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VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 1 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


CHAPTER 13
SPECIAL PROCEDURES
13.1 DESLUDGING OF DESALTER:
The Desalter is located in 1st stage PHT-1 after a successive preheat exchangers
i.e.(42E01,42E02a/b,42E03,42E04a/b,42E05,42E06&42E07) utilizing relatively low
tempts. Fluids such as HN, VD, KERO, VGO, KEROCR, HDCR & KEROCR
respectively. The temp gain through this pht is 129-136 0C.service water/dm water /sour
water from atmos O/H &hot-well drum /stripped water from DHDS-SRU&MEROX is
used for desalting which will be stored in a vessel (42v11). The water will be preheated to
122 in 42E55 using LP steam before injecting to desalter through 42PM3A/B pumps.
In normal desalting process water will be mixed with Crude in the mixing valve 42-DPC1101U/S of the Desalter (provision is there for a part of wash water@10% can be injected
into Crude line u/s of 42e01). on mixing the undesirable salts present in the Crude get
dissolved in the wash water and hence separated from Crude. the electrostatic field
employed in the Desalter helps in breaking the oil-water emulsion and thus the two
liquids phases separate out. the hot brine from the Desalter is sent to sour water stripper
unit(Merox)for heat recovery and subsequent transfer to ETP(effluent treatment plant).
Whenever observed the sludge in the Desalter by checking try-cocks/42li1102D radar LT
the sludge is tube removed after informing Manager (production)/ETP/YSF.
The water injection to Desalter via Crude line and mix valve to be suspended by closing
42FC1102 from MOI as well as in the field block valve located at first floor and d/s of
42E07.and the wash water to be resumed through a3line t/o from 42E55 and which is
going to Desalter (at bottom shell) directly with a check valve and a block v/v located at
north of Desalter. the water rate should be controlled from field only as there is no control
from MOI except a flow indication of water(42fi1103).the wash water entry to Desalter is
at the bottom where the sludge and emulsion is presented being separated out of Desalter
through two types of outlets which are available. one is a normal4nos. of draw off lines
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VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 2 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


and joining to a 4line and SDV1101 routing to ETP via MEROX. the second alternative
out-let is through 3nos.of draw off lines and joining a 4line with a gate v/v and it can be
routed to CBD via 3line.the routing provision is there from CBD to OWS and as well as
to SLOPR/D by using 42PM26.the routing of the sludge and hot brine should be
depended upon prime approval of the concern normal ,including power personnel/units.
During this process all conditions of Desalter can be maintained normal, including power,
pressure & tempt. And continue this process until the sludge is removed from Desalter by
time-to-time check of try-cocks at regular intervals.
Once the sludge is removed and effluent water is clear closing the block valve from field
can stop the online desludging process and Desalters normal wash water injection can
resume by opening the 42FC1103 and block v/v at 1st floor. The routing of clear effluent
water should restore as normal as earlier. the entire desludging process will take one hour
duration only. The RADAR LT indication will change from 50%T0100% also during the
process.
13.2 Chemical injections
Caustic of strength 5 0Be is injected to the feed booster. The flow should not exceed 4ptb
since higher rates result in preheat exchanger fouling and caustic embrittlement in the
furnace tubes and connected lines the capacity of caustic injection pumps is 75lits/hr.
Another guideline to ensure caustic rate is not high is the chloride level in the overhead
drum water should be 20ppm(max).if chloride is high (around 50 to 60) indicates caustic
is less.
Function of caustic: Crude contains cacl 2,mgcl2 which hydrolyses to HCL at lower
tempt>400c.hence NaoH convertsCacl2 and Mgcl2 to NaCl, Thus minimizing formation
of HCl. This further reduces consumption of NH3 to control the O/H PH.
RCOOH+NAOH

RCOONA+H2O

(naphthenic acid)

(na-Naphthides)

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Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 3 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


Cacl2+H2o

2Hcl+Ca(OH)2

Rcoona+Hcl

Rcoona+Nacl

NaCl formed escapes out with diesel rco and other streams.
Ammonia injection;1)maintain conc. of NH3 bet 2.5 to 3.0 wt.% in the charge
drum.2)maintain water seal in the vent line of Nh3 drums to minimize loss to
atmosphere.3)maintain pH6.8-7.2
NH3+Hcl

NH4cl.

Corrosion inhibitor : now used in indigenous HENKEL ESK-52,which is injected to the


reflux line and Crude tower o/h line. it protects the line by forming a film on the wall of
the lines/tubes. this chemical has to be injected on a continuous basis ,otherwise the film
formed gets removed and the metal again exposed to corrosion.
Demulsifier injection: stable emulsions can also be broken by use of demulsifier
chemicals .the amount of chemicals required depends on the nature of the emulsion, type
of Crude and other operating conditions like residence time, tempt, etc , Tests should be
made to ascertain the required chemicals injection rate for optimum operation of
desalting unit. Following are the chemicals generally used.
Details of chemicals.
S.N

NAME

OF PURPOSE

o
1
2
3

CHEMICAL
ESK50
N5186
PHILMPLUS-

USAGE
Atmos. Filmer
Atmos. Filmer
Atmos. Filmer

4
5

5K7
ESK50
N5186

Vac. Filmer
Vac. Filmer

OF Mix

MIXING

Dosage ratio

ratio
1:2
1:10
1:4

CHEMICAL
SRN
SRN
Naphtha/

LTs/hr
6.9
5
6.5

1:2
1:10

Kero
VD
VD

6.9

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VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 4 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


6

PHILM-PLUS-

Vac. Filmer

1:4

VD

1.3

1
2
3
4
5
1
2
3

5K7
Atsuandm101
Sm.dychem
Nalcods 537
Ec2429A
2w157
Ec1005A
4h4
Ammonia

Dmf
Dmf
Dmf
Dmf
Dmf
Neutralizer(atmos)
Neutralizer(atmos)
Neutralizer(atmos)

1:2
1:2
1:2
1:2
1:2
1:10
1:4
Cylind

Water
Water
Water
VD
VD
Water

13.9
11
16.6
12.9
10.4
8.4
14.4

4
5
6
7
8

5be caustic
Dorf5123
Ec1005A
4h4
Ammonia

Neutralizer(atmos)
Neutralizer(atmos)
Neutralizer(vac)
Neutralizer(vac)
Neutralizer(vac)

er
1:4
1:10
1:10
1:4
Cylind

9
10

5be caustic
Dorf5123

Neutralizer(vac)
Neutralizer(vac)

er
1:4
1:10

75
15.9
33

13.3 General safety guidelines


The following are general safety rules applicable to all plant operations. these must be
known to every-body and strictly observed by all.
Safety rules:
1. Smoking is to be prohibited inside the refinery premises
2. Usage of mobile/cell phones at approved locations.
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VISAKH REFINERY

Doc. No. OPM /CDU-III


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CHAPTER TITLE: SPECIAL PROCEDURES


3. If an employee clothing becomes contaminated with acids, caustics, alcohols,
hydrocarbons etc, he must move to nearest safety shower for washing & bathing.
4. Defective tools should not be used
5. Use proper tool to proper work involved
6. Over stressing tools or equipment causes serious injuries
7. ISI mark safety belts are to be used when working 2meters above grade level to
prevent serious injuries during falling/slipping
Falls are the second largest cause of accidental deaths. Following points are to be
observed.
1. Failure to look around while going around the plant.
2. Running/jumping in work places
3. Standing on boxes,chairs,and make-shifts instead of ladders/platforms
4. Neglecting to use handrails and running on stairs.
5. Failing to face ladder when carrying objects on the same.
6. Tools and materials should not be dropped from heights. they should be carried
down.
7. Standing/waiting under materials suspended by ropes.
8. Chains or cables should not be permitted. stay in the clear until material is well
secured.

Electrical equipments:
1. Do not tamper with electrical apparatus. This is the work of qualified electrician
2. Do not remove light bulbs to plug in power equipment
3. Use only approved electrical fittings. The cover of electrical fittings in hazardous
areas should be secured properly to avoid entry of explosive gases..
4. All electrical equipment must be properly grounded

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CHAPTER TITLE: SPECIAL PROCEDURES


5. An electrical extension wire must not be used if it is in bad condition, laid through
water or in such manner as to allow motors equipment to travel over it.
6. Employees should regard all electrical wires are as live as dangerous.
7. Never close a breaker /switch that has been opened unless authorized to do so by
supervisor concerned electrical engineer.
8. All electrical breakers must be de-energized and locked before process equipment
can be worked upon.
9. Though the equipment Is electrically isolated check physically in the field by
pressing START button before the job begins.
10. All live fuse, lighting and power cabinets must be kept closed.
11. If an electrical power unit motivates moving machinery and it is necessary to
make repairs to same then refer to and follow the electrical lock out procedure
laid down by the plant management.
Safety rules for particular operations
The following safety instructions are to be followed for frequent operations in the plant.
Sample & purge connections
Before opening a purge or sample connection, ensure that the product is tempt. so
that there is no risk of initiating a fire or causing burns. Hot & heavy products are most
dangerous as they are near their auto-ignition temperature. Sample connections for hot
products are normally connected with a sample cooler. Vents & drains of hot products,
which are not used regularly, should be capped or blinded. if a hot product is to be
vented. Connect the vent to a cooling coil first before proceeding with the venting. Vents
should always be opened slowly. Operator who opens to purge the sample connections
should be present till the same is closed. The plug/blind if provided should be put back
when the operation is complete.
Sample & purge connections of liquefied products have two valves (block & globe v/vs).
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VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 7 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


Always open the upstream v/v fully and adjust the flow by the down stream v/v. this is
done so that u/sv/v is always operable in case of frosting. Draining etc. of vessels should
not be done unattended. Operator/technician should be presented as long as draining
/venting is going on.
Isolation of safety valves;
Many safety v/vs are provided with isolation v/vs at u/s & d/s of the safety body.
This is to facilitate the repair of the safety v/v. it is important to ensure that that this
isolation v/v s is kept in open as per stipulations. When a safety v/v is to be taken out of
line, bring the spare safety v/v in line or shut down the equipment if spare v/v is not
there/provided.
Operation of furnace:
While lighting in a furnace it should be purged thoroughly with steam/air. Sometimes a number of trials are to be made to light up the burner. It is important to purge the
furnace every time a burner fails and trial for relighting is made. it should also be noted
that each burner be lighted with pilot &not with the flame or heat of the adjoining
fire/burner. Sometimes during a furnace shutdown all the burners are put-off. If it
becomes necessary to light up some burners, do not forget to purge the furnace. Purging
is to expel/remove the accumulated hydrocarbons inside to prevent explosions during
lighting/relighting.
High point vents & relief v/vs discharges.
The hydrocarbons discharges from the high point vents & relief v/vs discharging
to atmosphere pose hazard due to lighting. Such d/cs are normally provided with steam
purging connections. It is essential to keep purge steam in these lines, especially in
monsoons when there is like-hood of lightning.

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Doc. No. OPM /CDU-III


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Rev. Date: 01/04/2007
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CHAPTER TITLE: SPECIAL PROCEDURES


Flare system operation;
It is important that pilot burners at the flare stack are always lighted. Always
maintain a small flow of gas in the system to avoid ingress of air into the flare stack.
Maintain proper hydraulic seal in the water seal drum at all times when flare system is
operating.
13.4 Sampling procedures
Control tests provide the information to the operating staff for making necessary
adjustments to get max. Out-put and on-spec. Quality products. The control tests are to be
made at all steps to monitor the intermediate and final products whether or not they are at
the desired level. Samples are taken and analyzed at regular intervals such that the
operation of the plant is monitored and any deviation (from spec. will indicate some mal
operation/malfunction of the plant), which can be spotted in time without undue loss of
time and product. Sometimes samples are taken to find out the effect of certain changes
brought about in the plant conditions. The samples are to be taken with great care so that
the samples are of representative nature. The samples points are suitably located to
provide representative samples. The frequency of samples collection , type of analysis
and points where samples are to be collected are generally specified by the process
people. During guarantee tests some additional samples can also be taken at higher
frequencies, which will be specified in the procedures prior to test run. The following
guidelines are to be followed while collecting the samples.
13.4.1 Liquid sampling procedure (non-flashing type):
1. The person taking sample should wear proper safety clothing like face-shield,
aprons, rubber-gloves etc, to protect face, hands etc.
2. Whenever hot samples are taken check cooling water flow in sample cooler is ok
or not.
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CHAPTER TITLE: SPECIAL PROCEDURES


3. Sample points usually have two v/vs in series. One gate v/v for isolation and
globe v/v to regulate flow. Open gate v/v first and globe v/v next slowly after
placing samples containers. After the sample collection close globe v/v first and
gate v/v next. Then again open globe v/v to drain the content for congealing
liquids. In case of bitumen sampling two gate v/vs are used the purpose of two
gate v/vs is to facilitate poking in case of line got choked.
4. Sample v/v should be slowly opened first slightly to check for plugging. If
suddenly the plugging released the liquid comes-out at a dangerously uncontrolled
rate. Never tape the line to release the plugging. Call the maintenance to unplug
the line. In case of congealing type samples, sample points are to be equipped
with proper copper coil type steam tracer. it should be ensured that steam tracing
is functioning properly.
5. The operator taking the sample should be careful to stand in a position such that
the liquid does not spill on him at any cost and he has unobstructed way out from
the sample point in case of accident. While taking dangerous toxic material for
sampling, it will act as an observer for safety. Proper gas mask is to be used. It is
advisable to stand opposite to wind direction in case of volatile toxic liquid.
6. Sample should be collected in clean, dry and Stoppard bottle. In case of
congealing samples use clean dry ladle/grabber/tin.
7. Rinsing of bottle is to be done thoroughly before collecting the sample.
8. Before collecting ensure that the content has been drained and fresh sample is
collected.
9. Gradually warm-up the sample bottle/metallic tin by repeatedly rinsing before
collecting the sample
10. Stopper the bottle immediately after collecting the sample
11. Attach a tag to the bottle indicating the details concerned and tests are to be
carried-out.
12. A few products suffer deterioration with time.
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CHAPTER TITLE: SPECIAL PROCEDURES


13. For example, the color of the heavier distillates (in refinery), slowly deteriorates
with time. So these samples should be sent to LAB at the earliest after collection.
14. The samples after collection should be kept away from any source of ignition to
minimize fire hazard.
15. Volatile samples (naphtha) should be collected in bottles and kept in ice
particularly for some Critical tests like RVP. moreover sample should not be
collected fully to maintain vapor phase.
13.4.2 High-pressure hydrocarbon liquid samples (flashing type)
1. The person-taking sample should wear personal protection appliances like apron,
gas mark hand gloves to protect him.
2. Ensure that sample bomb is empty, clean & dry.
3. Connect the sample bomb I/l v/v to the sample point with flexible hose.
4. Open that I/l v/v of the sample bomb. Hold the sample bomb. Hold the sample
bomb o/l away from person. Keep face away from h/c vapor and stand in such a
way that prevalent wind should blow h/c vapor away. Open the gate valve of
sample point slowly till full open. Then slowly Cracks open the regulating valve.
One should be careful at the time of draining, because chance of icing is there. As
a result the formation of solid hydrates is a continuing process, which leads to the
plugging of v/vs.
5. When all the air in the hose and bomb are displaced as seen by the h/c vapor
rising from the o/l of sample bomb, close the sample o/l v/v. allow a little quantity
of liquid to spill to make sure that the bomb is receiving liquid. Frosting will be
an indication of liquid spillage.
6. Allow liquid h/c to fill the bomb. When the bomb is full upon the specified level.
Close the v/vs on sample point. Close I/l on the sample point.

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CHAPTER TITLE: SPECIAL PROCEDURES


7. Carefully disconnect the hose from the sample bomb. To allow for some vapor
space in the bomb for thermal expansion in case of overfilling, Crack open the o/l
v/v of bomb and d/s a small part of liquid. Close o/l v/v.
8. Closed sampling facilities are provided at some locations where it is not desirable
to waste the costly product or if the material is toxic. For filling the sampling
bomb, pressure drop across a control usually utilized or across pump s/c & d/s. air
is expelled from the bomb after it is connected to the u/s of control valve. The
bomb is then connected to the d/s of C/V or pump discharge side. The sample is
then collected and bomb is detached after closing valves on the both sides. Send
sample bomb to LAB for analysis.
9. Gas sample.
10. For collection of gas sample, which are not under high pressure and temperature,
rubber bladders are used. For the operation under vacuum or low pressure,
aspirator is used. For representative sample, purge the bladder 3 to 4 times with
the gas and then take the final sample. Use of 3-way v/v with bladder/aspirator
will facilitate purging & sampling.
11. Sample bombs are to be used for taking gas samples from high Pr & high tempt.
Source. Procedure mentioned under item4.1.2 (is to be used

13.5 Induced fan placing


Steps taken from MOI;

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CHAPTER TITLE: SPECIAL PROCEDURES


1. Ensure the field check-up of necessary dampers opening; lube oil & bcw systems,
power to motor &house keeping jobs.
2. Keep stack damper wide open.
3. Check the ARCH.TEMP.400c.
4. Check and ensure stack & hot flue gas dampers opening indications in the field.
5. Ensure hydraulic oil coupling loading in the AUTO (horizontal indication) to load
from MOI & the lever is in UNLOCK position.
Note: hydraulic oil coupling loading can be done MANUALLY by changing the mode to
manual (vertical position) in the field and lock the lever at required %of loading as and
when required. During that time loading cannot be changed from MOI.
6. Keep loading position at0%42PC-5007(arch pressure) in MOI. Keep the inter
locks1) fuel cut-off (PB5055)&Id fan failure bypass (PB5054) in BYPASS mode
at MOI.
7. Start the fan in the field
8. Start loading fan from MOI by 5%on regular intervals in slow steps from PC5007 only after resetting SOV5007.check RPM&LOADING panel indications of
SI&ZI
9. Ensure the conditions of fan in field before loading further. Often check heater
firing.
10. Watch APH tempts while loading fan. To normalize APH conditions reduce
openings of cold air by-pass & stack dampers slowly. When conditions are normal
put-back the inter-locks on line. & Observe id fan performance.
13.6 Pump stuffing-box/bearing housing acid cleaning
1. Isolate pump s/c,d/s & w/p v/vs and allow some time for cooling.
2. Flush the system with FLO after removing blinds on CASING TO CBD/FLO.
Also ensure passing of v/vs.
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CHAPTER TITLE: SPECIAL PROCEDURES


3. Update BLIND REGISTER
4. Isolate power to motor/display DO NOT START tag/board.
5. Acid cleaning of BCW lines improves flow circulation reduces bearing tempts.
6. Isolate pump BCW, SEAL-OIL&SEAL-STEAM.etc
7. Ensure wearing of PPE during attending the job.
8. Keep equp.under maint.display board.
9. After the job is over, pressure-up with FLO and close vents bleeders connected.
10. Ensure BCW, SEAL FLUSHING&SEAL STEAM, POWER to motor etc.
11. Open w/p v/v slightly and displace stock to cbd/ows.afterwards keep pump in
warm up condition.
12. Remove equt.under maint.display board.
13. Put blinds on CBD/FLO lines.
14. Finally update blind&gasket registers.
13.7 GAUGE GLASS ACID CLEANING
1. Isolate g/g both take-off v/vs
2. Depressurize the content to ows.
3. Ensure passing of v/vs. and release for acid cleaning
4. Ensure usage of PPE.
5. After acid cleaning, close all vents drains of g/g.
6. Slowly open bottom t/ov/v and see level is increasing in the g/g.open
vent&drainv/vs at slightly to displace air and close. Open top t/ov/v .see the g/g
level is representative with L threading. Cap-off drains&vents if any. During
commissioning of vaccum G/Gs open top t/o v/v and then bottom t/o v/v, see the
g/g level is representative.

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CHAPTER TITLE: SPECIAL PROCEDURES


13.8 Washing procedure for air-pre-heater:
Washing of air preheater should be carried out during outage of the APH.the washing
process should be carried out rapidly without any interruptions, otherwise sulphuric acid
will be formed by the dissolved heating surface deposits. This may leads to corrosion on
the metal heating plates. Hot water washing is the best for it.
WASHING SEQUENCE;
Before washing it should be investigated whether the deposits on the heating
plates can be dissolved by water/whether under influence of water they have a tendency
towards cementing. In the later case high pressure washing may be required.
The washing drive unit is taken into operation. Ensure that the main and reserve
drive units are switched off. Operating instructions for washing unit should be studied
carefully. Washing is carried out first along and subsequently against the airflow
direction. The washing should be continued until the heating surface is absolutely
clean&the drained off water has a PH of 6-6.8.During washing the water is to be routed
to OWS with quenching of service water for not affecting ETP operations.
An immediate careful drying should follow the washing. This is affected best by
the residual heat still existing in the furnace or by operating the forced draft fan. If the air
preheater is restarted in poorly dried condition, it may easily plug again owing to the
remaining moisure/muck.after washing the water drainage, lines should be well ventilated
and dried in order to avoid here, too, the occurrence of outage corrosion.

Operating Procedure of APH;


1,checks before start-up &during running:

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CHAPTER TITLE: SPECIAL PROCEDURES


By taking any part of the system on bypass it can be put to pre-start up checks for
smooth operation (i.e.open&close dampers etc.). Crack open test for stack dampers are
normally provided in the field to ensure their operation. But since these might trip
FD&IDFANS, SWITHES OR OVER RIDES FD fan by-pass and ID fan stack damper
bypass should be activated during the check. The bypasses should be removed after the
checking is completed.
2) Start-up.
1. Open burner air registers as per burner instruction manual
2. Press lamp test button. Ensure display is normal otherwise rectify the fault.
3. Put all trips on bypass mode.
4. Open stack damper fully
5. Open all blinds/dampers in airlines and flue gas lines to and from air pre-heater.
6. Close airline bypass damper.
7. Start one Fdfan and adjust flow to about 40% of max.
8. Start up pilots burners after purging the heater.
9. Light main gas burners and ensure proper combustion. For this, the appropriate
SDVs need tobe opened by resetting and taking trip bypass in line.
10. Increase FD fan load/heater through-out to desired level and let it stabilize
11. Though out above procedure, furnace draft pressure should be watched and
should never be allowed to become positive. If it becomes positive, adjust fan
capacity control such that it remains normal (0-2.5 mm WG)
12. Remove bypass on trips for FD fans
13. Start up ID fan with min.speed.
14. Increase Idfan capacity by manual control to max. Flow slowly, while watching
draft pressure. It should remain in between (0-2.5mm.WG)
15. After Idfan is fully stabilized at required flow rate (determined by pr at arch and
Orsat analysis), close the stack damper, taking air pre-heater fully in line. During

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Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 16 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


low flue gas flow through ID fan low tempt. Alarm at flue gas line out-let of APH
may sound.
16. Put ID fan on auto control&remove on all trip circuits.
3) SHUT-DOWN;
If for some reason like maint. /breakdown of APH, forced draft fans, ID fan or any other
part of APH system, this equipment has to be isolated with furnace still running,
following procedure should be adopted.
1. Put stack damper opening&ID fan trip on bypass mode
2. Open stack damper keeping burner flames &heater draft stable
3. Stop ID fan. Switch over to natural draft mode
4. After ducting has become cooler, close all dampers. Insert blinds into ducts and
isolate the system before carrying out any maint. Job.
13.9 Heater start-up (42F01)
FD FANS (START-UP)
1.keep the following inter-locks in BYPASS condition
Fd fan A fail bypass
Fd fanA/B fail bypass
Combustion air failure
Fuel cut-off bypass
Pass flow low low bypass
Turn down in bypass
2.turn the key HS-5008 and open the discharge damper
3.start the fan in the field in MANUAL mode
4.reset SOV5001

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Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 17 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


5.load the fan from HC5001 AND OBSERVE ZI-5001 (HYDRAULIC OIL
LOADING)&SI-5002 (RPM) INDICATIONS IN MOI&FIELD to know whether the fan
is getting loaded.
FAN-B placing on line.
1.start the fan using the same procedure but using INTERLOCKS and SOV related to
FAN-B.
2.ensure that when second FAN started its discharge damper is closed to avoid any
reverse rotation of fan. After loading the fan to required speed open the discharge damper.
T/D ACTUATED mode
In t/d actuation mode one fan will be running and the other will be standby. Once one fan
started put the other fan in AUTO in field to cut in immediately if the running fan fails
Put the standby fan fail bypass and FD FANA/B trip bypass interlock in BYPASS mode.
Once normal operating conditions are reached put all other interlocks on line
T/D BYPASS MODE
In T/D bypass mode both fans will be running at 50%load
After both fans are started, put both fans are in AUTO mode in FIELD.
Once normal operating conditions reached, put INTERLOCKS on line
After ensuring the equal% of output is given from HC5001/5002 take 42FC5003 on line.
OPENING OF FUEL SDVS
FUEL GAS
1.ensure the following interlocks are in healthy conditions
COMBUSTION AIR FAILURE BYPASS
FD FANA/B FAIL BYPASS
PASSES LOW LOW FLOWS IN BYPASS
If FUEL GAS SDV is tobe opened without FD FANS RUNNING BYPASS the above
interlocks
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Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 18 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


2.put fuel gas LOW LOW PRESSURE interlock in BYPASS mode
OPEN THE SDV by resetting SOV1403
NOTE: ensure all FUEL GAS PLUGCOCK VALVES are in closed position in
field&PURGING OF HEATER before opening the SDVs.
FUEL OIL SUPPLY& RETURN SDVs
1.ensure the following interlocks are in healthy conditions
Combustion air failure bypass
fd fan a/b fail bypass
passes low low flows in bypass
If FUEL OIL SDVs to be opened without FD FANS RUNNING BYPASS the above
interlocks
2.put fuel oil LOW LOW PRESSURE interlock in BYPASS mode
OPEN THE SDVs by resetting SOV1404&SOV1401
NOTE: ensure all FUEL OILVALVES are in closed position in field PURGING OF
HEATER before opening the SDVs. ATOMISING STEAM header is to be
commissioned.
ID FAN START-UP
1. ID FAN to be started only after ARCH temperature reaches 400c
2. Keep the following interlocks in BYPASS mode
3. FUELCUT-OFF&ID FAN FAILURE BYPASS
4. Start the fan from field
5. LOAD the fan from42PC-5007
6. Once the conditions are normal put back the interlocks on line

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Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 19 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


STACK DAMPER CLOSING
1. Ensure smooth operating conditions including ID FAN running
2. Ensure FUEL CUT-OFF & ID FAN fail interlocks on line
3. Turn the key 42HC5006A/B to close position
4. Reset 42SOV5006
5. Control the damper position from HC5006 from 100% opening to 0% opening
(totally closed)
6. Same procedure to be followed up for 42F02 heater following the respective
interlocks.
NOTE:
1. DO NOT CLOSE THE STACK DAMPER WHEN HC-5006 OP IS O%.
1. IN CASE OF ANY PROBLEM DURING OPENING OF STACK DAMPER
FROM MOI, IT CAN BE OPENED MANUALLY BY WINCH OPERATION
AFTER DISCONNECTING THE INSTRUMENT AIR TO IT.
IMPORTANT: Ensure release condition of EMERGENCY PUSH BOTTON in the
FIELD before start of heater activities.

13.9 Hardware panel details of 42F01


Push

button Interlocks bypassed

Effect

When to bypass

Why

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VISAKH REFINERY

Doc. No. OPM /CDU-III


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Rev. Date: 01/04/2007
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CHAPTER TITLE: SPECIAL PROCEDURES


no.
HS-5001C

To stop FD fanA (also,

bypass

PB-5051

closes D/S damper)


a) 42-KA-01A failure a) In case KA- When KA-01A If
sensed

by

motor 01A fails under needs

running indication and T/D


low air flow switch
b)hydraulic

oil

mode

to

bypassed started.

not

be bypassed,
KA-01A

KA01B When FD fan cannot

be

flow will not take up 01B running in started,

as

low low switch

100%load

T/D

actuated always trip

b) In case KA- mode.

signal exists

01A fails under

for the fan

T/D

actuated

when it is

mode KA-01B

not running.

will not start.


HS-5002C

To stop FD fan (also,


closes D/S damper)
a) 42-KA-01B failure a) In case KA- When KA-01B If
sensed

by

motor 01B fails under needs

running indication and T/D


low air flow switch

PB-5057

be bypassed,
KA-01B

KA01A When FD fan cannot

be

b) Hydraulic oil flow will not take up 01A running in started,

as

low low switch

mode

bypassed started.

to

not

100%load

T/D

actuated always trip

b) In case KA- mode.

signal exists

01B fails under

for the fan

T/D

actuated

when it is

mode KA-01A

not running.

will not start.


Failure of KA-01A&B In case both When FD fans If

not

as sensed by total air fans fail heater are to be started bypassed


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Rev. Date: 01/04/2007
Page No.: Page 21 of 55

VISAKH REFINERY

CHAPTER TITLE: SPECIAL PROCEDURES


flow

low

/individual

low will

not

be during start-up.

motor tripped, due to

running indication put this

interlock

started,

as

trip

flows put together.

will

exists to the

not

take

signal

fans.

To stop ID fan.
a) KA-02 failure as Incase ID fan During ID fan If
by

suction sack

damper starting

pressure HI HI and will


motor

not

not

bypassed the

get

fan can not

running opened due to

be started as

indication

this interlock

b) Hydraulic oil flow

trip

signal

exists

low low switch


Combustion air failure If

combustion During

Fdfans As

always

as sensed by low flow air fails heater start-up

trip

signal

switches

will not trip due

exists

to this interlock

the fans

(Fuel
will
PB-5055

be

(Fuel s cut-off

sensed

PB-5053

cannot

together/individual

place)
HS5007C
PB-5054

Fdfans

cut-off
not

place)
Fuel gut-off as sensed In case

take
both During FD fans As

by fuel oil&fuel gas fuels get cut- start-up

trip

low low pressure put off,

exists

together

for

stack

damper will not

always
signal

the fans

open and fans


(FD&ID)

will

not trip due to


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Doc. No. OPM /CDU-III


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Rev. Date: 01/04/2007
Page No.: Page 22 of 55

VISAKH REFINERY

CHAPTER TITLE: SPECIAL PROCEDURES

PB-5049

PB-5050

this interlock
Fuel gas pressure low Fuel gas will For opening FG As low low
low D/S of control not get cut-off SDV

Pr.exists

valve

unless SDV

due

to

this

interlock
is opened
Fuel oil pressure low Fuel oil will not For opening FO As low low
low D/S of control get cut-off due SDV

Pr.exists

valve

unless SDV

to this interlock

is opened
Note: the following interlocks do not have bypass facility
1) ArchPr Hi 2) Arch Pr Hi Hi 3) ID fan S/C Temp.Hi
Reset push button
SOV-5001

Function
To reset fdfan A hydraulic coupling (for

SOV-5002

loading the fan after starting)


To reset fdfan B hydraulic coupling (for

SOV-5006

loading the fan after starting)


To reset stack damper SOV (required to
close the damper from DCS as this air is

SOV-5008
SOV-5009
SOV-1401

supplied through this SOV)


To reset Fd fanA D/S damper
To reset Fd fanB D/S damper
To reset FO return SDV(required to open

SOV-1404

FO return SDV)
To reset FO supply SDV(required to open

SOV-1403

FO supply SDV)
To reset FG SDV(required to open FG
SDV)

13.10 Heater start-up(42F02)


FD FANS(START-UP)
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Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 23 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


1..keep the following inter-locks in BYPASS condition
fd fan A fail bypass
fd fanA/B fail bypass
combustion air failure
fuel cut-off bypass
pass flow low low bypass
turn down in bypass
2.turn the key HS-5108 and open the discharge damper
3.start the fan in the field in MANUAL mode
4.reset SOV5101
5.load the fan from HC5101 AND OBSERVE ZI-5101(HYDRAULIC OIL
LOADING)&SI-5102(RPM) INDICATIONS IN MOI&FIELD to know whether the fan
is getting loaded.

FAN-B placing on line.


1.start the fan using the same procedure but using INTERLOCKS and SOV related to
FAN-B.
2.ensure that when second FAN started its discharge damper is closed to avoid any
reverse rotation of fan. after loading the fan to required speed open the discharge damper.
T/D ACTUATED mode
In t/d actuation mode one fan will be running and the other will be standby. once one fan
started put the other fan in AUTO in field to cut in immediately if the running fan fails
Put the standby fan fail bypass and FD FANA/B trip bypass interlock in BYPASS mode.
Once normal operating conditions are reached put all other interlocks on line

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Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 24 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

T/D BYPASS MODE


In T/D bypass mode both fans will be running at 50%load
After both fans are started, put both fans are in AUTO mode in FIELD.
Once normal operating conditions reached, put INTERLOCKS on line
After ensuring the equal% of output is given from HC5101/5102 take 42FC5103 on line.
OPENING OF FUEL SDVS
FUEL GAS
1.ensure the following interlocks are in healthy conditions
Combustion air failure bypass
fd fan a/b fail bypass
passes low low flows in bypass
If fuel gas SDV is to be opened without fd fans running bypass the above interlocks
2.put fuel gas low low pressure interlock in bypass mode
open the SDV by resetting sov2001
NOTE: ensure all FUEL GAS PLUG COCK VALVES are in closed position in field &
PURGING OF HEATER before opening the SDVs.
FUEL OIL SUPPLY& RETURN SDVs
1.ensure the following interlocks are in healthy conditions
Combustion air failure bypass
Fd fan a/b fail bypass
passes low low flows in bypass
If fuel oil SDV s to be opened without fd fans running bypass the above interlocks
2.put fuel oil LOW LOW PRESSURE interlock in BYPASS mode
OPEN THE SDVs by resetting SOV2003&SOV2002

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Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 25 of 55

VISAKH REFINERY

CHAPTER TITLE: SPECIAL PROCEDURES


NOTE: ensure all FUEL OILVALVES are in closed position in field&PURGING OF
HEATER before opening the SDVs. ATOMISING STEAM header is to be
commissioned.
ID FAN START-UP
2. ID FAN to be started only after ARCH temperature reaches 400c
3. Keep the following interlocks in BYPASS mode
4. FUELCUT-OFF&ID FAN FAILURE BYPASS
5. Start the fan from field
6. LOAD the fan from42PC-5107Once the conditions are normal put back the
interlocks on line
STACK DAMPER CLOSING
1. Ensure smooth operating conditions including ID FAN running
2. Ensure FUELCUT-OFF&ID FAN fail interlocks on line
3. Turn the key42HC5106A/B to close position
4. Reset 42SOV5106
5. Control the damper position from HC5106 from 100% opening to 0%
opening(totally closed)
NOTE:
1.do not close the stack damper when hc-5106 op is o%.
2.in case of any problem during opening of stack damper from MOI, it can be opened
manually by winch operation after disconnecting the instrument air to it.
IMPORTANT: Ensure release condition of EMERGENCY PUSH BOTTON in the
FIELD before start of heater activities.
13.11 Hardware panel details of 42F02
Push button Interlocks
no.
HS-5101C

Effect

When to bypass

Why to bypass

bypassed
To stop FD

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Rev. Date: 01/04/2007
Page No.: Page 26 of 55

VISAKH REFINERY

CHAPTER TITLE: SPECIAL PROCEDURES


fanA(also,
closes
PB-5151

D/S

damper)
a) 42-KA-03A a)in case KA-03A When

KA-03A If not bypassed,KA-

failure sensed fails under T/D needs

to

by

motor bypassed

running

mode started..

KA03B will not When

indication and take up 100%load

be 03A can not be


started as always

FD

fan trip signal exists for

03B running in the fan when it is

low air flow b)in case KA-03A T/D

actuated not running.

switch

fails under T/D mode.

b)hydraulic

actuated

mode

oil flow low KA-03B will not


HS-5102C

low switch
start.
To stop FD
fanB(also,
closes

D/S

damper)
a) 42-KA-03B a)in case KA-03B When

KA-03B If not bypassed,KA-

failure sensed fails under T/D needs

to

by

motor bypassed

running

mode started..

KA03A will not When

indication and take up 100%load

be 03B can not be


started as always

FD

fan trip signal exists for

03A running in the fan when it is

low air flow b)in case KA-03B T/D

actuated not running.

switch

fails under T/D mode.

b)hydraulic

actuated

mode

oil flow low KA-03A will not


PB-5157

low switch
start.
Failure
of In case both fans When FD fans are If
KA-03A&B

fail

heater

will to

be

not

bypassed

started Fdfans can not be

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Rev. Date: 01/04/2007
Page No.: Page 27 of 55

VISAKH REFINERY

CHAPTER TITLE: SPECIAL PROCEDURES


as sensed by not

be

total air flow ,due


low

tripped during start-up.


to

low interlock(Fuel

/individual

this

started as trip signal


exists to the fans.

cut-off will not

motor running take place)


indication put
together/indiv
idual

flows

HS5107C

put together.
To stop ID

PB-5154

fan.
a)KA-04

Incase

ID

fan During

ID

fan If not bypassed the

failure

as sack damper will starting

fan

sensed

by not get opened

started as trip signal

suction

due

to

pressure

HI interlock

this

can

not

be

exists

HI and motor
running
indication
b)hydraulic
oil flow low
PB-5153

low switch
Combustion

If combustion air During

Fdfans As

always

trip

air failure as fails heater will start-up

signal exists for the

sensed by low not trip due to this

fans

flow switches

interlock(Fuel
cut-off will not

PB-5155

Fuel

take place)
gut-off In case both fuels During FD fans As

always

trip

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Rev. Date: 01/04/2007
Page No.: Page 28 of 55

VISAKH REFINERY

CHAPTER TITLE: SPECIAL PROCEDURES


as sensed by get cut-off ,stack start-up

signal exists for the

fuel oil&fuel damper will not

fans

gas low low open

PB-5149

and

pressure

put fans(FD&ID) will

together

not trip due to this

Fuel

interlock
gas Fuel gas will not For opening FG As

pressure

low get cut-off due to SDV

low D/S of this interlock


PB-5150

Pr.exists

low
unless

SDV is opened

control valve
Fuel
oil Fuel oil will not For opening FO As
pressure

low

low get cut-off due to SDV

low D/S of this interlock

low

Pr.exists

low
unless

SDV is opened

control valve
Note :the following interlocks do not have bypass facility
1)ArchPr Hi 2)Arch Pr Hi Hi 3)ID fan S/C Temp.Hi
Reset push button
SOV-5101

function
To reset fdfan A hydraulic coupling(for

SOV-5102

loading the fan after starting)


To reset fdfan B hydraulic coupling(for

SOV-5106

loading the fan after starting)


To reset stack damper SOV(required to
close the damper from DCS as this air is

SOV-5108
SOV-5109
SOV-2003

supplied through this SOV)


To reset Fd fanA D/S damper
To reset Fd fanB D/S damper
To reset FO return SDV(required to open

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Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 29 of 55

VISAKH REFINERY

CHAPTER TITLE: SPECIAL PROCEDURES

SOV-2002

FO return SDV)
To reset FO supply SDV(required to open

SOV-2001

FO supply SDV)
To reset FG SDV(required to open FG
SDV

Note :the following interlocks do not have bypass facility


1)ArchPr Hi 2)Arch Pr Hi Hi 3)ID fan S/C Temp.Hi

Reset push button


SOV-5201

function
To reset fdfan A hydraulic coupling(for

SOV-5202

loading the fan after starting)


To reset fdfan B hydraulic coupling(for

SOV-5206

loading the fan after starting)


To reset stack damper SOV(required to
close the damper from DCS as this air is

SOV-5208
SOV-5209
SOV-1304

supplied through this SOV)


To reset Fd fanA D/S damper
To reset Fd fanB D/S damper
To reset FO return SDV(required to open

SOV-1303

FO return SDV)
To reset FO supply SDV(required to open

SOV-13SOV-1302

FO supply SDV)
To reset FG SDV(required to open FG
SDV)

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Doc. No. OPM /CDU-III


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Rev. Date: 01/04/2007
Page No.: Page 30 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

13.13Procedure for unit CRUDE FEED TANK change over


1.unit feed rate is to be dropped to 440m3/hr
2.Desalter wash water injection is to be taken out
3.Desalter agar probe to be set in between70to75% and to be confirmed with try cocks
level (2&3) in the field by physical check. In case of any Desalter grid voltage/amperes
fluctuations, level can be reduced to suit operating conditions but it should be informed to
unit manager
4.after feed tank switch over, the plant should be observed for ONE hour at 440m3/hr
feed rate for stabilization, before bringing up the feed rate to the desired level at regular
steps
As the feed tank change over activity is more Critical due to presence of water/sludge
carry over in the Crude feed tanks. Hence the above factors are to be followed.
13.14 LEL DETECTORS STATUS
S.No

Tag. no.

Location

Type

remarks

1
2
3
4
5
6

42-AT-5007
42-AT-5008
42-AT-5107
42-AT-5108
42-AT-1501
42-AT-1601

42KA01A
42KA01B
42KA03A
42KA03B
42PM5A/B
42PM4A/B

HC
HC
HC
HC
HC
HC

INFRA-RED
INFRA-RED
INFRA-RED
INFRA-RED
INFRA-RED
INFRA-RED

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Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 31 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


7
8
9
10

42-AT-1602
42-AT-1701
42-AT-1702
42-AHH-1101

42PM35A/B
42PM13A/B
42PM14A/B
SOUR WATER O/F

11

42-AT-001

AREA
NEAR CBD PUMP HC

46-AT-1601
46-AT-1701
46-AT-1801
46-AT-3001
46-AT-2901
46-AT-2902
46-AT-2903
46-AT-002

AREA
46PM5A/B
46PM8A/B
46PM10A/B
46PM9A/B
46V15
46V16
46KO1AREA
ANALYSER

HC
HC
HC
HC
HC
HC
HC
HC

20
21

46AE5207
46AE5208

ROOM
46KAO1A
46KAO1B

H2S
H2S

22
23
24
25

42-AH-1603
42-AH-1604
42-AH-1605
42-Ah-1606

42em30afc north
42em30e/fafc north
42em30i/kafc north
42em30b/d
afc

HC
HC
HC
HC

12
13
14
15
16
17
18
19

HC
HC
HC
HC

INFRA-RED
INFRA-RED
INFRA-RED

INFRA-RED
INFRA-RED
INFRA-RED
INFRA-RED
INFRA-RED
INFRA-RED
INFRA-RED

INFRA-RED
INFRA-RED

south
26
27
28
29

42-Ah-1607

42em30d/f

afc HC

42-Ah-1608

south
42em30f/h

afc HC

46AH1602
46AH1603

south
VBU AFC SOUTH
VBU AFC NORTH

HC
HC

13.15 RADAR TYPE LTs


42LI1102D EMULSION PROBE
42LC1102A DESALTER INTER-PHASE LEVEL
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Rev. Date: 01/04/2007
Page No.: Page 32 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


42LI1102E DESALTER SLDGE PROBE
42LI2601 CBD DRUM LEVEL
42LC2103 HVGO LEVEL
42LC2104 SLOP-CUT LEVEL
42LC2201 HOT WELL WATER LEVEL
42LI2202 HOT WELL OIL LEVEL
46LC1602 46V02 O/HH/C DRUM LEVEL
46LC1704 46V03 O/HH/C LEVEL
13.16 Guide lines for SR exchangers:
1.if SR flow >100m3/hr,all exchangers are tobe on line
2.42e51to54 exchangers are to be bypassed.
If>30m3<100m3/hr sr flow then e15,18A/B/C,&28 are in service.e25 is to be
bypassed.E51,52,53&54 are to be kept parallel to e15,18,25&28.
3.for SR flow<30m3/hr,E15,25&28 ARE TO BE BYPASSED.E18 is to be in
service.E51,53&54are to be parallel to E15,25&28 andE52 in service with E18.
13.17 Advanced process control logics.
Effects of Advanced process control logics during the emergencies are stated as
follows
1)failure of ATMOS. heater(42F01):when 42f01 is tripped due to activation of
42SOV1403&42SOV1404 CLOSING, all except NSU-3(naphtha stabilizer) will get putoff automatically from APC CONTROL to OPERATOR mode.
2) Failure of 42F02 (VAC.heater) due to 42SOV2001&42SOV2002 CLOSING, only
VHT-3&VDU-3 will put off automatically from APC to OPERATOR mode.
3) During 42PM01A/B OR 42PM02A/B tripping all APC CONTROLLERS put-off
automatically from APC to OPERATOR mode.

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Doc. No. OPM /CDU-III


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CHAPTER TITLE: SPECIAL PROCEDURES

13.18 Instrument air fail to open control valves in CDU-3


1.42PC1104 Desalter Pr
2.42dpc101 Desalter mix v/v
3.42HC1201 PH-2 spilt C/V
4.42FRC1201 PH-3spilt C/V
5.42FC1401 to 1404 42F01feed passes C/Vs
6.42dpc1420 42F01atomising steam C/V
7.42FC1501 Kero CR C/V
8.42FC1502 LD CR C/V
9.42FC1503HDCR C/V
10.42FC1504A Atmos O/H gas to flare
11.42FC1505 top Reflux C/V
12.42FC1701 stab. Feed C/V
13.42PV1701A stab.o/h gas to v-14
14.42FC1703 stab Reflux C/V
15.42HC1801 mix v/v on v-25
16.42FC1801 caustic circulation flow C/V
17.42HC1802 mix v/v on v-26
18.42FC1802 water circulation flow C/V
19.42FC2002 to 2005 42F02 feed passes flow C/Vs
20.42dpc2020 42F02 atomizing steam C/V
21.42FC2020 slop-cut recycle C/V
22.42FC2108 Sr quenches C/V
23.42FC2101 cold VD CR
24.42FC2102 VD (hot) CR
25.42FC2103 LVGO cold Reflux
26.42FC2104hot LVGO Reflux
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CHAPTER TITLE: SPECIAL PROCEDURES


27.42FC2105 hot HVGO Reflux
28. 42FC2106 cold HVGO Reflux
29 42FC1601 min.flow C/V on 42PM35a/b to v-13
30.42FC1704 min.flow C/V on 42PM14a/b to v-14
31.42FC1211 HD from e06
32.42HC1301 HDCR from e53 to 42c01
33.42FRC1203 LVGO from e11
34.42HC1202 LVGO from e21a/b
35.42HC1203 HVGO from e14
36.42FRC1206 HVGO from e24a/b/c/d
37.42HC1204 sr from e15a/b
36.42FRC1210 sr from e25
37.42PC7301 hp flow pr C/V

13.19 Oil guns cleaning procedure

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CHAPTER TITLE: SPECIAL PROCEDURES

During oil gun dropping and placing oil fire keep stack damper wide position to
prevent excessive pressure developing in the furnace

Remove oil fire

Purge oil gun with steam for some time to prevent plugging with fuel oil

Keep gas fire and pilot fires

Before dropping oil gun close oil and purge steam valves

Check burner in-side for oil accumulation through burner view ports

Use face shield and asbestos gloves during checking and dropping of oil gun

Keep burner drain at assembly open to drain oil inside, if any.

Do not allow oil gun more time without steam purging when gas fire is in-side as
the oil burner tip will get damage

If oil accumulation is not there gun can be dropped safely for cleaning

If oil accumulation is there then remove all fires and close air registers for cooling
before dropping

After dropping gun with face shield and asbestos gloves soak it in the soaking pit
after cooling

Remove outer barrel, inner barrel and tip etc burner parts for checking condition
and replace, if any, before assembling after cleaning

Fix gun with new lead gaskets

Purge the gun with steam for testing leaks, if any.

Ensure no leaks then keep oil fire ensuring gas fire in side by adjusting air
registers

Finally, up-date burner spares register.

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CHAPTER TITLE: SPECIAL PROCEDURES

13.20 Procedure for dropping Fuel-gas/Hot well off gas burners

During dropping and placing Fuel-gas/Hot well off gas fire keep stack damper
wide position to prevent excessive pressure developing in the furnace

Remove Fuel-gas/Hot well off gas fire&oil and pilot fires&blind them. Also
isolate air registers.

Purge oil gun with steam for some time to prevent plugging with fuel-oil

purge steam valves are to be closed

Check burner in-side for oil accumulation through burner view ports

Use face shield and asbestos gloves during checking and dropping of Fuelgas/Hot well off gas burner tips

Keep burner drain at assembly open to drain oil inside, if any.

After removing all fires&closing air registers allow the burner to cool for 2to3hrs.

If oil accumulation is not there can Fuel-gas/Hot well off gas burners can be
dropped safely for cleaning

If oil accumulation is there then remove all fires and close air registers for cooling
before dropping

After dropping Fuel-gas/Hot well off gas burners/tips with face shield and
asbestos gloves soak it in the soaking pit after cooling

Remove&replace damaged tips of the burners with new parts after checking
condition if any, before assembling after cleaning

Fix Fuel-gas/Hot well off gas burners

Deblind Fuel-gas/Hot well off gas lines pilot gas lines.

Ensure no leaks then keep Fuel-gas/Hot well off gas fire ensuring pilot gas fire in
side& adjusting air registers

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CHAPTER TITLE: SPECIAL PROCEDURES

Finally, up-date burner spares register.&blind registers

13.21 Procedure for burners assembly dropping

During dropping and placing burner assembly keep stack damper wide position to
prevent excessive pressure developing in the furnace

Remove Fuel-gas/Hot well off gas fire&oil and pilot fires&blind them. also
isolate air registers.

Disconnect pilot burner electrical power

Purge oil gun with steam for some time to prevent plugging with fuel-oil

purge steam valves are to be closed

Check burner in-side for oil accumulation through burner view ports

Use face shield and asbestos gloves during checking and dropping of burner
assembly

Keep burner drain at assembly open to drain oil inside, if any.

After removing all fires&closing air registers allow the burner to cool for 2to3hrs.
Disconnect oil&steam flexible hoses, drop oil gun

Drop Fuel-gas/pilot gas burners/tips with face shield and asbestos gloves soak it
in the soaking pit after cooling

Then drop the burner assembly for repairs&fix a plate at the bottom

Remove&replace damaged tips of the burners with new parts after checking
condition if any, before assembling after cleaning

Fix burner assembly after repairs&after removing plate at the bottom after taking
clearances from INSPECTION/TSD.

Fix Fuel-gas/Hot well off gas/pilot burners.connect oil burner flexible hoses&oil
gun.restore power to pilot burner

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CHAPTER TITLE: SPECIAL PROCEDURES

Deblind Fuel-gas/Hot well off gas lines pilot gas lines.

Ensure no leaks then keep Fuel-gas/Hot well off gas fire ensuring pilot gas fire in
side& adjusting air registers

Ensure no leaks for oil gun before placing oil fire.

Finally, up-date burner spares register.&blind registers

Modifications

All product sample points are provided with block v/v&globe v/vs

All products individual lines to slop are provided with check v/s provision to
prevent contamination due slop back-up.

CBD pump is provided to trip on LOW discharge Pr in addition to trip on LOW


level to PROTECT the pump.

42v21 steam generator o/l shell v/v was removed as per boiler inspection

LEL detectors changing to INFRARED type

RADAR TYPE LTs are provided

Advanced process controllers are incorporated for optimizing products


quality&yields.

Vb naphtha to DHDS line was commissioned

Vb naphtha to FCCU-2 line hook-up is to be made.

Off-sites feed booster (vbu) 120pc2201 is incorporated on cdu-3/vbu panel.

13.22 Centrifugal pumps start-up:


Inspect whether all the mechanical jobs are over.
No load test of the motor during decoupling condition.
De-energize the motor for coupling with pump.
Clean pump suction strainer and self coolant strainer (if any)
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CHAPTER TITLE: SPECIAL PROCEDURES


Establish bearing cooling water flow
Establish seal steam system.
Commission seals coolant systems to seals and check for leaks.
Check bearing housing oil level and check the oil content is free of
foreign material.
Rotate the shaft by hand for free movement.
Check the coupling guard intact or not.
Check the pump bay is clean and clear.
Check and remove all the foreign materials like cotton waste , used gaskets
And bolts lying in and around pump area.
Keep discharge valve and warm up valve in closed position. open suction
valve slightly and ensure that the casing is full of liquid by priming.
After wards keep the pump in warm up condition by opening warm up
valve slightly.
Check for leaks and open suction valve fully. Hot bolting of flanges are
to be done. Close the warm up valve.
Energize the motor and start the motor and check the pump direction ,
Rectify if the direction is incorrect.
Check the discharge pressure.
Open the discharge valve slowly while watch the discharge pressure
and Amps in the ammeter.
After steady state is attained check the flow ,temperature of the bearings
and vibration readings.
Check for gland\seal leaks for tightness.
CBD related blinds on pumps are to be blinded.
Update the blind register.
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CHAPTER TITLE: SPECIAL PROCEDURES

Shut down:
1. First close the discharge valve then only stops the pump. Then to keep
warm up
2. Condition warm up valve is to be opened slightly.
3. If the pump is to be released for maintenance proceed as follows
4. Close suction warm-up and discharge valves.
5. Close seal oil systems to pump.
6. Keep the pump for cool down.
7. Flush the pump content to CBD after rebinding the concerned blinds.
8. Depressurize the pump for blinding.
9. Close cooling water to bearings.
10. Close seal steam system.
11. Open pump bleeder and check for passing of valves before handing over
to maintenance for blinding.
12. Blind suction, Discharge, warm-up seal oil and seal steam systems.
13. Cut off electrical supply to pump motor before handing over to
maintenance.
14. Pump under repair signboard is to be tagged \displayed.

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CHAPTER TITLE: SPECIAL PROCEDURES

13.23 Trouble shooting problems:


A. Pump is not developing pressure due to improper priming or cavitation
1. Check bleed \vent pump casing.
2. Check the line up of the system \suction.
3. Check the suction strainer.
4. Check the level where the pump is taking suction.
5. Check pump coupling and pump rotation.
6. Check the temperature of the liquid.
B. Unusual sounds
1. Check coupling guards.
2. Check pump, motor fan gland and motor guard.
3. Check for pump cavitation.
4. Get it further checked by rotary after stopping the pump.
C. Raise of bearing temperature:
1. Improper lubrication due to low oil level
2. Insufficient bearing cooling water to bearing housing.
3. Stop the pump if the temperature is more than 75 0 C and inform to rotary to check
the pump and to do acid cleaning of BCW lines and bearing housing system.
D. Unusual sounds:
1. Check the foundation bolts.
2. Check the fan cover for looseness.
3. Stop the pump to check alignment.
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CHAPTER TITLE: SPECIAL PROCEDURES


E. Leaky glands:
1. Check pumps discharge pressure.
2. Tighten the gland nut slowly if possible.
I (a) Pumps / Turbines seal repairs:
1. Isolate suction, discharge and warm up valves
2. Allow the system to cool down and then flush it with cutter to CBD through
casing after removing blinds on cutter and CBD of the concerned.
3. After ensuring the stock becomes light depressurize it to CBD \OWS.Open pump
vent \D\d PG point value for proper depressurizing.
4. Blinding is to be done for proper isolation on S\C,D\S,warm up ,flushing oil ,seal
oil ,seal steam and CBD lines and update blinds register.
5. Isolate power to the pump.
6. Isolate steam to the turbine .If depressurize and blind it on steam side.
7. Issue permit, Decouple turbine \pump after ensuring the above.
8. Keep equipment under maintenance display board.
Note: disconnect instrument thermocouples as per rotary.
I (b) After the seal replacement on pump \ Turbine:
1. Check BCW, seal system, seal oil systems and remove any foreign materials in
and around pump \turbine basements
2. Remove blinds on s\c, d\s ,warm up , CBD, seal systems, seal oil and flushing oil.
Ensure proper gaskets are installed.
3. Close pump vent, open casing drain to OWS\CBD. Throttle pump discharge PG
drain valve to remove air.
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CHAPTER TITLE: SPECIAL PROCEDURES


4. Open flushing oil slightly to fill casing and to remove air from D\S PG point.
5. Once oil is coming through D\S PG point close it. Also close casing drain to
CBD\ows and check pump blind flanges with FLO Pr (9 Kg\Cm2) for leaks.
6. Depressurize the cutter to OWS\CBD and open pump warm up valve slightly for
warm up condition(only for hot service pumps).
7. Allow rotary to do hot alignment.
8. Allow maintenance to do hot bolting on blind flanges.
9. After hot alignment and coupling fixing, check for free movement of shaft.
10. Check no load before coupling as per rotary\Electrical and isolate power.
11. After ensuring all the jobs are over power to motor is to be released . Steam blind
to turbine is to be removed.
12. Check the direction of the motor while placing the pump\Turbine.
13. When all the above factors are ok place the pump \Turbine and see the
performance.
14. Keep casing drain to CBD\OWS blind.
15. Ensure updating of gaskets and blind registers.
16. Remove equipment under maintenance display board.
II (a) Pump \ Turbine suction strainers cleaning repeat steps 1,2,3,4,5,6 and 8.
(b) after pump\turbine suction strainers cleaned follow the steps 1,3,4,5,6,11,13,14,15
and 16.
III (a): LPG\ Naphtha pumps repairs:
1. Isolate suction, discharge and warm up valves
2. Isolate self-coolant lines.
3. Depressurize the content to flare through casing vent to flare.
4. Provide steam hose connection pump D\S PG point.
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Page No.: Page 44 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


5. After ensuring gas is depressurized close casing vent to flare, Open casing drain
to OWS and check if any gas is coming.
6. Observe passing of valves during depressuring to flare through

of lines.

7. Ensuring system is depressurized blind S\C,D\S ,self coolant ,casing CBD\OWS


and flare systems ,update blind register.
8. Isolate power to the pump and disconnect steam hose.
9. Issue permit to rotary to carry out the seal replacement job.
10. Keep equipment under maintenance display board.
Note: Inform instrument people to check and repair seal pot pressure and low level
switches if any.
III (B): When seal replacement job is over
1. Provide steam hose at pump D\S PG point.
2. Check self-coolant systems.
3.

Check and remove all foreign materials in and around pump basement area.

4. Remove blinds on S\C ,D\S, self coolant systems.


5. Open steam and pressure test the pump for blinding flange leaks.
6. Close vents and bleeders.
7. During slight steam purge open suction valve and casing vent to flare for some
time, and close steam completely.
8. Close casing vent to flare after some time.
9. Open casing drain to displace condensate if any.
10. Blind pump casing drain to OWS\CBD.
11. Check for no load test before fixing coupling as per rotary \ electrical.
12. When all jobs are over release power to motor and check direction of pump.
13. Place the pump online slowly and check the performance.
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CHAPTER TITLE: SPECIAL PROCEDURES


14. Ensure updation of blind and gasket registers.
15. Remove equipment under maintenance display board.
13.24 Depressurizing, Steaming and commissioning of coolers, condensers and
exchangers for tube leaks:
1. Isolate inlet and outlet valves. On shell and tube and open bypass valve.
2. Depressurize the content to CBD\OWS after removing blind.
3. Cooling water is to be depress red to intermediate sewer.
4. Provide steam connection on shell side vent and start initial steaming.
5. After ensuring sweat steam and non passing of isolation valves stop steaming and
blind both sides shell and tube inlet and outlet lines and update blind register.
6. Again carry out final steaming for 2 to 3 hrs then stop steam.
7. again put blinds.
8. Allow maintenance to carry tube leak jobs.
9. Care should be taken while bundle is pulled out and when fixing and dropping of
components.
For exchanger :
1. Isolate I\L ,O\L,warm up valves,TSVs on shell and tube sides and open bypass.
2. Steam connections are to be given to vents and depressurize to CBD\OWS on
both sides.
3. Ensuring sweat steam and non passing of isolation valves blind both shell and
tube sides I\L and O\l.
4. Release exchanger for dropping components after closing steam valve.
Disconnect it only after final steaming for 2 to 3 hours.
5. Blind CBD lines and update blind register.

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Page No.: Page 46 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

Commissioning of steam gens :


1.

After the maintenance jobs are over connect steam hoses on shell and tube side
vents.

2.

Deblind the shell and tube sides.

3.

Steam test the blinding flanges at 5 to 6 Kg\Cm2.

4.

When there is no leak deblind FLO and CBD blinds.

5.

Cutter flush to CBD\OWS.

6.

Remove all steam hoses and cap off vents.

7.

Build up levels in steam gens and V21 up to 30 %.

8.

Keep steam gen vents open.

9.

After filling with cutter displace cutter to CBD\OWS with SR through top of the
bundle.

10.

Ensuring cutter is displaced open I\L and O\L valves slightly keeping bypass in
wide open condition. Slowly open I\L and O\L valves and slowly close bypass of
one steam gen.

11.

Keep 42V21 warm up open.

12.

Observe steam gen pressure and temperature and slowly open steam O\L valves.

13.

Slowly close SR side bypass and steam gens one by one online.

14.

Close local vent and keep the steam pressure control on system finally.

15.

Check for leaks for flanges if any.

16.

Blind CBD\OWS and FLO lines.

17.

Update gasket and blind register.

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Page No.: Page 47 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

13.25 Hot well off gas routing to 42 F01 :


1. Check all hot well burners readiness.
2. Check the hot well off gas system from hot well to heater and flame arrestors.
3. Drain the liquid content at flame arrestor and catch pot.
4. Keep the hot well off gas plug cock in close position.
5. Reset hot well off gas SDV and check the system once again for leaks and free of
liquid content.
6. During this activity one person at heater one person at hot well and one person at
feed pumps PA has to coordinate with MOI person for effective operation .
7. Ensure the system is ok and light up pilots of hot well off gas burners and main
gas fires before routing hot well off gas.
8. Keep one hot well off gas burner plug cock valve open and close hot well vent
slowly.
9. Ensure hot well off gases are burning in the burner . Observe this flame then light
up all four burners.
10. Slowly close the hot well vent and observe the flame pattern in the heater.
11. Finally check the system and vacuum of the column after routing.

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Page No.: Page 48 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

13.26 ID fan placing :


Field observation :
Check readiness of ID fan for lube oil level,motor,suction and discharge dampers
openings, cooling water and circulating oil systems , foreign material removal and
stack damper opening.

MOI observation :
1. Check whether the furnace arch temperature is >400
2. Keep fuel cutoff .
3. Keep ID fan fail bypass and interlocks in bypass mode.
4. start the fan from field.
5. Load the fan from PC5007 after resetting.
6. Observe the RPM, loading indication and check in the field about shaft
movement.
7. Slowly increase the loading to increase the temperature of APH gradually.
8. Once the temperature of APH reached to the normal state ,then damper can be
closed.

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Page No.: Page 49 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

13.27 Introduction of bottom stripping steam to the columns(Atmos ans vac):


1. During the introduction of bottom stripping steam to the column ensure whether
the shell valve , C\V,B\P and D\S isolation valves are closed or not.
2. Before introduction of steam drain the condensate from U\S and D\S bleeders of
the C\V.
3. After ensuring that the system is condensate free open the C\V by 2 to 3 % and
ensure dry steam from the drains.
4. Then Crack open the shell valve of the column.
5.

Open shell valve and control valve gradually for the introduction of steam to the
column.

6. Check whether oil is being backed up during this activity.


7. Slowly establish the steam flow.
8. Finally check for leaks.
Crude feed pump change over procedure:
1. First take clearance from CPP as it is a HT pump.
2. Check all the parameters like BCW, seal stream ,self coolant system ,suction
valve opening and discharge valve closed position.
3. Check the pump basement for foreign materials removal.
4. Inform the field person to start the pump after CPP clearance.
5. Start the pump and adjust the discharge pressure around 27 Kg\Cm 2 by opening
the discharge and simultaneously close the running pump discharge valve
gradually so that the discharge pressure PT1111 is maintained at 27 Kg\Cm 2 , also
watch the amps of the two pumps
This document contains proprietary confidential information and is the sole property of HPCL-Visakh Refinery operations department and must not
be disclosed to others or reproduced in any manner or used for any other purpose whatsoever without its written permission from appropriate
authority

VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 50 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


6. When the running pump discharge is fully closed and amps become lower side
stop the feed pump after taking permission from control man in MOI.
7. check for leaks after changeover of pumps.
13.28 Crude feed booster pump change over procedure:
1. Check all the parameters like BCW, seal stream, self coolant system, suction
valve opening and discharge valve closed position.
2. Ensure the discharge is fully closed and in warm up condition.
3. Close warm up after readiness of pump and motor, take out feed pass C\V from
APC mode to operator mode.
4. Reduce Desalter pressure to 11.5 Kg\Cm2
5. Keep pass flow low low and Desalter low pressure trip in bypass mode during this
activity.
6. Take clearance from CPP, as it is a HT pump.
7. Start the pump and adjust the discharge pressure around 32 to 34 Kg\Cm 2 by
opening the discharge and simultaneously close the running pump discharge valve
gradually so that the discharge pressure 42PT1112 is maintained at 11 to 12
Kg\Cm2, also watch the amps of the two pumps.
8. When the running pump discharge is fully closed and amps become
Lower side stop the feed pump after taking permission from control man in MOI.
9. Check for leaks after changeover of pumps.
10. Keep the stand by booster pump warm up condition.
11. Place necessary trips online after the activity.

This document contains proprietary confidential information and is the sole property of HPCL-Visakh Refinery operations department and must not
be disclosed to others or reproduced in any manner or used for any other purpose whatsoever without its written permission from appropriate
authority

VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 51 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

13.29 Power failure:


1. Open Atmos flare control valve bypass to control the top pressure by observing
the 42V13 O\H pressure gauge.
2. Stop all pumps and take out all fires.
3. Bypass Desalter and close water injection.
4. Close all product rundown valves.
5. Stop all stripping steams to columns and product strippers, Vac ejectors steam and
chemical injections.
6. Close V21 BFW shell valve.
7. Open hot well vent and close all hot well off gas valves to 42F01.
8. Bypass stabilizer and close LD CR to reboiler
Note: Check whether all related trip interlocks are activated or not during the
emergency.

This document contains proprietary confidential information and is the sole property of HPCL-Visakh Refinery operations department and must not
be disclosed to others or reproduced in any manner or used for any other purpose whatsoever without its written permission from appropriate
authority

VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 52 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

13.30 Fluid coupling oil coolers change over ;


Each fan is having two coolers for circulating oil. One is in online and other is stand
by. If the online cooler performance is poor then the stand by is to be taken online to
reduce circulating oil temperature.
The following steps are to be followed
1. Keep FD FAN A fail bypass , FD FAN B fail bypass FD FAN A\B fail bypass and
interlocks PB5051,PB 5057 in bypass mode.
2. Combustion air fail PB 5053 in bypass.
3. Fuel cutoff in bypass(PB 5055)
4. Keep stack damper in open condition.
5. Then establish cooling water flow through stand by cooler by pinching down 3
way valve on inlet and outlet lines with out affecting flow to running fan.(observe
42FT5012).
6. Same way adjust circulating oil flow by watching the meter 42FT5010.
7. Adjust flows on water and oil and slowly close the flows through running cooler
and increase stand by cooler. Finally establish flows through the stand by cooler.
This way the fan does not get starvation of flows either on circulating oil or water
side.
8. Then check the temperature physically and also observe leaks on the system.
9. Finally keep all trips in online position.

This document contains proprietary confidential information and is the sole property of HPCL-Visakh Refinery operations department and must not
be disclosed to others or reproduced in any manner or used for any other purpose whatsoever without its written permission from appropriate
authority

VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 53 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

13.31 FD fan Change-over


Change over from FAN A to FAN B
Check list:
1. Check the running indication of both the fans and their discharge damper open
indication.
2. On the hardware panel, check the discharge damper open / Close switch
indication .The running fans switch should be in open state and the standby fans
switch in closed state. In case of mismatch/Difference change the switch to match
the same.
3. Check the stack damper opening % age (HS5006/5106) and whether it tallies with
stack damper open indication. If not change HC value to 100 % irrespective of
whether damper indication is there or not.
4. Put combustion air fail, Fan A fail, Fan B fail and Fan A/B fail hardware switches
in bypass mode. This will bypass the interlock.
5. For both fans put air flow control in manual mode and change the selector switch
(HS5001/5002) to hand control mode (HC5001, 5002) for fan loading.
6. After steps 1 to 5, Check all the parameters and in the hardware panel put heater
in Turndown bypass mode ( Switch vertical to horizontal)
Note : In case the running fan A had also cut in at some earlier time, after putting in
turndown bypass , all solenoids will get energized and both fans discharge dampers
may close if the hardware switch is not in open condition.
To do:
1. After putting in turndown bypass, reduce standby fanB loading to 2-5 %
2. Start the standby fan in field
3. Reset fan B loading and open discharge damper of fan B.
4. Increase fan B loading in gradual steps of 2 % and reduce fan A loading in a
similar fashion. this might result in internal circulation of air and momentary low
combustion air to furnace.
5. Slowly go up on fan B loading to restore normal air flow and continue to reduce
fan A loading. Continue till fan B has taken full load.
6. Close fan A discharge damper after reducing fan loading to minimum. If all in OK
stop fan A from hardware panel.
7. After fan A has tripped restore fan loading to a value almost equal to running fan.
This document contains proprietary confidential information and is the sole property of HPCL-Visakh Refinery operations department and must not
be disclosed to others or reproduced in any manner or used for any other purpose whatsoever without its written permission from appropriate
authority

VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 54 of 55

CHAPTER TITLE: SPECIAL PROCEDURES


8. Put all the trips online. Fan A fail in bypass state and Fan B fail in online state.
Fan a/B fail should also be bypassed. Combustion air fail in online position.
9. In the end put turndown in activation mode (Vertical switch)
Note: During entire operation stack damper open indication should be there and
damper opening (HC value) should be 100%.
For opening stack damper always use software switch in the DCS. Operate Hard ware
switch only during emergency.

This document contains proprietary confidential information and is the sole property of HPCL-Visakh Refinery operations department and must not
be disclosed to others or reproduced in any manner or used for any other purpose whatsoever without its written permission from appropriate
authority

VISAKH REFINERY

Doc. No. OPM /CDU-III


Rev. 1
Rev. Date: 01/04/2007
Page No.: Page 55 of 55

CHAPTER TITLE: SPECIAL PROCEDURES

This document contains proprietary confidential information and is the sole property of HPCL-Visakh Refinery operations department and must not
be disclosed to others or reproduced in any manner or used for any other purpose whatsoever without its written permission from appropriate
authority

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