI.4.4 Flare header shall be purged by all units maintaining a minimum Purge velocity of 0.1 fps
in respective unit headers with fuel gas. For sour flare system, flare header shall be
purged with fuel gas / Nitrogen.

VI.4.5 For Sour gas flare a maximum allowable back pressure of 0.5 Kg/cm2 G shall be
considered at the Sulphur block battery limit, a maximum allowable built-up backpressure
of 0.7 Kg/cm2g shall be considered at PSV outlet.

VI.4.6 SMOKELESS CAPACITY: Normal flare load in a refinery is negligible and there is no
extended start up requirement for any process unit. The HC flare may be designed for a
smokeless capacity of 2% TPH of peak flare load

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Chapter-7
NORMAL SHUTDOWN PROCEDURES

7.0 SHUT DOWN PROCEDURES

7.1 PLANNED SHUT DOWN

For planned shut down following steps to be followed.

1. Isolate the elevated flare gas inlet and fit a spectacle blind between the inlet
flanges.

2. Shut off the purge gas supply

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3. Shut off ignition gas supply

4. Isolate power supply

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Chapter-8
EMERGENCY SHUTDOWN
PROCEDURES

8.1 EMERGENCY PROCEDURES

Emergency can result from equipment failure, interruption of utilities or due to feed
supply failure. Obviously any written procedure cannot cover all the details of
problem which might arise in an emergency as degree of emergency varies from
time to time. However, a general guideline is described here.

LOSS OF INSTRUMENT AIR

Loss of instrument air will cause the various control valves to go to their respective

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fail safe position. Although the plant can be kept running during short interruption of
instrument air by taking all control valves on bypass, it is not advisable to do so for
long periods as controlling of various parameter becomes difficult and unsafe.

LOSS OF MP STEAM

Loss of MP steam will cause smoke generation in flare stack and flare tip may
become red hot due absence of steam cooling. So due to losses of MP steam
emergency shutdown takes place.

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Chapter-9
NORMAL OPERATION OF THE UNIT

NORMAL OPERATING PROCEDURES

9.1 PRE STARTUP OPERATIONS:

1) All mechanical, instrumentation, interlock, function and leak checks of the

flare and its auxiliaries are complete, and the flare is ready for service.
2) Make service water, instrument & plant air, fuel gas, Purge gas, nitrogen are
open at flare battery limit.

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3) Check the instrument air supply to the valves, actuators, solenoid valves and
make sure all instruments have been checked and accurate.
4) Ensure all instruments, electrical power supplies are available and
functioning.
5) Ensure purge gas system is available.
6) Ensure nitrogen back-up system is available.
7) Safety Valves have been set and are in service.
8) Ensure fire and gas & ESD systems are fully operational.
9) Ensure all vents and purge points in the flare headers are closed.

STARTUP OPERATIONS:

Preparation for start up:

1) Ensure that all pre-start checks have been completed.

2) Purge the flare header by using nitrogen (provided at header end) sufficiently. Check for oxygen content
in the flare header, it should be less than 0.5%.
3) Once this level is attained, positive nitrogen purge pressure must be maintained at all times.
4) Fill the flare seal drum with service water.
5) Adjust service water flow and confirm continuous minimal water flow on the seal drum drain.
6) Check that the level LG-1706 on seal drum is normal.
7) Energize system with the “Power” switch SW1 located on the FFG control panel enclosure.
8) Ensure power ON lamp glows and pilot failure alarms is activated.
9) Open main pilot purge gas supply block valve.

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Note: Verify that the flare system has been properly purged prior to initiating the pilot operation. Failure to
properly purge the system may result in explosion.

START-UP

To operates system in manual mode:

1) Inform all concerned personnel that the flare stack is to be started.

2) Turn HS902 (FFG manual-off-auto selector switch) to manual position.
3) Turn HS903 (FFG selection pilot selector switch) to the pilot that is to be lit.
4) Open the pilot fuel gas valve. The pilot gas regulator should be set to give 15 psig (1barg) pressures at
the pilot tips.
5) Open the instrument air block valve. The air regulator should be set to give 1.4Kg/cm2 pressures at the
pilot tips.
6) Push and release the ignition button PB-1 on the FFG panel.
7) Ensure the corresponding pilot failure or low temperature alarm gone out.
8) Repeat the above steps for all other pilots to be lighted up.
9) Return the manual-off-auto selector switch to the OFF position and close the block valves supplying fuel
and air to the FFG Ignition chamber. Leave the pilot fuel gas line(s) open.
10) After ignition of all pilots has been verified, flare gas can be safely admitted to the flare stack to verify
that pilots are operational.

To operate the system in automatic mode:

1) Open the pilot fuel gas valve.

2) Open the instrument air block valve.
3) SW-2 (FFG manual-off-auto selector switch) to auto position.

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4) Ignition sequence will start automatically after switching to auto mode starting from pilot # 1 up to pilot #
7.
5) After ignition of all pilots has been verified, flare gas can be safely admitted to the flare stack to verify
that pilots are operational.

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Chapter-10
PROCESS INTERLOCKS & PSV
SCHEDULE

10.1 LIST OF INTERLOCKS

NOT APPLICABLE

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10.2 PSV SCHEDULE:

PSV List Of Flare Unit

Sr Instrument
No Tag No Description Line Description P & ID No
PSV- HC Flare KOD Blow Down Pumps
1 1701 Safety Valve discharge 5844-A2-001
PSV-
2 1702 Safety Valve Fuel Gas Knock Out Drum 5844-A2-001

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Chapter-11
HAZARDS, SAFETY &
COMMUNICATION

11.1 INTRODUCTION

This chapter covers Hazard & Safety guidelines to be followed by all plant personnel during startup
and normal plant operation. It also covers provisions that have already been incorporated in this
regard. In the following sections, various toxic / hazardous substances have been identified and

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specific instructions have been given for handling of such substances. Instructions have also been
summarized in different sections those need to be followed in case of release of any of the
hazardous / toxic substance to minimize the adverse effect on the health of the operating personnel.

11.2 HAZARDS OF PETROLEUM PRODUCTS

All petroleum products give out vapors in amount depending upon the type of product. On
expansion LPG forms a thick cloud of vapors. These vapors in a confined space will tend to make the
atmosphere leaner in oxygen content thus making it difficult to sustain normal breathing
(asphyxiation). The hydrocarbon vapors also produce some adverse physiological effects. Fire and
explosion hazards are associated with these vapors under favorable conditions. The hydrocarbon
vapors heavier than air collect at low points near ground level. These vapors have anesthetic effects.
If air with hydrocarbon concentration of 0.1% is inhaled for about 5 minutes, the person feels giddy.
If the concentration increases to 0.5% and person inhales such air for about four minutes, the person
exhibits symptoms similar to alcoholism. The maximum concentration of hydrocarbon (except H2S)
should not exceed 0.1% to avoid intoxication of personnel.

Special hazards pertaining to this plant are the risks of poisoning, fires and explosions due to the
materials handled. The fact that the plant is an open-air installation reduces the effects of these
risks, and any unnecessary housing of the equipment should be avoided.

11.2.1 Explosion – Fire

When the proportion of hydrocarbons in the hydrocarbon air mixture falls within the explosive
limits, an explosion or fire could occur in presence of ignition, such as spark or an open fire. A
hydrocarbon air mixture can move on the ground over a considerable distance and catch fire on
contact with a spark or an open fire. An explosion occurs when the air hydrocarbon mixture is
enclosed in a vessel and a fire takes place when the above conditions exist in the open. Explosion
produces a considerable volume of gas, which creates high pressure causing damage. Explosion

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could initiate another explosion or fire at a distance of ten to a hundred meters because of its
physical nature. Explosion is generally followed by a fire. In case of fire, it is normal to use water to
keep the surroundings cool until the leak causing the fire can be shut off. If the fire is extinguished
before the supply is stopped, there is a danger that an explosion hazard may be created.

Lower Explosive Limit Higher Explosive Limit

Product
(LEL, % Vol./Vol of air) (LEL, %Vol /Vol of air)

Hydrogen 4.1 74.2

Methane 5.3 14

Ethane 3.2 12.5

Ethylene 2.75 28.6

Propane 2.37 9.5

Propylene 2 11.1

Butane 1.6 8.5

Butylene 1.7 9

Pentane 1.45 7.5

Hexane 1.2 6.9

Gasoline 1.3 6

Naphtha 1.1 6

Carbon Monoxide 12.5 74.2

Hydrogen Sulphide 4.3 45.5

11.3 SOURCE OF HEAT AND OPEN FIRE

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Any fire source near the area having presence of Hydrocarbons constitutes a danger by its open
flame igniting the hydrocarbon vapors of evaporating and heating the hydrocarbons to the ignition
point. Example of each hazards are match sticks, cigarettes, blow-pipe, smithy shop various furnaces
etc.

11.3.1 AUTO IGNITION

For combustion, three conditions are necessary. They are; combustible material, sufficient quantity
of oxygen and a source of heat. In free air, there is no risk of ignition if the hydrocarbon vapor
temperature is less than the ignition temperature. However, if the temperature of hydrocarbon
vapor is equal to its ignition temperature, the vapor can catch fire on mixing with oxygen from the
atmosphere, even without the help of a flame or a spark. This is known as Auto-ignition
temperature. The auto ignition temperatures of some of important hydrocarbons are given below:

Product Auto Ignition Temperature ºC

Hydrogen 589

Methane 595

Ethane 516

Ethylene 450

Propane 466

Butane 430

Pentane 309

Hexane 247

Carbon Monoxide 605

Hydrogen Sulphide 270

Naphtha 293

High Speed diesel 256

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11.3.2 SPARKS

Ignition of Hydrocarbon vapors and air mixture can be produced by a spark, which may cause an
explosion or fire. The possible sources of sparks are:

• Rubbing of ferrous metals between themselves or with other hazardous material like concrete.

• Rubbing of iron shoe sole with ground or metallic parts.

• Falling of iron tools

• Stroke of a steel hammer on a hard body like metal or concrete.

• Sparks from lose electrical wheel.

• Match sticks, cigarettes, open flame.

11.3.3 LIGHTNING

Lightning can fall on metallic objects such as chimneys, tower, tanks and tall building. These can
damage the structures or lead to ignition of hydrocarbon air mixture, if present. The vent/safety
relief valve discharges at high points to the atmosphere are especially vulnerable to lightning.

11.3.4 STATIC ELECTRICAL CHARGES

Static electrical charges can be produced by rubbing different bodies between themselves and these
can accumulate and produce sparks strong enough to initiate a fire or an explosion. Such charges can
be produced by rubbing of petroleum products on the internal surfaces of pipes, tanks and various
equipment. The handling of dry substances as coke, sulfur, etc. in metal chute, binds or even though
relatively dry air can also result in the generation of static electricity. Static charges can also be

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produced by other operation such as a driving belt, cleaning with silk or nylon cloth and fine mesh
screens and filters, etc. A proper system of grounding is essential for such operation.

11.4 POTENTIAL HAZARDS

Although essential precautions / steps that need to be taken care of during various stages of plant
operations i.e. start-up, normal operation, shut-down, emergency as described in relevant chapters,
certain potential hazards must be safeguarded all the time during operation and maintenance of the

Unit. These hazards are listed below:

1. Toxic chemicals
2. High temperature media

11.4.1 TOXIC CHEMICALS

It is recommended that operating personnel must refer to the Material Safety Datasheets provided
in Chapter-20 before handling these chemicals.

11.4.2 HIGH TEMPERATURE MEDIA

Pipes and large equipment containing water, steam and gas/liquid at high temperature and pressure

are installed in the plant. Protection of personnel from burns, caused by blowing-out of these
materials, should be provided.

11.5 GENERAL SAFETY GUIDELINES

All employees and persons responsible for operation in the FG/LPG TREATERS UNIT process should
be experienced in petroleum refinery operating techniques and should be familiar with applicable
safety practices. All necessary precautions should be taken to avoid accidents. The following general
safety rules are applicable to FG/LPG TREATER unit operations. These must be known and strictly
observed by all personnel.

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1. Smoking should be permitted only at approved smoking locations.

2. If an employee’s clothing becomes contaminated with acids, caustics, alcohols, aromatic

hydrocarbons or any other chemical solution, he must remove clothes immediately and take shower.

3. If anybody’s skin is contaminated with oil or grease then, clean off the oil and grease from the skin
carefully. If allowed to stay, it serves as an agent for maintaining dust, dirt and harmful bacteria on
the skin. Wash the hands and skin with soap and water.

4. Defective tools should not be used.

5. When using chisels, cold cuts, sticking wrenches, hammers or punches, examine the striking
surfaces frequently for burrs and other foreign matter. Non sparking tools should be used.

6. Use proper tools for the work involved, i.e. do not use a file for a bar, a hand wrench for a
hammer etc.

7. Over-stressing tools or equipment has frequently caused serious injuries. Take precaution to
prevent injuries to yourself or others.

8. Safety belts or lifelines shall be used when working 2 meter’s or more above ground, where it is
not practical to make other provisions to prevent falling.

9. Falls are the second largest cause of accidental deaths. Do not take the following chances:

• Failure to look where you are going.

• Running or jumping in work place.

• Standing on boxes, chairs and make shifts instead of ladders or platforms.

• Neglecting to use handrails and running on stairs.

• Failing to face ladder when carrying objects on the same.

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10. Tools and materials should not be dropped from heights. They must be carried down.

11. Standing or walking under materials suspended by ropes, chains or cables should not be
permitted. Stay in the clear until material is well secured.

12. Use or storage of combustible materials at the site should be avoided.

13. In case of unconsciousness, artificial respiration should be applied only by first aiders or medical
staff.

14. The general safety practices should be followed which includes - Traffic safety, Firefighting, First
aid, Work permit procedures, Vessel entry procedures, Sampling procedures, etc.

11. Don’t tamper with electrical apparatus. This is the work of qualified electrician.

16. Don’t remove light bulbs to plug-in power equipment.

17. Use only approved electrical fittings; the cover of electrical fitting in hazardous areas should be
secured properly to avoid entry of explosive gases.

18. All electrical equipment must be properly grounded.

19. An electrical extension wire must not be used if it is in bad condition, laid through water or in
such manner as to allow motorized equipment to travel over it.

20. Employees should regard all electrical wires as live and dangerous.

21. Never close a switch or breaker that has been opened unless authorized to do so by your
supervisor.

22. All electrical breakers must be de-energized and locked before process equipment can be
worked upon.

23. All live fuse, lighting and power cabinets must be kept closed.

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24. If an electrical power unit motivates moving machinery and it is necessary to make repairs to it,
then refer to and follow the electrical lock out procedure laid down by the plant management.

11.6 EQUIPMENT FOR PROTECTION OF PERSONNEL

For protection of personnel, the following equipment should be available:

Part Of Body to be Equipment Protects Against

Protected

Fibre Helmet Fall of objects or hitting against object during

Head
handling

Plastic Face Shield Against liquid chemical splashing, striking of

Face dust particles

Asbestos Hood Against radiation of heat in furnace work

Goggles with Clear Oil and chemical splashes, dust and chip
Plastic Vision entries

flying objects

Spectacle Type During furnace work against high

Eye Goggles with Blue temperature
Lens flame

Acid and Alkali Proof Splashes of corrosive substances like acid,

Rubber Goggles alkali

and other chemical substance.

Ear Ear Plug High Noise level

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Ear Muffs High Noise level

Dust Respirator Against dust and powder particles, chemical

powder enters lungs through nose.

Canister gas make for Against Acid Fumes, vapor and gas.

low concentration

Air Respirator Other than oxygen atmosphere and also

where air

line cannot be connected

Nose
Self contained breathing apparatus
Oxygen Deficiency
Mask with Blower

Particulate Dust Respirator

contaminant Airline Respirator

Self contained breathing apparatus

Toxic gaseous
Mask with Blower
Contaminant
Canister gas mask

PVC Apron Against splashing of chemicals.

Lead Apron X-ray and Gamma ray equipment

Body
Asbestos apron Against heat radiation

Safety Belt Falling of persons from height

Hand Asbestos Gloves Handling of hot object.

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Acid and alkali proof Burns due to handling Acid & Alkalis

rubber gloves

Canvas Gloves Contact with oil grease and other dirt

PVC Gloves To handle corrosive liquid (cold)

Gum Boots To protect legs against acids and alkalis.

Leather shoes with To protect legs from falling objects.

iron
Legs
toes.- Safety shoes

Asbestos Safety Bots Heat radiation stepping on sharp and hot

objects.

11.7 SAFETY RULES FOR PARTICULAR OPERATIONS

The following safety instructions are for the operations carried out frequently in the FCCPC unit.
These must, in addition to the general safety rules, be understood and observed strictly by all
personnel.

11.7.1 SAMPLE AND PURGE CONNECTIONS

Sample and purge connections on liquefied products have two valves. Always open the upstream
valve fully and adjust the flow by the downstream valve. This is done so that upstream valve is
always operable in case of frosting. Draining of LPG or Gasoline vessels should not be done
unattended. Operator should be present as long as draining / venting is going on.

11.7.2 ISOLATION OF SAFETY VALVES

Many safety valves are provided with the isolation valves at upstream and downstream of the safety
valve. This is to facilitate the repair of safety valve. It is important to ensure that these isolation

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valves are kept in open condition. When a safety valve is to be taken out of line, bring the spare
safety valve in line or shut down the equipment if the spare safety valve is not provided.

11.7.3 HIGH POINT VENTS AND RELIEF VALVE DISCHARGES

The hydrocarbon discharges from the high point vents and relief valve discharges to atmosphere
pose hazard due to lightning. Such discharges are normally provided with steam purge connections.
It is essential to keep small purge of steam in these lines, especially in monsoons when there is
likelihood of lightning.

11.8 HAZARDS DURING STARTUP & SHUTDOWN AND PRECAUTION

Start up and shut down of units is the most critical period during which there is a possibility of
leakages / fires. So utmost precautions by all operating personnel should be taken for smooth & safe
start-up and shutdown. The precautions to be taken during various types of hazards are given below:

• During fuel gas backup in the unit, all the vents should be kept closed. Liquid draining should not
be left unattended. Any leak during startup leads to fire. Therefore before gas back up, withdraw all
the hot work permits.

• Fire water hose to be laid.

• Ensure that all the COC and AOC manhole are properly covered otherwise any gas pocket in the
channel may cause fire / explosion at some other end outside battery limit area.

• During hot oil circulation, exchanger flanges / cover flanges are likely to leak which causes fire. Hot
circulation should be done gradually and carefully as per procedure and hot bolting procedure
should be followed strictly.

 Columns / vessels level tapping specially in case of main fractionators are more prone to leakage
and fire. All such areas should be critically observed by production personnel. Steam lancers should
be readily available.

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 Compressor must be handed over to maintenance only after depressurizing, purging with N2, after
gas sampling and positive blinding.
 Debris left over in the exchangers shell cover, overhead vessel, Contains mostly pyrophoric iron
which may ignite as soon as it comes in contact with air. All such debris must be wet by water and
oxidized with KMnO4 and removed to safe place and must be carried in wet cloth. All the
maintenance crew should be made aware of such hazard.
 All the COC and AOC drains should be covered properly with sufficient water spray during hot job
in the unit.
11.9 PLANT MONITORING DEVICE

11.9.1 PROCESS CONTROL SYSTEM

The process control system is based on distributed control system (DCS concept). When process
control system is in operation and process variable exceed the specific limit. It will give a visual alarm
via the process control system. In general, the system is designed in such that a sufficient response
time is available for operator to take corrective action before automatic safeguarding system is
activated and / or consequently mechanical operating device start operating.

11.9.2 INSTRUMENT SAFEGUARDING SYSTEM

A comprehensive fail safe system has been designed and incorporated to provide maximum
protection for the installed equipment in FG TREATER and LPG TREATER unit. The instrument
safeguarding system is independent from the process control system having its own transmitters and
shut down valves which acts on the unit completely independent from the process control system
when a process control exceed the specific limit. The emergency shutdown system may be activated
manually by activating either the panel mounted or from the field mounted emergency buttons.

11.9.3 MECHANICAL PROTECTION DEVICE

Relief valves are installed in the unit to ensure safe operation and to provide adequate equipment
protection. The mechanical protection devices will activate only in case of failure of both process

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control and instrument safeguarding system. All equipment can be blocked in and is protected
against over pressure.

11.10 COMMUNICATION SYSTEM

In case of emergency situations like fire in the plant, in order to effectively alert the operating
personnel working elsewhere in the plant as well as Fire Station, communication system has been
provided which mainly includes fire alarm system and communication system (provision of
speakers).

To be detailed Later

11.11 ENVIRONMENTAL ASPECTS

All basic aspects for environmental protection as per applicable statutory / legal requirements have

been considered during the conceptualization, evaluation and execution of this project. For example,
provision of flare system, CBD system, stack flue gas monitoring, etc. reflect some of these essential
ingredients. In addition to above, some of the specific systems that have been provided to take care
of environmental protection are described below:

11.11.1GAS DETECTION SYSTEM

Leakage of HC gases may lead to potential hazard in the plant. Timely detection of such leakages and
blinding off them immediately is highly desirable since these gases cannot be confined and are likely
to disperse into other areas (depending upon wind direction and velocity) making more & more
personnel exposed to potential hazard.

Hence, in order to prevent large scale spread out of hazardous gases through leakages, HC gas
detectors have been installed in the plant. These gas detectors sense the leakage immediately, if
any, and alarm the operating personnel to take immediate counter measures. Location of these gas
detectors is based on critical process equipment as well as specific requirements of the refinery.

List of Smoke/Fire/Gas Detectors table to be prepared with its corresponding location

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Chapter-12
CATALYST SPECIFICATION AND
SPECIAL PROCEDURE

Not Applicable in Flare unit.

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Chapter-13
MAJOR EQUIPMENT AND THEIR
OPERATIONS

13.1 INTRODUCTION

This section covers the general procedure for operation and trouble shooting of commonly used
equipment like pumps, heat exchangers and furnace etc. For specific information and more detail

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refers vendor's manuals.

13.2 PUMP

Centrifugal Pumps
Start-up

1) Inspect and see if all the mechanical jobs are completed.

2) Establish cooling water flow where there is such provision. Also open steam for seal
quenching in pumps having such facilities.
3) Check oil level in the bearing housing, flushing may be necessary if oil is dirty or contains
some foreign material.
4) Rotate the shaft by hand to ensure that it is free and coupling is secure. Coupling guard
should be in position and secured properly.
5) Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from the
bleeder valve.
6) Energize the motor. Start the pump and check the direction of rotation. Rectify the direction of
rotation if it is not right.
7) Check the discharge pressure. Bleed if necessary to avoid vapour locking.
8) Open the discharge valve slowly. Keep watch on the current drawn by the motor, if ammeter
is provided. In other cases, check at motor control centre.

In some pumps a by-pass has been provided across the check valve and discharge valve to keep the
idle pump hot. In such pumps, the by-pass valve should be closed before starting the pump. It should
be ensured that casing of these pumps are heated up sufficiently prior to starting of the pump to guard
against damage of the equipment and associated piping due to thermal shock.

b) Shutdown

1) Close discharge valve fully.

2) Stop the pump

1. If pump is going to remain as standby and has provision for keeping the pump hot proceed as
follows:

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 Open the valve in the by-pass line across the discharge valve and check valve.
 The circulation rate should not be so high to cause reverse rotation of idle pump and also
overloading of the running pump.

2. If pump is to be prepared for maintenance, proceed as follows:

 Close suction and discharge valves.

 Close valve on check valve by-pass line, if provided.
 Close cooling water to bearing, if provided. Also shut off steam for seal quenching, if
provided.
 Slowly open pump bleeder and drain liquid from pump if the liquid is very hot allow sufficient
time before draining is started. Ensure that there is no pressure in the pump.
Also drain pump casing.
 Blind suction and discharge and check valve by-pass line and flare connection if any. Cut-off
electrical supply to pump motor prior to handing over for maintenance.

c) Trouble Shooting

1) Pump not developing pressure

 Bleed to expel vapour/air
 Check the lining up in the suction side.
 Check the suction strainer.
 Check the liquid level from where the pump is taking suction.
 Check pump’s coupling and rotation.
 Get the pump checked by a technician.

Unusual Noise
 Check the coupling guard if it is touching.
 Check for proper fixing of fan and fan cover.
 Check for pump cavitations.
 Get the pump checked by a technician.

Rise of Bearing Temperature

 Generally the bearing oil temperature of up to 80°C or 50°C above ambient, whichever is
lower, can be tolerated.
 Arrange lubrication if bearing is running dry or oil level is low.
 Adjust cooling water to the bearing housing, if there is such provision.

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 Stop the pump, if temperature is too high, call the pump technician.

Hot Gland
 Adjust cooling water if facility exists.
 Slightly loosen the gland nut, if possible.
 Stop the pump and hand over to maintenance.
 Arrange external cooling if pump has to be run for some time.

Unusual Vibration
 Check the foundation bolts.
 Check the fan cover for looseness.
 Stop the pump and hand over to maintenance.

Leaky Gland
 Check the pump discharge pressure.
 Tighten the gland nut slowly, if possible.
 Prepare the pump for gland packing or adjustment/replacement of mechanical seal as
the case may be.

Mechanical Seal Leak

 Stop and isolate the pump and hand over to maintenance.

Positive Displacement Pumps

a) Start-up
 Check if all mechanical jobs are completed.
 Flush and renew oil in pump gear box.
 Check whether suction strainer is installed.
 Check for proper lining up including the pressure safety valve in the discharge. Open suction
valve fully.
 Check that the motor shaft is reasonably free and coupling secured. Coupling guard should
be in position.
 Energies motor. Open discharge valve. Start the motor and check direction of rotation.
 Stop and rectify if direction of rotation is wrong.

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 Adjust the pump stroke and run the pump at different settings. Watch discharge pressure and
check the rate of pumping using the flow meter or by taking suction from the calibration pot.
 In case the pumps are provided with a pressure controller adjust it to obtain the required
discharge pressure.
 Care should be taken to avoid dry running of pump and back flow of liquid. Bleed if necessary
to expel vapour/air.
 Check for unusual noise, vibrations, rise of temperature of both motor and gears.

b) Shutdown
 Stop the pump.
 Close the suction and discharge valves.
 Drain the liquid if maintenance jobs are to be carried out on the pump.

c) Trouble Shooting

A. Insufficient Discharge Pressure

 Check the lining up in the suction side.

 Check the functioning of the safety valve and pressure control valve on discharge to suction.
 Check the strainer on the suction side.
 Check for insufficient liquid level in the tank.
 Check the pump’s coupling and rotation.
 Get the pump checked by pump technician.

B. High Discharge Pressure

 Check the line up on the discharge side.

 Check pressure control valve opening.

C. Leak Gland
 Check for normal pump discharge pressure.
 Tighten the gland nut slowly if possible.
 Hand over the pump for replacing gland packing.

D. Unusual Vibrations
 Check the foundation bolts.

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 Check motor fan cover for looseness.

 Stop the pump and hand over to maintenance.

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Chapter-14
MATERIAL SAFETY DATASHEETS

14.1 SAFETY DATA SHEET FOR HYDROGEN

Hydrogen is a colourless, tasteless, odorless and highly flammable gas and is the lightest element.
Since hydrogen is lighter than air, less danger exists of it collecting in pockets in low areas. However,
the potential danger from fire or explosion is high. Gaseous fuels such as hydrogen can mix with air or

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oxygen in all proportions. However, the proportions must be within certain limits before those mixtures
will burn. The limiting proportions are referred to as “flammable limits” or “explosive limits” and are
expressed as the percentage by volume of the fuel in the air-fuel mixture. Fuel-air mixtures outside of
the flammable range will not explode.

Hydrogen has a very wide range (4-75%) of “flammability or explosive limits” in air at atmospheric
pressure. In addition to, the flammability range becomes wider at higher pressure or if oxygen is
substituted for air. Thus, explosions can occur over a very wide range of hydrogen concentrations in
air. The safest approach to safeguard against possible fires or an explosion is to make sure that
hydrogen leaks do not develop.

The auto ignition temperature of a substance is the lowest temperature required to initiate or cause
self-sustained combustion in the absence of a spark or flame. The auto ignition temperature of
hydrogen in air is 580°C at atmospheric conditions. However, other factors such as the nature, size,
and shape of the igniting surface can affect this temperature.

Unlike most gases, which cool when expanded or bled off, hydrogen heats up when expanded and
great care must be exercised when bleeding down lines or compressors to the atmosphere. In its pure
state, hydrogen burns with a bluish white flame (almost invisible) that is extremely hot. Such a hot
flame can weaken any support beams or lines on which it may impinge. Any leaks should be put
under a steam blanket immediately to prevent the possibility of a fire. Be aware, however, that many
leaks can auto ignite and will be difficult to see. Replacing the source of the hydrogen with a nitrogen
or steam purge is the most effective way of combating a hydrogen fire.

Hydrogen, although a not a poisonous gas itself, is an asphyxiate (i.e. cuts off oxygen supply to the
body by displacing air in the lungs) and can cause unconsciousness and even death if the victim falls
and remains in a high hydrogen atmosphere. Because of the small size of hydrogen molecules, a
pressure check with air or nitrogen or a hydrostatic test will not always show all leaks that will occur
with hydrogen.

14.2 SAFETY DATA SHEET FOR HYDROGEN SULPHIDE:

A hazard and handling procedures of H2S is as follows:

I. Potential for Exposure

The existence of H2S concentration with the fluids normally handled in this unit constitutes an
additional hazard to operating personnel that demands special attention. The properties of H2S make
exposure to even very low concentrations extremely dangerous. However, many years of industry
experience in handling the problems associated with H2S have resulted in procedures which, if
properly implemented, permit a reasonable level of safety for unit personnel. The danger of exposure
of H2S cannot be lessened. The potential for exposure can only be minimized.

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The procedures and precautions contained within this section and elsewhere in this manual constitute
minimal requirements for dealing with H2S only. The implementation of additional safety measures
which can be found in various industry manuals is encouraged.

II. Properties of H2S (Hydrogen Sulphide)

The chemical formula H2S represents a compound which is made up of two hydrogen atoms and one
sulphur atom. H2S (Hydrogen Sulphide) is a colourless (transparent), gas heavier than air. Hydrogen
sulphide is a poisonous gas that can paralyse the breathing system and kill a person in minutes. In
small amounts it is dangerous to health. This risk is increased by heat or hot weather.

At low concentrations (small amounts) H2S has an offensive odour similar to rotten eggs. At slightly
higher concentrations (small amounts), H2S may have a sick-sweet odour. At high concentrations no
smell can be detected, because H2S rapidly deadens the sense of smell by paralysis of the Olfactory-
Nerve. Consequently the sense of smell cannot be depended upon to detect H2S.

III. Characteristics of H2S

Hydrogen sulphide has the following characteristics:

a) Deadly-extremely toxic gas.

b) Colourless.
c) Heavier than air tends to settle in low lying areas.
d) Readily dispersed by wind movement of air currents.
e) Burns with a blue flame, producing Sulphur Di-oxide (SO2), which is also a toxic gas.
f) Odour of rotten eggs. Only in low concentrations rapidly deadens the sense of smell. Do
not depend on the sense of smell to detect H2S
g) Highly corrosive to certain metals.
h) More deadly than Carbon Monoxide (CO), and almost as toxic as Hydrogen Cyanide
(HCN) gas.

IV. Property Table of H2S

I. Auto ignition Temperature 500°F(260°C)

II. Boiling Point @ 1 atm -76.6°F(-60.33°C)
III. Critical Density 0.349 g/ml
IV. Critical Pressure 1309 psig (89.05 atm) 92 kg/cm2, absolute
V. Critical Temperature 212.7°F (100.4°C)
VI. Density, gas @ 0°C 1 atm 1.5392 g/l

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VII. Density, Liquid @ b.p. 0.993 g/l

VIII. Flammable Limits in Air 4.3-4.5 % (by volume)
IX. Freezing Point @ 1 atm -121.9 °F (-85.49°C)
X. Latent Heat of Fusion @ m.p. 508 cal/mole (16.7 cal/g)
XI. Latent Heat of Vaporization @ b.p. 4.463 kcal/mole (131 cal/g)
XII. Molecular Weight 34.08
XIII. Solubility in Water @0°C 1 atm 0.672 g/100 ml water
XIV. Specific Heat, Gas @ 25°C 1 atm Cp = 0.240 cal/ (g) (°C) Cv = 0.181 cal/ (g) (°C)
XV. Specific Gravity Gas 1.1895 15°C, 1atm (Air = 1)
XVI. Specific Heat Ratio, Gas 1.32 @ 25°C, 1 atm, Cp/Cv
XVII. Thermal Conductivity @ 0°C 0.305 cal/(Sec)(Cm2) (°C/cm)
XVIII. Vapour Pressure @ 70°F 252 psig (17.7 kg/cm2g)
XIX. Specific Volume @ 70°F, 1 atm 11.23 cu ft/lb (701 ml/g)
XX. Viscosity of Gas @ 0°C 1 atm 0.01166 centipoise
XXI. Explosive limits: Lower 4% volume in air upper 44% volume in air

Effects of H2S on Personnel

Itemized concentrations of Hydrogen Sulphide, prepared by American National Standards Institute,

(ANSI Standard No. Z37.2-1972), are tabulated below:

Concentration of H2S in air Effect Of H2S on personnel

0.13 ppm Minimal perceptible odour

4.60 ppm Easily detectable, moderate odour

10 ppm Beginning eye irritation

27.0 ppm Strong, unpleasant odour, but not intolerable

100 ppm Coughing, eye irritation, loss of sense of smell after 2-15
minutes.

200-300 ppm Marked conjunctivitis (eye inflammation) and respiratory tact

irritation after one hour of exposure.

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500-700 ppm Loss of consciousness, possible death in 30 minutes to 1

hour.

700-1000 ppm Rapid unconsciousness, cessation (stopping or pausing) of

respiration and death.

1000-2000 ppm Unconsciousness at once, with early cessation of respiration

and death in few minutes. Death may occur even if individual
is removed to fresh air at once.

H2S handling procedure

General Procedures:

Industry practice mandates that the following precautions procedures should be followed by all
personnel:

a) When approaching the work area it is necessary to take the following precautions to insure safe
entry

 Observe “Condition” signs and observe for audio/visual alarms.

 Check for wind direction.
 Look for personnel and their activity.
 Enter work area slowly.
b) Maintain mental image of two (at least) escape routes preferably cross wind.
c) Continuous atmosphere monitoring or detecting equipment is required along with an adequate
audio/visual alarm warning system. Portable detectors and combustible gas meters give an additional
degree of safety.
d) Gas ignition hazard must be eliminated and “No Smoking” regulations strictly enforced.
e) Continued observation of wind indicators, windsocks and streamers is a must. During atmospheric
contamination by H2S, move upwind/cross wind from source, not downwind.
f) Select a partner and use the “Buddy System” for mutual safety.
g) Maintain and observe warning signs.
h) Post emergency numbers in a conspicuous place. Maintain reliable communication systems.
i) Locate emergency stations a minimum of 250 feet or as far from the H2S source as practical.
During an emergency all personnel will assemble at the briefing stations for instructions and for

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refilling air bottles.

j) Hazardous concentrations of H2S can be disposed of by discharging through flare stacks with
automatic ignitions.

Note: Burning H2S produces Sulphur Dioxide (SO2), a deadly toxic gas that is heavier than H2S.
Because of the heat it rises and disperses into the upper atmosphere.

Maintenance Procedure

There are two basic areas of maintenance operations which are inherently dangerous from the
standpoint of H2S exposure. These are venting / draining of piping and confined space entry.

I. Depressurization of piping, valves, fittings, strainers, etc. in H2S service represents a safety
hazard in the unit, since the vent and drain valves are not “hard-piped” to a closed vent or
drain header. Without exception, breathing air respirators are to be worn when opening
piping, removing valves or performing any operation which might permit vapours to enter the
immediate area. When valves are removed, install blind flanges.

II. Confined space entry is entrance into areas such as tanks, vessels, etc. This is one of the
most dangerous activities of the unit and should be avoided whenever possible. When it is
absolutely necessary that a confined entry be made, entry should be made only after the
following safety conditions have been met.
 Entry permit form has been filled out and signed.
 Space contains at least 19.5% of oxygen by volume.
 Sample does not contain combustible vapours above L.E.L.
 Space does not contain toxic gas contaminants above the limit of appropriate threshold
values for the substance.
 Even if the above mentioned conditions are met, personnel entering such enclosed
spaces shall be equipped with self contained breathing apparatus (SCBA) pressure demand
type.
 Rescue equipment must be in close vicinity of the confined space.
 All personnel entering the confined space must wear safety harness and reflective tape.
 An adequate number of personnel must be stationed outside for emergency assistance.
 Communications must be clearly established and a system of safety signs and signals
understood by all. Any battery operated or electrical communications system such as hand-
held walkie-talkie or throat type microphone, if used in a hazardous environment must be
intrinsically safe.

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 There are a number of other safety precautions and equipment to be considered when a
confined space entry must be made such as: Resuscitation equipment, litter, safety lanterns
or chemical lights, tripped for hoisting over hatches, instrument calibration, mechanical
ventilation, cascade systems, continuous monitoring, houseline units, and separate means of
access where possible, emergency team and plan and proper training

Remember the fact that any entry into a confined space is inherently dangerous.

Emergency Procedures

If all the above procedures have been adhered to strictly, a catastrophic release of H2SNshould never
occur. In the unlikely event such a release does occur the emergency procedures detailed in this
section should be followed

Egress

H2S is a dangerous, deadly gas. However serious injury or death can be avoided by simply
evacuating the contaminated area and moving to a safe area upwind. Therefore, the most important
things to remember are to Stay Calm and Get Away.

1. Precise emergency escape procedures will be defined by the operations management of the
complex. However the following general procedures should be followed:

2. Remain Calm-Do Not Panic

3. Hold your breath
4. Extinguish all fires
5. Alert the rest of the crew
6. Make a quick, cursory check of the area to see if the source of the gas is obvious.
7. Do not spend time looking for a leak
8. Observe windsock to determine wind direction. Move upwind or crosswind, not
downwind, until the “safe breathing area” is reached.
9. Active alarms if not already done.
10. Once assembled at the safe briefing area, the foreman will make a head count to determine if all
personnel have evacuated safely.

Rescue and First Aid

Although H2S is a dangerous, deadly gas, its effects are readily reversible provided the appropriate

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action is taken in a timely manner. In the event of, a fellow worker is down or overcome by H2S, the
necessity of an immediate and effective rescue effort is or utmost importance. A natural reaction is to
unthinkingly rush to the side of the downed victim, which could be a fatal action.

Instead, before proceeding into the hazardous area to rescue a downed victim, stop, think and:

1. Put on an appropriate safe breathing apparatus.

2. Move quickly, but carefully to the victim, side. Move the victim to a safe area; either upwind or
crosswind from the hazardous area. Do not evacuate in a downwind direction.
3. Begin mouth-to-mouth artificial respiration if the victim has stopped breathing. Check the victim’s
pulse periodically to ensure that the victim’s heart is still beating. If the victim’s heart stops beating,
administer CPR. Artificial respiration or CPR should be continued until:

 The victim begins to breathe and, if applicable, the heart begins to beat.
 He is pronounced dead by a doctor.
 Seek assistance at the first opportunity and make arrangements for transportation to a
medical facility to seek medical attention by a physician.

Abatement Procedure

Once the safety of all personnel has been determined, the next order or business is to determine the
source of H2S and stop it, if possible.

Control Room Personnel

 Control Room personnel Stay in the Control Room since it is equipped with a positive
ventilation system pulling suction from a higher elevation. Since H2S is heavier than air, the
Control Room should be safe.
 If leak can be located, activate the deluge system for that area.

Field Personnel

 Use breathing apparatus (Respirator).

 Establish communication with Control Room.
 Communicate with first personnel to sound alarm/notice of the H2S.
 To determine the general area of the source, slowly begin searching the source from the
upwind side.

14.3 SAFETY DATA SHEET FOR LPG

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This is a flammable gas.

Permissible Exposure Limits in Air : 1000 ppm

Short term exposure Limit : 1250 ppm
Immediately Dangerous to life or Health : 19,000 ppm

Routes Of Entry: Inhalation, skin, and eye contact.

Harmful Effects And Symptoms : Light headedness and drowsiness.

First Aid : If this chemical gets into the eyes, irrigate immediately. If a person breathes in
large amounts of this chemical, move the exposed person to fresh air at once, and
perform artificial respiration.

Respirator Selection
10,000 ppm : SA/SCBA
19,000 ppm : SAF/ SCBAFISA: PD, PP, and CF
Escape : SCBA

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Chapter-15
FIRE FIGHTING FACILITIES

15.1 INTRODUCTIONS- FIRE PROTECTION AND SAFETY MEASURES

This section on fire protection and safety includes the following points:
a) Fire protection

b) Process unit fire fighting procedure

Normally fires are divided in three principal groups, according to the modality they start and shall
be faced in a different way.

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Group “A Fires

Fires started from combustible materials of common type such as wood, paper fabric, rubber etc.
These fires can be extinguished with media such as sand, foam, powder, CO2, and steam.

Group “B Fires

Fires started from flammable liquid such as gasoline lubricants, painting etc

These fires shall be extinguished with media such as sand, foam, powder, CO2 and steam. In case
fire caused by leakage of gases or LPG, immediately isolate the interested area, intercept as
practicable the gas leakage and fight flame with dry powder or steam.

As soon as fire has been extinguished, particular care shall be taken in dispersing any gas leakage
with steam to avoid danger from new flammable gas accumulation. As a consequence of large
quantity of heat released by Group B fire, besides operating directly on flame, it is necessary to cool
the area affected by fire, to avoid mechanical failure of equipment and piping with consequent
extension of fire area.

Group “C fire

Fires started in electrical equipment such as motors, generators, transformers, cables, electric
panels etc. These files shall be extinguished with substances that have no electric conductivity such
as dry powder extinguishers that can be used also on electrical equipment connected to electric
power.

Only when electric refinery personnel has confirmed that all electrical users located in the zone
affected by fire have been disconnected, it is possible to use different extinguishing media such as
foam or steam.

15.2 FIRE PROTECTION

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The Plant personnel shall be informed about the safety measures contained in these paragraphs.
Though these notes represent a starting point for the development of the prevention policy for fires
and accidents, it is necessary to integrate them with the refinery safety regulation with the operating
experience of personnel.

As a general rule all the operators shall be aware of the safety procedures and the relevant regulation
of products sampling, procedures and of the locations and using modalities of fire fighting and personal
protection equipment.

The operating personnel should be fully conversant with Fire Fighting system provided in the unit. All
of them should have adequate fire fighting training and will serve as an auxiliary Fire Squad in the event
of a fire breakout. It will be the primary responsibility of unit personnel to fight the fire at the very
initial stage and, at the least, localize it.

Major Fire fighting facilities provided in the unit comprise the following:

15.2.1 Fire Water System

Water is most important fire fighting medium. Water is used for fire extinguishment, control,
equipment cooling & exposure protection of equipment/personnel from heat radiation.

An elaborate fire water distribution network is provided around unit. Fire Water
Hydrants/Monitors are provided around unit, which give coverage to most of equipment.

15.2.2 Foam System

For containing large Hydrocarbon fires, foam systems are useful. They have inherent blanketing ability,
heat resistance and security against burn back. low expansion foam is used for hydrocarbon oil fire.

Foam can be applied over burning oil pool with the help of foam tenders/foam delivery system.

15.2.3 Portable Fire Extinguishers

Fire should be killed at the incipient stage. Portable fire extinguishers are very useful in fighting small
fires. All extinguishers in the unit must be located in specified places only. The operating crew should

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be acquainted with exact location of the extinguishers. They also must know most suitable type,
which, when and how to use an extinguisher. For example, electrical fires should be put out with CO2
or dry power extinguishers; water and foam should not be used. The used extinguishers should be
checked and restored by fire station personnel.

15.2.4 Fire Signal

Break Glasses have been provided at strategic locations of unit to see fire alarm in fire station. if a fire
is sighted, glass of window should be smashed, causing fire alarm switch to actuate. This is an
emergency call & should be periodically tested for proper functioning.

15.2.5 Steam Smothering

LP Steam hose connections have been provided at every convenient point inside unit. Steam
lances of standard 15M length can be fitted with these hose stations. Where ever hydrocarbon
leakage is detected which is likely to catch fire, Steam blanketing may be done. Apart from diluting
combustible Hydrocarbons, steam prevents atmospheric oxygen from taking part in combustion & thus
helps in extinguishing fire. However, steam should never be applied on large pool of hydrocarbon fire.
Direct application of steam on burning oil may result in spillage of burning hydrocarbon & spread of
fire. Similarly use of fire water on hot oil surfaces may cause sputtering & spread of fire.

15.3 PROCESS UNIT FIRE FIGHTING PROCEDURES

15.3.1 General
Process unit fires are extinguished principally by fuel removal. This is accompanied by making
operational changes to reduce pressure, by introducing steam to the affected system and by
blowing down sections of the unit as required.

The area and intensity of a fire will indicate the proper method of extinguishment. Small fires can
be fought with dry chemical powder, CO2 or steam. Foam should be used only were it can blanket
the burning fuel. Water in form of spray or high-pressure fog is most effective on large area of
intense fires that threaten damage to supporting structures and adjacent equipment. The use of

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water, however, may cause flanges and joints to leak thereby adding to the fire. Adjusting the water
steam to spray or fog will lesser the danger.

15.3.2 Relief Valve Vent Fire

Make operational chances particularly as the following:

 Open the drain line from stack to be sure all the oil is drained.
 If there is evidence that a relief valve has opened and will not rest, proceed to take the
equipment out of service and depressurize it.
 If liquid hydrocarbon overflows the vent, apply high pressure water fog working upwards
from the lowest flames.
 Apply water spray to the entire structure developed in flame at points of advantage around
the bay of the structure to prevent damage to the structural members.

15.3.3 Exchanger Fires

In most cases exchanger fires are the result of abrupt changes in temperature, therefore:

 Make an effort to obtain the normal operating temperature at the equipment.

 Apply steam dry powder or carbon dioxide (preferably steam) to the point of leakage.
 If the fire cannot be extinguished by use of portable equipment, apply high-pressure water spray to
the immediate vicinity of the leak.
 Protect structures and lines on which fire is impinging by applying water spray from
monitor/hydrants.
 Apply foam on ground/trenches in which burning oil may accumulate covering the sewer drain to
prevent fire entering the sewers.
 Avoid working above sewer drains or near fire traps since there is a possibility of explosion.
 Maintain adequate drainage of the fire area.

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15.3.4 Electrical Machinery Fires:

 Operators should start the standby machine, if possible. If this not possible, operations should be
adjusted or discontinued units equipment is operable.

CAUTION: do not use water or foam.

 De-energies the circuit if possible.

 Apply CO2, dry power of Halon to extinguish the fire.

15.3.5 Pumps and Compressors Fire

 Operators should start immediately the standby machines. If this is not possible, the operation
should be adjusted to take the affected machine out of service and to isolate it.
 Drain or depressurize the equipment and the connecting lines, if the conditions allow it.
 Apply steam dry powder from portable extinguishers.
 If portable extinguishers are inadequate, blanket the fire area with water spray and direct jets of
high-pressure water fog into the source of leakage until the operators have succeeded in stopping
the flow of fuel.
 Apply from on the ground/trenches in which burning oil may accumulate covering the sewer drain to
prevent fire entering the sewers.
 Avoid working around sewer drains or near the fire traps.
 Maintain adequate drainage of fire area.

15.3.6 Trench or Pit Fires

 Operators should check immediately to locate and stop the source of leakage into the trench or pit.
 Apply steam, CO2 or dry powder to the fire If this not successful, apply foam covering the sewer
drain as possible.
 Apply high-pressure water flog or water spray to prevent damage to adjacent equipment.
 Avoid overflowing trenches or pits with water as this may cause spread of the fire.

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 Avoid working above sewer drains or near fire traps.

15.3.7 Furnace header or tube rupture fires

A header box fire is normally the result of a radical operating change. Injection of steam into the
header box will usually extinguish such a fire. If it is of significant size and cannot be extinguished
steam, this fire must be treated as a tube rupture fire.

Tube Rupture Fire

 Take the necessary action to remove the hydrocarbons by isolating and or depressurizing.
 Inject steam into firebox and header box.
 Inject steam into the furnace tubes.
 Protect the structural members outside of the firebox, threatened by flame, with water spray.
 Do not use foam. It is ineffective on this type of fire and it will result only in waste.

15.3.8 Sewer Fires

In most cases, a sewer fire may follow a sewer explosion. In such a case, the operator should see
that steam from steam hoses is directed at sewer outlets in all gaseous area.

If there is a sewer fire and no explosion has occurred, the operator should first be sure that no one
is standing or working on or near the sewer outlets.

 Apply dry power at each manhole or drain from which flame is exiting.
 Direct water streams into the involved trenches to maintain flow towards the fire area. If there is oil
on the water in the trenches, use foam.

15.3.9 Spill Fire -Above Ground Level

 Operators should immediately determine the source of leakage or spill and stop it, if possible.

 If it is a continuous leakage, which cannot be stopped, the particular piece of equipment involved
should be taken out of service, depressurized and steamed if necessary.

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 Blanket small fire area with steam or dry powder but avoid scattering burning material.

 Blanket large fire areas with water spray from monitors or fire hydrants to protect the supporting
structures.

 Maintain the water flow until operators control the flow of fuel.

 If quantities of oil are flushed to lower levels and continue to turn in pools apply foam to these
pools.

 Maintain adequate drainage of the area.

 Avoid working above sewer drains or near fire traps.

15.3.10 Spill Fires at Ground Level

Operators should determine the source of leakage or spill immediately and stop it if possible. If it is
a continuous leakage, which cannot be stopped, the particular piece of equipment involved should
be taken out of service depressurized and steamed if necessary.

 Blanket small fires with steam or dry powder but avoid scattering burning material.

 In case of a large spill fire, direct high-pressure water fog into the source of leakage. Protect
surrounding structures with water spray, maintaining the water flow until the operator’s control
the flow of fuel.

 Apply foam to extinguish fires in pools or trenches.

 Maintain an adequate drainage of the fire area.

CAUTION: Avoid working above sewer drains or near fire traps

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Chapter-16
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CONSEQUENCES DUE TO UPSETS IN

OUTGOING B/L STREAMS

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Chapter-17
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EQUIPMENT DATASHEETS

17.1 FLARE HEADER

There shall be three separate flare headers, one carrying the high pressure hydrocarbon
flare relief, second carrying low pressure hydrocarbon flare and the third handling Sour flare
relief from Sulphur block. The main hydrocarbon flare header shall cater to collect relief
from CDU/VDU, MS-block, DCU, HCU/DHT & HGU units. The sour flare header will cater to
relief from SRU, SWS-1, SWS-2 and ARU units.

The main HC flare LP header size estimated is 72”, HC flare HP flare header size estimated is
42” and the sour flare header size shall be 32” based on the design relief loads as mentioned
above.

The HP and LP flare header shall be joined at the inlet of HC flare knock-out drum located in
the flare area.

17.2 KNOCK-OUT DRUM

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Individual flare KOD is provided within each process unit battery limit. In addition, a
common HC flare knockout drum (KOD) shall be provided near the flare stack. The knock
drum is provided with ~30 minutes liquid hold up by considering 5 % liquid entrainment in
HC vapor & to account for condensation due to vapor cooling. Two electric motor driven
blow down pumps of 30 m3/hr capacity each (1 operating + 1 stand-by) are provided near the
knock-out drum to pump out the condensate to offsite heavy slop tank. These pumps shall be
given emergency power back-up and status lamp indication in central control room. The
pumps are provided with auto start/stop facility on high high and low low levels respectively.
Various signals and alarms for flare system shall be routed to central control room.

For sour flare relief there will be a main knock out drum in the HC flare stack area and
another common KOD shall be provided in Sulphur block ISBL common for SRU, SWS-1,
SWS-2 & ARU.

17.3 HYDROCARBON FLARE

The main flare header shall collect the emergency hydrocarbon relieves from all the
equipment (Except equipment discharging to the Sour gas flare header) and shall route it to
main HC flare system.

Short term H2S rich reliefs from process units (other than Sulphur block) shall also be joined
into hydrocarbon flare.

This Flare system shall have its own dedicated set of molecular seal and flame pilots.

A vertical water seal drum shall be provided at the bottom of the stack. The water seal drum is
an integral part of the HC flare stack. It shall not be possible to take water seal drum under
maintenance without shut down of entire complex. Thus to avoid any such situation all the
internals of water seal drum shall be of SS316L.

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The metallurgy of the HC flare tip shall be considered as Incoloy 825.

Flare stack components shall be designed for maximum flare load to minimum purge gas rate.
Flare stack shall be purged either with fuel gas or inert gas. It is to be ensured by vendor that
flame is always outside the tip for normal as well as turndown conditions. An ultrasonic flow
meter will be provided for flare gas flow measurement downstream of KOD.

17.4 OUR FLARE

 The main Sour flare header shall be post weld heat treated and hardness of 200 BHN
maintained. This header shall be steam traced. The line downstream sour flare KOD in
the flare area shall be SS-304L.

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Chapter-18
EQUIPMENT HANDOVER PROCEDURES

18.1 PUMPS

1. Close the discharge valve of the pump to be released for maintenance fully.

2. Stop the pump.

3. Close the suction valve fully.

4. Close valve on check valve by-pass line, if provided.

5. Close cooling water to bearing, casing and pedestal.

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6. Close the external flushing liquid to mechanical seals.

7. Slowly open pump bleeder and drain liquid from pump casing to COC/CBD depending on the
service. If the liquid is very hot allow sufficient time before draining is started. Ensure that there is no
pressure in the pump.

8. In case of heavier material like Slurry oil, Fuel oil, the pump should be flushed with wash oil before
handing over to maintenance.

9. Isolate the power to motor and enter the tag number in the logbook, which is to be mentioned in
the work permit.

18.2 COLUMNS, VESSELS

Before opening any equipment, it should be purged to ensure that the inside atmosphere is non-
explosive and breathable. For adhering to the objective the following operations have to be carried
out

1. Isolation with valves.

2. Draining and depressurization.

3. Blinds provision/spool removal as per the blind list.

4. Replacement of vapors of gas by steam, water or inert gas.

5. Isolate instrument tapping.

6. Wash the towers and vessels with water.

7. Open the top manhole and ventilate the equipment.

8. Test with explosive meter for any hydrocarbon.

9. Open other man ways and provide air eductors/exhaust fan.

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10. Check oxygen content inside the equipment before issuing Vessel entry permit.

18.3 L.T. & H.T. MOTORS

1. Switch over to spare pump on the same service and watch the performance.

2. Stop the pump for which the motor has to be handed over.

3. Electrically De-energize and enter isolation number in appropriate log book, which in turn has to
be mentioned in the work permit.

4. Depending upon the type of the job, terminals may be disconnected. For Ex. Motor replacement
or motor major overhaul, terminal flashing, Motor coil burning etc.

18.4 PROCEDURE FOR TAKING BACK EQUIPMENTS AFTER MAINTENANCE:

18.4.1. PUMPS

1. Inspect and confirm that all mechanical jobs are completed. Check for proper housekeeping
around the pump and also ensure closure of work permit

2. Establish cooling water flow where there is such provision. Open external flushing liquid to seal in
pumps having such facility.

3. Check oil level in the bearing housing, flushing may be necessary if oil is dirty or when it contains
some foreign material.

4. Rotate the shaft by hand to ensure that it is free and coupling is secured. Coupling guard should
be in position and secured properly.

5. Close the drain, keep vent minimum open and crack open suction valve to fill up the casing with
process fluid.

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6. Check for seal leak or gasket leaks, otherwise close the vent valve and open drain to drain out for
a short while. Close the drain.

7. Open the suction valve. Ensure that the casing is full of liquid. Bleed if necessary, from the bleeder
valve. Keep the discharge valve in closed condition.

8. Pressure test to be done by using suction head pressure and see any leaks in the pump. In case of
heavy material, flushing oil to be used for pressure test.

9. In case of hot fluids open NRV bypass and warm up the pump from discharge to suction.

10. It should be ensured that casing of the pumps are heated up/ cooled sufficiently if required, prior
to starting of the pump to guard against damage of the equipment and associated piping due to
thermal shock / vapour locking.

11. Energize the motor. Start the pump and check the direction of rotation if not right, stop the
pump.

12. Correct the direction of rotation of motor by informing to electrical department.

13. Gradually open the discharge of the pump and gradually close the discharge of the other running
pump.

14. Check the discharge pressure.

15. Watch the flow from the flow meter, if satisfied with the performance of the pump, close the
discharge of other pump and fully open the discharge of the pump that was put on service
simultaneously.

16. Keep watch on the current drawn by the motor, if ammeter is provided. In other cases check at
substation.

17. Stop the spare pump.

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18. Frequent checks are must for any pump i.e. bearing oil levels, cooling water flow and any
abnormalities.

19. Check gland / seal and if necessary adjust gland tightness / flow of the coolant to the seal.

18.4.2. TOWERS AND VESSELS

1. Check that all maintenance jobs are completed and also ensure permit is close.

2. Check all instrument jobs are completed and also permit is close.

3. All connected nozzles to be made clear by flushing with water.

4. Check the cleanliness of vessels and towers.

5. Ensure all Tray man ways are boxed up.

6. Check and get the tower man holes closed one by one.

7. Ensure all blinds are removed as per blind list.

8. Ensure that all flanges that were gas for opened are boxed up with new gaskets.

9. Arrange for steaming out the vessel for 4 hrs and check Oxygen. Conduct pressure test.

10. Before fuel gas backing into the vessels, close the vents and cap them. Pressure test to be done
preferably using steam/nitrogen/fuel c hecking flange leak.

11. Water to be drained before taking cold material.

12. Arrange for hot bolt tightening of all flanges.

13. Take the equipment on line.

18.4.3 L.T. / H.T MOTORS

1. Get proper clearance about the completion of job and also ensure closure of permit.

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2. Check around the motor for good housekeeping.

3. Inform maintenance to couple back and do alignment if situation warrants.

4. Check the terminal box whether it is properly sealed with waterproof/ explosion proof compound.

5. Energize the motor. Take kick trial for checking direction of rotation.

6. Take the motor to normal service and watch the performance.

7. Note the amperage with normal load.

Chapter-19

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BLIND LIST

19.1 Flare Unit Blind List:

LINE NO BLIND
B/L
SIZ
S.N POS VAL
DESCRIPTION PID NO TY E(I RAT
O ISBL OSBL ITIO VE
PE NC ING
N TYPE
H)
SP
EC
2"-AI-589- 3"-AI-563- INSTRUMENT AIR 5844-
1 TA 2 150 IN GATE
1701-A3A 1318-A3A TO FLARE UNIT A2-001
CL
E

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SP
12"-(H)-
10"-SM- EC
SM-589- MP STEAM TO 5844-
2 563-1810- TA 12 300 IN GATE
1701-B2A- FLARE UNIT A2-001
B2A-IH CL
IH
E
SP
EC
6"-FG-589- 8"-FG-563- FULE GAS TO FLARE 5844-
3 TA 6 150 IN GATE
1701-A1A 1911-A1A UNIT A2-001
CL
E
SP
EC
2"-AP-589- 3"-AP-563- PLANT AIR TO 5844- GATE
4 TA 2 150 IN
1701-A3A 1314-A3A FLARE UNIT A2-001
CL
E
SP
EC
3"-IG-589- 3"-IG-563- NITROGEN TO 5844-
5 TA 3 150 IN GATE
1701-A3A 1222-A3A FLARE UNIT A2-001
CL
E
SP
3"-WS- 3"-WS- EC
SERVICE WATER TO 5844-
6 589-1701- 563-1617- TA 3 150 IN GATE
FLARE UNIT A2-001
A3A A3A CL
E
SP
HC FLARE KOD B/D EC
4"-BD-589- 4"-P-561- 5844-
7 PUMP TO LIGHT TA 4 150 OUT GATE
1703-A1A 12112-A1A A2-001
SLOP TANKS CL
E
SP
1.5”-CL- EC
FUEL GAS KO 5844-
8 589-1701- NA TA 1.5 150 OUT GATE
DRUM TO OWS A2-001
A1A-IS CL
E
SP
FUEL GAS KOD EC
2”FL-589- 5844-
9 NA DRAI TO FLARE TA 2 150 OUT GATE
1706-A1A A2-001
HEADER CL
E
2”FL-589- FUEL GAS KOD 5844- SP
10 NA 1 150 OUT GATE
1706-A1A DRAI TO FLARE A2-001 EC

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TA
HEADER CL
E
SP
1.5”-IG- EC
HC FLARE KOD B/D 5844-
11 589-1702- NA TA 1.5 150 OUT GATE
PUMP N2 LINE A2-001
A3A CL
E
SP
1.5”-IG- EC
HC FLARE KOD B/D 5844-
12 589-1703- NA TA 1.5 150 OUT GATE
PUMP N2 LINE A2-001
A3A CL
E
SP
HC FLARE KOD B/D EC
5844-
13 ¾”-A1A NA PUMP VENT LINE TA 3/4 150 OUT GATE
A2-001
TO OWS CL
E
SP
HC FLARE KOD B/D EC
5844-
14 ¾”-A1A NA PUMP VENT LINE TA 3/4 150 OUT GATE
A2-001
TO OWS CL
E
SP
3”-OWS- HC FLARE KOD EC
5844-
15 589-1701- NA DRAIN LINE TO TA 3 150 OUT GATE
A2-001
A1A OWS CL
E
SP
2”-OWS- SOUR FLARE KOD EC
5844-
16 589-1901- NA DRAIN LINE TO TA 2 150 OUT GATE
A2-001
A19A OWS CL
E
SP
4”-WS- WATER SEAL DRUM EC
5844-
17 589-1702- NA DRAIN LINE TO TA 4 150 OUT GATE
A2-001
A11K OWS CL
E

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Chapter-20
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CHECK LIST

This section consists of the check list points for various equipments. This is a general list
compiled based on the earlier experience. Other points may also well be added in case of
special equipments supplied by vendor. Check list facilitates an expedient start up and
minimize the troubles encountered during start up phase. So it should be executed by
vigilant personnel.

20.1 CHECK LIST FOR COLUMNS, REACTORS AND VESSELS

S.
JOB DESCRIPTION
No.

1. Check whether the hydraulic test is taken before erection.

2. Check internals like trays, baffles etc. are not damaged.

Check that the platforms for safe operations and maintenance are provided.
3.
Platform should have toe-guard. Steps of the staircase should be proper and

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S.
JOB DESCRIPTION
No.

there is no chance of falling. All opening in the platform to have guard chain.

4. Check the safety valves and see that they are at proper settings.

5. Check for installation of all instruments.

Check the column/reactor/vessel against P & ID and data sheets, demister,

6.
vortex breaker, weep hole, distributors etc.

7. Check column trays.

Check that the quantity of catalyst and packing is exactly what is required for
8.
packed columns and reactors.

9. Check the catalyst is not damaged.

10. See that the expansion provision as per drawing.

11. See that sight glasses are properly fixed.

12. Check grounding of vessels/column.

13. Check completion of fire proofing as per drawing.

14. Check blinding of all spare nozzles with proper rated blinds.

15. Box up manholes after clearance.

16. Check supports (e.g. spring) for cold and hot setting at appropriate time.

17. Check the insulation as per the specification.

18. Check that all valves. Specially instrument drain valves and root valves are
approachable from working platform.

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S.
JOB DESCRIPTION
No.

19. Check all gauges are visible from the grade.

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20.2 CHECK LIST FOR PUMPS

S.
JOB DESCRIPTION
No.

Check installed pump and motor are suitable and meets the operating
1.
requirements. Check the test certificate if in doubt.

2. Check the earthing of motor.

3. Check the tightness of foundation bolts.

Check the no load current of the motor. Ensure the alignment of coupling is
4.
within tolerance. Check for an alignment record.

5. Ensure lubrication of bearing prior to turning of shaft (alignment).

6. Check the coupling bushes and lubrication for Greased/oil bath couplings.

Check suction & discharge piping and ensure no piping strain is transmitted to
pump nozzles. This will be done by either visually observation of unconnected
7.
pipes for small pumps or by checking alignment with and without piping
connection for bigger pumps.

Insert suitable strainer in suction piping. Ensure that there is no gap between
8.
strainer and pipe wall. Ensure that strainer cleaning would not be a problem.

Check all the accessories viz. pressure gauge, oil cup, safety valve, vent valve,

9. non-return valve, drain valve, foot valve etc. Ensure that drain and vents are
properly plugged as per drawing.

Ensure the pump surroundings are cleared up and easy approach to the
10.
valves, start/stop push buttons etc.

11. Ensure the availability of spares and consumables

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S.
JOB DESCRIPTION
No.

12. Ensure availability of lifting arrangements.

Check coupling guards and mark the direction of Rotation outside. (Coupling

13. guard to be of non-sparking type material whenever hydrocarbon is being

used (or any other inflammable material).

14. Road carefully the operating manual for any special instructions/precautions

Check whether the piping layout is not fouling from pump maintenance point
15.
of view.

Check completion of cooling system/lube system/seal flushing system/seal

16.
quench system as per date sheets specifications

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20.3 CHECK LIST FOR SAFETY VALVES AND RUPTURE DISCS

S. No. JOB DESCRIPTION

PRESSURE SAFETY VALVES (PSV)

Ensure the safety valve has a Test Certificate issued by Competent Authority
1.
provided by the vendor.

Check the right safety valve is mounted at the right place and tagged
2.
properly. Safety valve should have sealing arrangement after setting at shop.

Individual safety valve must be pressure tested and set pressure certified.

3. Pressure test has to be carried out either pneumatically (Using Nitrogen) or

hydraulically depending on the value of set pressure of the PSV.

While mounting in position, ensure plastic and caps fixed at the flanges are
4.
removed.

Ensure the safety valve mounted in position is completely isolated by

5. blinding while flushing the line or carrying out the pressure test of the
system.

Check the tag of the safety valve for the following details:

a) PSV No.
6.
b) Test Pressure/Set Pressure

c) Date of Testing

In case there safety valves are on steam, water or condensate lines releasing

7. to atmosphere 1/4" weep hole on the exit pipe to drain out stagnant water is
provided.

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S. No. JOB DESCRIPTION

8. Ensure 0test gags are removed from safety valve top.

Check main. Back pressure shown with pressure seen in discharge line. (if
PSV is conventional type).
9.

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20.4 CHECK LIST FOR PIPING

S. No. JOB DESCRIPTION

1. GENERAL

Provision of branch lines, vents and drains, supports anchors, guides, etc. as
2.
per P&IDs.

3. Steam traps/strainers/Valve/control valves/Blinds as per ISOs/P&IDs.

To obtain clearance from construction with regard to

- Mechanical completion with exception, if any

Blinds/caps/welded plates provided for testing are removed

4. - Supports including spring supports

- Testing

- Correct installation of gasket, bolts etc.

- Position of blinds (if any)

- Instrumentation

5. Ensure all instruments are provided.

6. Flange joints with gaskets and bolts.

7. Sliding support is free to slide (Visual).

8. Expansion joints/loops/spring supports are provided.

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S. No. JOB DESCRIPTION

9. Proper vents are provided for pipes rising upwards.

10. Proper drains are provided on downwards loops.

11. Proper slope is given towards drain points.

12. All bolts are of correct size and uniform length.

13. Access to vents/drains and isolation valves.

Support to safety valves and vent line and drain hole in the vent line, if open
14.
to atmosphere.

15. Vent line should be clear (No clogging).

16. Spectacle blinds for isolation are provided at right points.

Flush the lines with steam of proper pressure (never beyond design pressure
17.
of line), in case of steam lines.

During flushing, no slip blind to be inserted without tail and no blind gaskets
18.
are left off.

19. While filling/draining/the lines, vents are opened first.

While flushing the system control valves and orifice plates, instruments are
20.
to be removed. Control valves to be replaced by spool pieces.

Check the state of insulation, tracing etc. There should not be any gap
21.
between pipe and tracer.

22. Check all foundations of supports have been laid.

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S. No. JOB DESCRIPTION

23. Check respective hydro test is complete before flushing of lines is done.

FUEL OIL LINE

24. Check as per P&IDs.

25. Check for provision of steam tracing.

26. No larger gap between oil and tracing line for better heat transfer.

IN LINE FILTERS

27. Check proper filter is installed as per specifications.

28. Check whether it is at the required position as per P&ID.

29. Check filter for any checking and damage.

30. Check vents, drains and gaskets on filter chamber.

Check whether sufficient room is there for draining, removal of filter candle
31.
etc.

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20.5 CHECK LIST FOR VALVES

S. No. JOB DESCRIPTION

1. Check whether Globe & NRVs are mounted in proper direction

Check whether valves can be properly operated. Valve wheels should be in

2.
position properly locked.

3. Check whether gland are properly packed and bolted.

Check whether valves are properly accessible. Turning of the valve may be
4.
necessary in few cases.

Check whether proper arrow indication for valve operation is provided. If

5.
not provided this should be done by paint/or by punch and torque.

Check whether limit switches, are properly working for motor operated
6.
valves.

Check whether spindle extension is provided where valves are to be

7.
operated towards mounted place.

Ensure proper greasing of spindle, gear box etc.

8.

Valves having locking arrangement should be properly checked for this

9.
facility.

Valves in flare line should be normally mounted horizontally to avoid

10. inadvertent falling of gate. Vertical mounting with steam below is not
desirable as liquid is likely to drip the gland.

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S. No. JOB DESCRIPTION

Control valves are to be checked for proper mounting and direction. Control
valves with handle are to be installed in such a way that handles can be
11. operated as properly.

Check the greasing of the valve. Vent/breather on the top of the valve
12.
diaphragm should be checked

For most of the valves before installing protective plastic valve caps are to be
13.
removed. It is to be ensured.

14. Check location of mixing port of three way valves before installation.

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20.6 CHECK LIST FOR STEAM TRAPS

S. No. JOB DESCRIPTION

1. Check whether mounted in proper direction.

2. Check whether strainer is provided and the screen is in position and clean

Check whether trap outlet line connected properly to the right condensate

3. Return Header/Drain. Ensure atmospheric bleeds are available with proper

isolation in case of condensate recovery.

Check whether steam trap connection line is properly flushed by dropping

4.
traps.

5. Trap vent where provided should be checked for cleanliness.

Ensure that trap is mounted in such a way that its removal for maintenance
6.
is possible without effecting the process operation.

Where a bank of steam traps is located at one place, e.g. condensate station,

7. ensure that all valves are operable and approachable, staggering or lowering
of valves or rising of headers may be necessary to achieve this.

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Chapter-21
ATTACHMENTS

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