Operating Manual For Sws Unit No.08: Persian Gulf Star Oil Company REF - No.: 3034-PR-MAN-AA014-A1

REF.No.
: 3034-PR-MAN-AA014-A1
PERSIAN
GULF STAR
OIL COMPANY DOCUMENT CODE PAGE 1 OF 48
PLAN/PRJ UNIT PHASE DISC. DOC. TYPE SER. No. REV. No DATE
PROJECT:
BANDARABBAS
GAS CONDENSATE
3034 08 ED PR MAN AA014 A1 24JULY 2014
REFINERY
OPERATING MANUAL for SWS UNIT NO.08
A1 24 JUL 2014 FINAL ISSUED Gh.Aghakhani A.Reshad H.Dehghan

A0 15 JUL 2012 ISSUED FOR APPROVAL Gh.Aghakhani A.Reshad H.Dehghan
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
Subcontractor Name: NARDIS

REF.No.: 3034 -PR-MAN-AA014-A1
OPERATING MANUAL for PAGE 2 OF 48

SWS UNIT NO.08
Revision Index
Rev. A0 A1 A2 A3 A4 B0 B1 Rev. A0 A1 A2 A3 A4 B0 B1
Sheet Sheet
1 × × 36 ×
2 × × 37 ×
3 × × 38 ×
4 × × 39 ×
5 × × 40 ×
6 × × 41 ×
7 × × 42 ×
8 × × 43 ×
9 × × 44 ×
10 × × 45 ×
11 × × 46 ×
12 × × 47 ×
13 × × 48 ×
14 × × 49
15 × × 50
16 × × 51
17 × × 52
18 × × 53
19 × × 54
20 × × 55
21 × × 56
22 × × 57
23 × × 58
24 × × 59
25 × × 60
26 × 61
27 × 62
28 × 63
29 × 64
30 × 65
31 × 66
32 × 67
33 × 68
34 × 69
35 × 70

SWS UNIT NO.08
Table of Contents
1. INTRODUCTION 4
2. DESIGN BASIS 4
3. BRIEF PROCESS DESCRIPTION 4
4. OPERATING VARIABLE AND CONTROLS 8
5. AUXILIARY SYSTEMS 8
6. EQUIPMENT OPERATION 11
7. EQUIPMENT SUMMERY 12
8. INSTRUMENTATION AND CONTROL 18
9. START-UP PROCEDURE 24
10. PLANNED SHUTDOWN 27
11. NORMAL OPERATION 28
12. EMERGENCY SHUTDOWN 29
13. SAFETY 31
14. ANALYTICAL TESTS 40
15. ATTACHMENT 41

SWS UNIT NO.08
1. INTRODUCTION
The Process flow sequence, arrangement of process equipment, major control scheme &
heat and material balance for Sour Water Stripping Unit No. 08 are shown in the Heat &
Material Balance (3034-08-ED-PR-HMB-AA001) and Process Flow Diagrams (3034-08-ED-
PR-PFD-0001&2).
Sour water stripping unit will remove Hydrogen Sulphide (H2S), Ammonia (NH3), and traces
of hydrocarbons from all sour effluents of refinery. Two parallel identical sour water stripping
units have been proposed in the refinery.
Each sour water stripper unit has been designed to process 46907 kg/hr of sour water. The
stripped water from the unit will be used in the process units as wash water and the balance
stripped water will be routed to Waste Water Treatment Plant while the acid gas is sent to
Sulfur Recovery Unit (SRU) for sulfur recovery.
The operating procedures presented here cover start-up procedures, normal operating
conditions, shut-down procedures and safety aspects of the unit. These instructions are
intended as guidelines and reference for the Detailed Engineering Contractor to take care
during Detailed Engineering stage and to firm up the operating procedures to be included in
the plant operating manual. Reference is made to the drawings and equipment
specifications furnished in the earlier sections. These specifications relate only to the
process design. For details beyond these, reference should be made to appropriate
mechanical specifications and manufacturer's instruction, etc. The special procedure
furnished by the equipment manufacturers must be kept in mind while firming up the
operating procedure. The operating conditions mentioned in the PFD and data sheets are
based on design feed compositions. Hence these conditions may have to be adjusted as
per the operating necessities from time to time. Start-up and shutdown are the most critical
periods in plant operation. It is then that the hazardous possibilities for fire and explosion
are the greatest.
2. DESIGN BASIS
Refer to “Basic Engineering Design Data” (3034-00-ED-PM-DBS-AA002) and NIOEC-SP-
00-50.
3. BRIEF PROCESS DESCRIPTION

The sour components such as NH3 (base) and H2S (acid) in sour water are partially
present in ionic form and are in equilibrium with molecular form as given by the following
equation:
NH3 + H2S NH4+ + HS-
The sour water stripping is based on the application of heat to strip the molecular form of
H2S and NH3 from water and pushing the above reaction to the left. Counter current
contact in a multi stage column is provided to facilitate the stripping with rising steam vapor
from reboiler.

SWS UNIT NO.08
There are two sour water stripping units (SWS unit08 & SWS unit58) of the same
configuration which are designed to treat total sour water produced in following process
units:
• Condensate Distillation units (3 trains)
• Naphta Hydrotreating units (3 trains)
• Kerosene Hydrotreating unit (1 train)
• Gas oil Hydrotreating units (2 trains)
• Sulphur Recovery Unit-TGT (1 train)
• Amine Treating Units (2 trains)
Each Sour Water Stripping Unit is comprised of feed surge drum, one day storage tank, a
stripper column with pump-around and kettle type steam reboiler.
Refer to process flow (3034-08-ED-PR-PFD-0001 &2) and Process and Instrumentation

Diagrams 3034-08-ED-PR-PID-0104 to 3034-08-ED-PR-PID-0111for details.
3.1 SWS FEED SURGE DRUM (VH-0801)
Sour waters from all the process units are combined in a header and split into two equal
streams under flow control. In Sour Water Stripper Unit 08 (SWS 08) the sour water feed at
54 deg C to the unit is received in an elevated feed surge drum (VH-0801) which is floating
with the stripper column overhead at 1.1 barg pressure. High pressure alarm is provided on
the surge drum to detect the over pressurization of the drum. This drum is a three phase
separator designed to remove oil and vapor from the inlet water stream. The flashed vapor
phase is vented to sulphur recovery unit along with the stripper overhead vapors. The
entrained hydrocarbon liquid, if any, is separated through a partition baffle inside the drum
and drained to Oily Water Sewer (OSW) periodically.
The sour water is collected on the other side of the partition baffle. The surge drum is
provided with a nitrogen connection to maintain drum pressure in case of low pressure.

SWS UNIT NO.08
3.2 SOUR WATER DAY TANK (TK-0801)
The sour water from Surge Drum (VH-0801) is routed to Sour water Day Tank (TK-0801)
through an inverted U line which provides a water seal to avoid over pressurization of the
Day Tank. The tank capacity is equivalent to one day unit hold up. Provision of storage tank
in the unit provides operational flexibility of uninterrupted operation of upstream process
units or draining of sour water to WWT (Waste Water Treatment) during short shut down
since large numbers of units are feeding sour water to SWS. The tank is maintained at
slightly positive pressure by blanketing with N2 to prevent the release of vapors containing
H2S and NH3 during out breathing. The excess vapors released from the tank are routed to
incinerator stack located in SRU through a PSV/PCV for safe disposal. A floating skimmer is
provided inside the sour water tank to remove any floating oil which is routed to OSW.
3.3 FEED/BOTTOM EXCHANGERS (E-0801 A/B)
The sour water free of hydrocarbons from Sour Water Day Tank (TK-0801) is pumped by
Stripper Feed Pumps (P-0801 A/B) to the Stripper Column (CC-0801) under flow control
cascaded with FRC on steam line. Prior to entering stripper, the sour water is preheated up
to 95 degree C by counter current heat exchange with the bottom hot stripped water in E-
0801A/B. The flow control valve assembly is located close to the inlet of CC-0801 to
minimize two phase line.
3.4 STRIPPER COLUMN (CC-0801)
The Stripper column is provided with 39 trays. The feed enters the column at 24th tray
which is the normal feed location for this column. An alternative tray location at tray number
32 is provided in case of high ammonia/hydrogen sulphide from upstream units.
The high ammonia in feed streams requires higher number of trays due to its lower volatility
as compared to hydrogen sulphide. The high ammonia is expected in sour water generated
in Naphtha Hydrotreater. Naphtha Hydrotreater is normally operated without any wash
water. The wash water is to be used once a week to wash any salts formed in NHT air
condenser followed by trim condenser. These salts are made of ammonia and hydrogen
sulphide. In case of high ammonia in feed to sour water stripper, feed tray location at tray
#32 should be used.
The stripper column operates at the top pressure of 1.1 barg and pressure is controlled by a
control valve located on the line of acid gas to SRU. A high set point pressure control valve
is also provided for routing any excess gas to Acid Gas Flare. The column top temperature
is controlled at 90 deg C through pump-around stream flow and air cooler outlet
temperature control.
The overhead product is essentially H2S and NH3 rich sour gas and is routed to SRU
through a steam jacketed line for further processing.

SWS UNIT NO.08
The column is provided with overhead pump-around circuit consisting of recirculating

pumps (P-0802 A/B) and Air Cooler (E-0803). A chimney tray (tray #33) is provided at the
bottom of the pump-around section to provide the required hold up for pump-around pumps.
The circulating reflux is drawn from tray # 33 and returned to tray # 39 under flow control,
after cooling in the air cooler (E-0803).
The descending sour water and cooled pump around liquid counter currently contacts with
the rising vapor from the kettle type reboiler (E-0802). In this process, essentially all the
ammonia and hydrogen sulphide is stripped and concentrated in overhead vapor. The
reboiler uses desuperheated LP steam as heating medium. The LP steam flow to reboiler is
controlled by flow ratio controller which is reset by the sour water feed flow controller.
The bottom temperature is maintained at a temperature of 127.5 deg C which is governed

by the column pressure. LP steam condensate is collected in the condensate pot (VV-
0801). The condensate pot also provides partial flooding of reboiler in case the unit is
operated at turn down. The steam condensate is routed to Amine unit for condensate
recovery under level control of the condensate pot (VV-0801).
The stripped water free from ammonia and hydrogen sulphide from the bottom of the
stripper is pumped by Stripper Bottom Pumps (P-0803 A/B) under column bottom level
control and is normally routed to Condensate Distillation unit and Hydrotreaters (NHT,KHT,
GOHT) as wash water and the balance stripped water is discharged safely to Waste Water
Treatment Unit. The stripped water is cooled in stripped water air cooler (E-0804) and trim
cooler (E-0805) to 45 deg C before sent to battery limit.
3.5 BLOW DOWN DRUM (VH-0802)
The sour water drains from the equipments, lines, instruments etc inside the battery limit of
SWS unit is collected in sour water blow down drum (VH-0802). The sour water from the
Blow Down drum is pumped to Day Tank (TK-0801) for processing. The Drum is directly
floating on the acid Gas Flare line.

SWS UNIT NO.08
4. OPERATING VARIABLE AND CONTROLS
4.1 PRESSURE
The pressure of the material in the stripper should be as high as possible, and is primarily
limited by the pressure at which the charge streams are variable .the set point of the
pressure controller should be set so the inlet pressure or limiting the optimum steam rate
when liquid flow rate is at its design.
4.2 FLOW RATE
Steam rate through flow control valve is adjusted by hand control and should be set at
design rate.it may by varied according to experience , if desired , so that if adequate
removal of sulphides can be obtained at reduced steam rates, this may be done.
5. AUXILIARY SYSTEMS
5.1 UTILITY SUMARY
Consumption of cooling water, electrical power,steam, condensate; and fuels is tabulated

as follows

SWS UNIT NO.08

SWS UNIT NO.08

SWS UNIT NO.08
6. EQUIPMENT OPERATION
6.1 CENTRIFUGAL PUMPS
Many centrifugal pumps have sustained damage to mechanical seals, bearings, wear rings
drivers, etc, because of improper operating procedures. To minimize damage, operating
procedures are listed below:
6.1.1. STARTUP PROCEDURE
• Close all bleeders in suction and discharge lines.

• Open water valves to water jackets (if any) and to the packing glands.
• Check pump lubrication.
• Be sure suction valve is opened as wide as possible and that discharge valve is closed on
pump.
• Open vent to displace air and vapors; then close.
• On hot oil pumps, allow hot liquid to circulate through pump to bring pump up as near to
operating temperature as possible.
• Open discharge valve slightly.
• After pump is filled with liquid, start pump. Check for unusual noises and vibrations.
• When pump is up to normal speed slowly full open discharge valve.
• Stand by for several minutes to see that bearings, seals, or packing are not overheating
6.1.2. SHUT DOWN PROCEDURE
• Close discharge valve (pump).

• Stop pump quickly after discharge valve is closed.
• Close pump suction valve.
• Close off cooling water and seal oil (if any).
• Drain case of pump if required.
6.2 HEAT EXCHANGERS
When an exchanger is to be put in service, the following steps should be carried out:
• Drain water from shell and tube sides. Close drain valve.
• Deblank shell and tube inlets and outlets.
• Crack open inlet and outlet valves on cold fluid and fill up the exchanger slowly. Drain or vent
off vapors, etc.
• Crack open inlet and outlet valves on hot fluid and fill up exchanger slowly.
• Open inlet and outlet valves on shell and tube sides.
In the case of water cooled exchangers, always keep inlet water valve fully open. the water outlet
valve should be opened as much as to give the required water outlet temperature.
• f. Check pressure drop and heat transfer rates.

SWS UNIT NO.08
7. EQUIPMENT SUMMERY
7.1 E-0803 (Pump Around Air Cooler)
E-0803 (Pump Around Air Cooler)

Duty 4670 kw
Design Pressure 12.8 barg/FV
Design Temperature 160 C
Bare Surface 330 m2
Driver Number Per Item 2
Driver Type Electric Motor
Power Installed 68 kw
Especial Requirement Toxic Fluid
Finned Tube Type Extruded
Bundle Number Per Item 2
Overall Dimension Per Item
6.65 x 9.3 m
(WedthxLength)
Material SS316L (for bare tube and heads)
Corrosion Allowance 0.75 mm
Mass 62940 kg
7.2 E-0804 (Trim Air Cooler)
E-0804 (Trim Air Cooler)

Duty 1500 kw
Design Pressure 20.3 barg/HV @ 130
Bare Surface 109 m2
Driver Number Per Item 2
Driver Type Electric Motor
Power Installed 40 kw
Especial Requirement Toxic Fluid
Bundle Number Per Item 2
Overall Dimension Per Item
2.94 x 9.3 m
(WedthxLength)
Material KCS (for bare tube and heads)
Corrosion Allowance 3 mm
Mass 62940 kg

SWS UNIT NO.08
7.3 CC-0801 (Sour Water Stripper)
CC-0801 (Sour Water Stripper)

Type Trayed Column
Design Pressure 3.9 barg/FV
MDMT 2C
Internal Diameter 1700 m
Height 34775 mm
Tray Number 39
X. ray Yes
Material KCS
Internal Material SS316L
Clad SS316L (top, tray 23and above)
Mass 64406 kg
Insulation Yes
7.4 E-0801 (Feed/Bottom Exchanger)
E-0801 (Feed/Bottom Exchanger)

Shell Side/Tube Side Service Stripped Water/Sour Water
Number of Shell 2 in Series
Duty 2210 kw
Tema Type AES
Shell Side/Tube Side Design Pressure 20.3 barg-HV @ 130 / 15.5 barg-HV @ 130
Shell Side/Tube Side Design Temperature 160 C/128 C
Shell Side/Tube Side MDMT 2 C/ 2C
Shell ID 438.16 mm
Tube Length 4877 mm
Tube OD 19.05
Surface Per Shell 43.77 m2
Shell Side/Tube Side Material KCS / SS316L
Mass Per Shell 2148 kg

SWS UNIT NO.08
7.5 E-0802 (Stripper Reboiler)
E-0802 (Stripper Reboiler)

Shell Side/Tube Side Service Stripped Bottom/LP Steam
Number of Shell 1
Duty 6500 kw
Tema Type AKU
Shell Side/Tube Side Design Pressure 5.5-FV-/7.2 barg-FV
Shell ID 1295/1800 mm
Tube Length 7315 mm
Tube OD 19.05
Surface Per Shell 857 m2
Shell Side/Tube Side Material KCS / SS316L
7.6 E-0805 (Stripper Water Trim Cooler)
E-0805 (Stripper Water Trim Cooler)

Shell Side/Tube Side Service Stripped Sour Water/Sea Cooling Water
Number of Shell 1
Duty 810 kw
Tema Type AES
Shell Side/Tube Side Design Pressure 20.3 barg-HV@130C/15.5 barg-FV@85C
Shell ID 620 mm
Tube Length 6096 mm
Tube OD 19.05
Surface Per Shell 123.4 m2
Shell Side/Tube Side Material KCS / Ti

SWS UNIT NO.08
7.7 DS-0801 (LP Steam Desuperheater)
DS-0801 (LP Steam Desuperheater)

Max LP Steam Flowrate 11985 kg/hr
Max Boiling Feed Water Flowrate 957 kg/hr
Material Body:KCS Internal:SS316L
Design Pressure 7.2 barg-FV@100C
7.8 P-0801 (Stripper Feed Pump)
P-0801 (Stripper Feed Pumps)

Type Centrifugal Vertical
Quantity Main/Spare 1 /1
Capacity Normal/Design 47.8 / 52.6 m3/hr
Suction Pressure 0.047 barg
Discharge Pressure 8.55 barg
Fluid Operating Temperature 54 C
Differential Head 88.5 m
Fluid Density 980.8 kg/m3
Available NPSH 126 m
Estimated BHP 22.2 kw
Material Casing/Impeller SS316L / SS316L
Toxic Fluid Yes
Total Mass 700x2 kg
7.9 P-0803 (Stripper Bottom Pump)
P-0803 (Stripper Bottom Pump)

Type Centrifugal Horizontal
Capacity Normal/Design 49.6 / 54.6 m3/hr
Fluid Operating Temperature 128 C
Differential Head 139 m
Fluid Density 937.3 kg/m3
Available NPSH 4.5 m
Toxic Fluid Yes
Total Mass 1435x2 kg

SWS UNIT NO.08
7.10 P-0804 (Sour Water Blow Down Pump)
P-0804 (Sour Water Blow Down Pump)

Type Centrifugal Vertical(Submerged)
Capacity Normal/Design - / 10 m3/hr
Fluid Operating Temperature 30-128 C
Differential Head 416 m
Fluid Density 1000-940 kg/m3
Available NPSH 14.12 m
Toxic Fluid Yes
Total Mass 800x2 kg
7.11 EJ-0801 (Sour Water Close Drain Sump Ejector)
EJ-0801 (Sour Water Close Drain Sump Ejector)

Capacity Normal/Design - / 10 m3/hr
Suction Pressure -0.55 barg
Design Pressure 7.2 barg/FV @ 100 C
Fluid Density 1000 kg/m3
Material Diffuser/Nozzles CS / SS316
7.12 TK-0801 (Sour Water Day Tank)
TK-0801 (Sour Water Day Tank)

Type Atmospheric / Cone Roof
Geometric Capacity 1400 m3
ID x Height 12500 x 11410 mm
MDMT 2C
Design Pressure Positive Full of Liquid+150 mmwc / Vacuum 50 mmwc
Material KCS (Severe Wet H2S service)
PWHT Yes
Insulation No
Heater/Mixer No / No
Total Mass 68500 kg

SWS UNIT NO.08
7.13 VH-0801 (Sour Water Surge Drum)
VH-0801 (Sour Water Surge Drum)

Type Horizontal
Geometric Capacity 1400 m3
ID x Height 2400 x 9800 mm
MDMT 2C
Design Pressure 3.5 barg
Material KCS (Severe Wet H2S service) /Internal 316L
PWHT Yes
Insulation Yes
Heater/Mixer No / No
Demister No
Boot No
Total Mass 14307 kg

SWS UNIT NO.08
8. INSTRUMENTATION AND CONTROL
8.1 LOGIC DIAGRAM
TYPICAL 2A
TRIP
GZAY
o o o
xx.n
o
o
CURRENT IIY HZYY IZ HZSY
INDICATOR M
xx.n (NOTE 3) xx.nA
(MV MOTORS ONLY)
TRIP CIRCUIT, WHEN REQUIRED
GSY (NOTE 2)
HYY (NOTE 2)
STOP
MANUAL
HSHY o o o HSY
o o o
xxn.N I xxn.A
NOTES:
1- INDICATION AND COMMANDS EXIST ONLY IF SHOWN ON P&ID. GLY
o o o
o
2- THE FOLLOWING SIGNALS FROM/TO DCS LOGIC TO/FROM MCC SHALL BE CONSIDERED: xx.nA
RUNNING THE LOOP SHALL BE IDENTIFIED AS MY-uuxx.n WHERE:
o
STOP COMMAND HYY-xx.nA (DIGITAL OUTPUT) (IF REQUIRED BY LOGIC) MY = MP(PUMPS), MC(COMPRESSORS),MX (MIXERS), ME (AIR COOLERS),MBL (FANS),etc.
START COMMAND HYY-xx.nB (DIGITAL OUTPUT) (IF REQUIRED BY LOGIC) uu = UNIT
o
RUNNING STATUS GSY-xx.nA (DIGITAL INPUT) GLY o o o xx = EQUIPMENT SERIAL NUMBER

LOC/REM STATUS GSY-xx.nB (DIGITAL INPUT) xx.nB n = EQUIPMENT SUFFIX (IF USED)
o
NOT AVAILABLE ALARM GSY-xx.nC (DIGITAL INPUT)

ELECTRICAL FAULT ALARM GSY-xx.nD (DIGITAL INPUT) LOC/REM
o
LOC/REM STATUS IS DEPENDENT FROM THE POSITION OF THE MOTOR A/M FIELD SWITCH. GAY o o o
FIELD SWITCH IN "MAN" MEANS LOCAL CONTROL. FIELD SWITCH IN "AUTO" MEANS REMOTE CONTROL. xx.nC
o
NOT AVAILABLE
o
3- THE FOLLOWING SIGNAL FROM ESD LOGIC TO MCC SHALL BE CONSIDERED.

GAY o o o
TRIP COMMAND HZYY-xx-n (DIGITAL OUTPUT) xx.nD
ELECTRICAL FAULT
(MV MOTORS ONLY)
4- SIGNALISATION "AVAILABLE" WILL SUMMARIZE THE FOLLOWING INFORMATION.
- MOTOR NOT TRIPPED

- NOT IN ELECTRICAL FAULT
- REMOTE OPERATION SELECTED
5- LOCATE START/STOP PUSH BUTTON AT AIR COOLER PLATFORM.

6- MOTOR PROVIDED WITH AUTOSTART FACILITIES.
7- LOCATE START/STOP PUSH BUTTON AT FIELD.
TYPICAL INSTRUMENTS LOOP 2A- LV/MV MOTORS
ESD DCS
MOTOR TAG P&ID N° TRIP EMERGENCY REMOTE TRIP INTERLOCK REMOTE STOP NOT AVAILABLE REMOTE LOC/REM REMOTE CURRENT NOTES
LOGIC STOP ESD INDICATION LOGIC HAND SWITCH INDICATION RUNNING INDICATION ELECTRICAL INDICATOR
PANEL INDICATION FAULT (MV MOTORS ONLY)
HZSY GZAY HSY GAY GLY GLY GAY
IZ I IIY
xx.nA xx.n xx.nA xx.nC xx.nA xx.nB xx.nD xx.n
xxx xxx
ME-0803-1 3034-08-ED-PR-PID-0109 007 - GZAE-03-1 002 HSE-03-1A GAE-03-1C GLE-03-1A GLE-03-1B - - NOTE 5
ME-0855-A-1 3034-08-ED-PR-PID-0156 511 - GZAE-55-A-1 004 HSE-55-A1A GAE-55-A1C GLE-55-A1A GLE-55-A1B - - NOTE 5
ME-0855-A-2 3034-08-ED-PR-PID-0156 511 - GZAE-55-A-2 004 HSE-55-A2A GAE-55-A2C GLE-55-A2A GLE-55-A2B - - NOTE 5
ME-0855-B-1 3034-08-ED-PR-PID-0156 511 - GZAE-55-B-1 004 HSE-55-B1A GAE-55-B1C GLE-55-B1A GLE-55-B1B - - NOTE 5
ME-0855-B-2 3034-08-ED-PR-PID-0156 511 - GZAE-55-B-2 004 HSE-55-B2A GAE-55-B2C GLE-55-B2A GLE-55-B2B - - NOTE 5
MP-0801-A 3034-08-ED-PR-PID-0105 002 - GZAP-01-A 001 HSP-01-AA GAP-01-AC GLP-01-AA GLP-01-AB - -
MP-0801-B 3034-08-ED-PR-PID-0105 002 - GZAP-01-B 001 HSP-01-BA GAP-01-BC GLP-01-BA GLP-01-BB - -
MP-0802-A 3034-08-ED-PR-PID-0110 004 - GZAP-02-A 005 HSP-02-AA GAP-02-AC GLP-02-AA GLP-02-AB - - -
MP-0802-B 3034-08-ED-PR-PID-0110 004 - GZAP-02-B 005 HSP-02-BA GAP-02-BC GLP-02-BA GLP-02-BB - - -
MP-0804-A 3034-08-ED-PR-PID-0111 005 - GZAP-04-A 007 HSP-04-AA GAP-04-AC GLP-04-AA GLP-04-AB - - NOTE 6
MP-0852-A 3034-08-ED-PR-PID-0160 507 - GZAP-52-A 013 HSP-52-AA GAP-52-AC GLP-52-AA GLP-52-AB - - -
MP-0852-B 3034-08-ED-PR-PID-0160 507 - GZAP-52-B 013 HSP-52-BA GAP-52-BC GLP-52-BA GLP-52-BB - - -
MP-0855-A 3034-08-ED-PR-PID-0157 508/502 - GZAP-55-A 011 HSP-55-AA GAP-55-AC GLP-55-AA GLP-55-AB - -
MP-0855-B 3034-08-ED-PR-PID-0157 508/502 - GZAP-55-B 011 HSP-55-BA GAP-55-BC GLP-55-BA GLP-55-BB - -
PK-0851-MP1A 3034-08-ED-PR-PID-0165 513/022A HZSPK-51-A GZAPK-51-A 015A HSPK-51-P1AA GAPK-51-P1AA GLPK-51-P1AA - - - NOTE 7
PK-0851-MP1B 3034-08-ED-PR-PID-0165 513/022B HZSPK-51-B GZAPK-51-B 015B HSPK-51-P1BA GAPK-51-P1BA GLPK-51-P1BA - - - NOTE 7
PK-0852-MP1A 3034-08-ED-PR-PID-0166 514/023A HZSPK-52-A GZAPK-52-A 017A HSPK-52-P1AA GAPK-52-P1AA GLPK-52-P1AA - - - NOTE 7
PK-0852-MP1B 3034-08-ED-PR-PID-0166 514/023B HZSPK-52-B GZAPK-52-B 017B HSPK-52-P1BA GAPK-52-P1BA GLPK-52-P1BA - - - NOTE 7
PK-0851-MX1 3034-08-ED-PR-PID-0165 513 - - 015 HSY-51CA GAY-51CC GAY-51CA - - - NOTE 7
PK-0852-MX1 3034-08-ED-PR-PID-0166 514 - - 017 HSY-52CA GAY-52CC GAY-52CA - - - NOTE 7

SWS UNIT NO.08
TYPICAL 4A
RESET CLOSE CLOSE RESET RESET CLOSE

UZHS UZHS UZHS UZHS UZHS UZHS
zzzE zzzD zzzA zzzB zzzC zzzF
(NOTES 1,4) (NOTES 1,2,5) (NOTES 1,4,5) (NOTES 1,4) (NOTES 1,3) (NOTES 1,3,5)
o
o
o
o
o
o o o o o
IZ o o o o o o o o
o o o o o o o o o UZZLH
o o o o o o zzz
o
UZEV o o o UZZLL
UZEV zzzB zzz
zzzA
// // // // // //
ISA // //
//
//
//
UZZSL UZZSH
//
zzz zzz
//
UZV
zzz
FC
NOTES:
1 - ONLY IF SHOWN ON P&ID
2 - LOCATED ON ESD AUXILIARY PANEL IN CONTROL ROOM (WHERE SHOWN ON P&ID'S)
3 - SOFTWARE IN DCS SYSTEM (WHERE SHOWN ON P&ID'S)
4 - LOCATED IN FIELD (WHERE SHOWN ON P&ID'S) AT SAFE LOCATION
5 - IN CASE OF FAILURE OPEN VALVE "CLOSE" SHALL BE REPLACED BY "OPEN"
TYPICAL INSTRUMENTS LOOP 4A ON-OFF VALVE WITH DOUBLE SOLENOID (ESD FUNCTION)
LOCATED ON VALVE DCS FIELD ESD PANEL ESD
VALVE TAG P&ID N° OPEN LIMIT CLOSE LIMIT FIRST SOLENOID SECOND OPEN LIMIT CLOSE LIMIT RESET DCS CLOSE CLOSE VALVE RESET VALVE RESET VALVE CLOSE VALVE ESD LOGIC
SWITCH SWITCH VALVE SOLENOID VALVE SWITCH SWITCH LOCATED IN LOCATED IN LOCATED IN
INDICATION INDICATION FIELD FIELD FIELD LOCAL
PANEL
UZV UZZSH UZZSL UZEV UZEV UZZLH UZZLL UZHS UZHS UZHS UZHS UZHS UZHS IZ
zzz zzz zzzz zzzA zzzB zzz zzz zzzC zzzF zzzA zzzB zzzE zzzD
xxx
UZV-001 3034-08-ED-PR-PID-0105 UZZSH-001 UZZSL-001 UZEV-001-A UZEV-001-B UZZLH-001 UZZLL-001 - - UZHS-001-A UZHS-001-B - - 001
UZV-403 3034-08-ED-PR-PID-0161 UZZSH-403 UZZSL-403 UZEV-403-A UZEV-403-B UZZLH-403 UZZLL-403 - UZHS-403-A UZHS-403-B - - 506

SWS UNIT NO.08
TYPICAL 5
SINGLE TRANSMITTER
YHL YHS YHL PROCESS OVERRIDE
xxxP.B xxxP xxxP.A (IF ANY)
o
o
o
o
H (or L)
YHS YZI
o o o o IZ o o o o o
xxxM xxx
o o
(or YZALL)
YZAHH
YHL o o o o o o o
xxx
xxxM
MAINTENANCE OVERRIDE
NOTES: YZT
xxx
1 - ONLY IF SHOWN ON P&ID

2 - LOCATED ON ESD AUXILIARY PANEL IN CONTROL ROOM (WHERE SHOWN ON P&ID'S)
3 - SOFTWARE IN DCS SYSTEM (WHERE SHOWN ON P&ID'S)
4 - LOCATED IN FIELD (WHERE SHOWN ON P&ID'S) AT SAFE LOCATION
5 - IN CASE OF FAILURE OPEN VALVE "CLOSE" SHALL BE REPLACED BY "OPEN"
TYPICAL INSTRUMENTS LOOP 5 - TRANSMITTER TO ESD

ESD PANEL DCS
TRANSMITTER P&ID N° PROCESS PROCESS REMOTE REMOTE REMOTE REMOTE REMOTE HIGH REMOTE LOW ESD LOGIC
TAG OVERRIDE OVERRIDE PROCESS MAINTENANCE MAINTENANCE PROCESS HIGH ALARM LOW ALARM
HAND SWITCH INDICATION ESD OVERRIDE OVERRIDE HAND OVERRIDE VARAIBLE
ESD PANEL PANEL INDICATION DCS SWITCH DCS INDICATION DCS INDICATION
YZT YHS YHL YHL YHS YHL YZI YZAHH YZALL

xxx xxxP xxxP.B IZ
xxxP.A xxxM xxxM xxx xxx xxx
xxx
LZT-005 3034-08-ED-PR-PID-0104 - - - LHS-005-M LHL-005-M LZI-005 - LZALL-005 001

LZT-020 3034-08-ED-PR-PID-0108/1 - - - LHS-020-M LHL-020-M LZI-020 - LZALL-020 003
LZT-025 3034-08-ED-PR-PID-0108/1 - - - LHS-025-M LHL-025-M LZI-025 - LZALL-025 004
LZT-039 3034-08-ED-PR-PID-0111 - - - LHS-039-M LHL-039-M LZI-039 LZAHH-039 LZALL-039 005
LZT-407 3034-08-ED-PR-PID-0151 - - - LHS-407-M LHL-407-M LZI-407 LZAHH-407 - 502



SWS UNIT NO.08
TYPICAL 6
2ooN TRANSMITTER
PROCESS OVERRIDE YHL YHS YHL
(IF ANY) xxxP.B xxxP xxxP.A
o
H (OR) L
YZI
xxx
o
A/B/N
o
o
o
YHS o o o o o o o o o
IZ o o o o o o o YZA
xxxM A/B/N xxx
o o o o o o
o o
DISCREPANCY
o
YHL
o
o o o
xxxM
(OR YZALL) (OR YZALL)
MAINTENANCE OVERRIDE YZAHH YZAHH
xxx 2ooN xxx
A/B/N
YZT YZT YZT

xxxA xxxB xxxC
TYPICAL INSTRUMENT LOOP 6 TRANSMITTER TO ESD (2ooN)
ESD PANEL DCS

TRANSMITTER P&ID N° PROCESS PROCESS REMOTE REMOTE REMOTE REMOTE REMOTE HIGH REMOTE HIGH REMOTE LOW DISCREPANCY REMOTE HIGH HIGH REMOTE LOW ESD LOGIC
TAG OVERRIDE OVERRIDE PROCESS MAINTENANCE MAINTENANCE PROCESS HIGH SINGLE SINGLE LOW SINGLE 2oo3 ALARM LOW 2oo3 ALARM
HAND SWITCH INDICATION ESD OVERRIDE OVERRIDE HAND OVERRIDE VARAIBLE ALARM ALARM ALARM
ESD PANEL PANEL INDICATION DCS SWITCH DCS INDICATION DCS INDICATION
YZT YHS YHL YZAHH YZAH YZALL YZA YZAHH YZALL

YHL YHS YHL YZI
xxx xxxP xxxP.B xxx xxx xxx xxx xxx xxx
IZ
xxxP.A xxxM xxxM xxx
A/B/N A/B/N A/B/N xxx
PZT-475-A 3034-08-ED-PR-PID-0158 - - - PHS-475-AM PHL-475-AM PZI-475-A PZAHH-475-A - -

PZT-475-B 3034-08-ED-PR-PID-0158 - - - PHS-475-BM PHL-475-BM PZI-475-B PZAHH-475-B - - PZA-475 PZAHH-475 - 506
PZT-475-C 3034-08-ED-PR-PID-0158 - - - PHS-475-CM PHL-475-CM PZI-475-C PZAHH-475-C - -
LZT-400-A 3034-08-ED-PR-PID-0150 - - - LHS-400-AM LHL-400-AM LZI-400-A - LZAH-400-A LZALL-400-A
LZT-400-B 3034-08-ED-PR-PID-0150 - - - LHS-400-BM LHL-400-BM LZI-400-B - LZAH-400-B LZALL-400-B LZA-400 - LZALL-400 501
LZT-400-C 3034-08-ED-PR-PID-0150 - - - LHS-400-CM LHL-400-CM LZI-400-C - LZAH-400-C LZALL-400-C
LZT-417-A 3034-08-ED-PR-PID-0152 - - - LHS-417-AM LHL-417-AM LZI-417-A - - LZALL-417-A
LZT-417-B 3034-08-ED-PR-PID-0152 - - - LHS-417-BM LHL-417-BM LZI-417-B - - LZALL-417-B LZA-417 - LZALL-417 503
LZT-417-C 3034-08-ED-PR-PID-0152 - - - LHS-417-CM LHL-417-CM LZI-417-C - - LZALL-417-C

SWS UNIT NO.08
TYPICAL 7A
OPEN CLOSE OPEN CLOSE

UHS UHS UHS UHS
zzzA zzzB zzzC zzzD
(NOTES 1,3) (NOTES 1,3) (NOTES 1,2) (NOTES 1,2)
o
o
o
o
o
o
o
UZLH
I o o o o o o zzz
o
UEV UZLL
o o o o zzz
zzz
ISA // // // // //
//
//
//
//
UZSL UZSH
zzz zzz
FC
UV
zzz
TYPICAL INSTRUMENTS LOOP 7A - ON-OFF VALVE (DCS FUNCTION)

LOCATED ON VALVE DCS FIELD
VALVE TAG P&ID N° OPEN LIMIT CLOSE LIMIT SOLENOID VALVE OPEN LIMIT CLOSE LIMIT OPEN CLOSE OPEN VALVE CLOSE VALVE DCS LOGIC
SWITCH SWITCH SWITCH SWITCH LOCATED IN LOCATED IN
INDICATION INDICATION FIELD FIELD
UV UZSH UZSL UEV UZLH UZLL UHS UHS UHS UHS I

zzz zzz zzz zzzA zzz zzz zzzC zzzD zzzA zzzB xxx
UV-002 3034-08-ED-PR-PID-0104 UZSH-002 UZSL-002 UEV-002-A UZLH-002 UZLL-002 UHS-002-C UHS-002-D - - 020
UV-404 3034-08-ED-PR-PID-0153 UZSH-404 UZSL-404 UEV-404-A UZLH-404 UZLL-404 UHS-404-C UHS-404-D - - 021

SWS UNIT NO.08
E S D L O G IC - P & I D R E P R E S E N T A T I O N F O R L O G IC R E S E T A N D L O G I C A C T IV A T E D
L O G IC R E S E T
HZSR
nnn
o
o
XZA IZ
o o
nnn nnn
L O G I C A C T IV .
E S D L O G I C R E S E T A N D L O G IC A C T I V A T E D
E S D L O G IC P & ID N ° E S D L O G IC E S D L O G IC
R E S E T (F R O M A C T IV A T E D (D C S
DCS) ALARM )
NO TES
HZSR XZA
nnn nnn
IZ -0 0 1 3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 0 4 H Z S R -0 0 1 X Z A -0 0 1
3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 0 5
IZ -0 0 3 3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 0 8 - 1 /3 H Z S R -0 0 3 X Z A -0 0 3
3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 1 0
IZ -0 0 4 3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 0 8 - 1 /3 H Z S R -0 0 4 X Z A -0 0 4
3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 1 0
IZ -0 0 5 3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 1 1 H ZS R -0 0 5 X ZA -0 0 5
3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 5 7
3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 5 4
3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 5 8
3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 6 1
3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 6 2
IZ -5 0 9 3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 6 3 H Z S R -5 0 9 X ZA -5 0 9
IZ -0 2 2 A 3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 6 5 H Z S R -0 2 2 A X ZA -0 2 2 A
IZ -0 2 2 B 3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 6 5 H Z S R -0 2 2 B X ZA -0 2 2 B
IZ -0 2 3 A 3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 6 6 H Z S R -0 2 3 A X ZA -0 2 3 A
IZ -0 2 3 B 3 0 3 4 - 0 8 - E D - P R - P ID - 0 1 6 6 H Z S R -0 2 3 B X ZA -0 2 3 B

SWS UNIT NO.08
9. START-UP PROCEDURE
• INITIAL START-UP
When all the precommissioning activities are completed the plant is ready for start-up. All
process equipments have been flushed clean, tested, drained. At this stage, the availability
of utilities, storage tankage for Sour Water storage is ensured. The unit is ready for feed cut
in.
9.1 PREPARATION FOR START-UP
Once the unit is mechanically complete, a thorough checking of the unit as per P&ID is to
be carried out. Modifications/rectifications, if any, are to be completed before the start of
precommissioning activities. Utilities are to be charged one by one after flushing the pipes
with appropriate medium. No load run of different motors, followed by functional test, are to
be carried out for all rotating equipment.
Once the instrument air is charged, the instrument and loop checking will be carried out.
The functioning of the DCS system is checked and system is commissioned. Before taking
feed, it should be ensured that all the safety valves are tested and installed in position,
Flare, CBD & OSW systems are in working condition, all interlocks are functional and
communication system between the Unit, Control Room and Offsite/Utilities area is
complete and in working condition.
9.2 SUMMARY START-UP PROCEDURE
The start-up of the unit involves the following consecutive main steps:
• Elimination of Air by steaming and Inertization
• Water circulation.
• Sour Water Feed Cut in
9.2.1. ELIMINATION OF AIR / INERTIZATION
• The main purpose of steaming is to remove air from the system before admitting
hydrocarbons. Steam connections are given at appropriate places for achieving this. Before
commencing steaming operation ensure that water to coolers/condensers is isolated and
drained.
• Keep all flow/level instruments, PSVs connections isolated.
• Isolate PV-045A on overhead line of stripper CC-0801 and its bypass routing to SRU
respectively.

SWS UNIT NO.08
• Keep PV-045B in line for elimination of air as well as inertization of line to Acid Gas flare.
• Condensate present, if any, is also drained from low point drains of equipment/pipes.
• Open the vent valve on the surge drums, reboiler, connected piping and exchangers, stripper
and pump suction strainers if there. These vent valves will prevent formation of vacuum in
case steam supply is failed.
• Start steaming in the unit by opening steam valves to the surge drum (VH-0801), stripper
column (CC-0801) slowly initially and then vigorously for 2-3 hours after show-off steam is
seen from all vents to ensure proper removal of air from the system after which it is expected
that the system will be free of air. This can be checked by examining oxygen content, which
should be less than 1%. Once air is removed start closing vent valves and gradually stop
steaming by closing the steam valves and simultaneously open nitrogen to the system to
maintain slight positive pressure at around 0.5 kg/cm2g in the system.
9.2.2. WATER CIRCULATION
Charge DM water to surge drum through the start-up line. For detail line up, please refer
start up circulation circuit, which is attached as attachment.
• Once a sufficient level in the surge drum VH-0801 is reached, start one of the stripper feed
pumps P-0801A/B and charge this water through feed/bottom exchanger E-0801 A/B to
stripper CC-0801.
• Keeping feed flow controller FIC-002 on manual & maintain a flow and make up level in
surge drum as required.
• After attaining normal operating level of (CC-0801), start one of the stripped water pumps
P-0803 A/B and route the water to surge drum (VH-0801) taking in line feed/bottom
exchanger E-0801 A/B, Trim air cooler E-0804 and Stripped Water Trim Cooler E-0805
through start up circulation line SWA-08-0003-A3C1 (Z)-4-PT. Keeping B/L valves of
stripped water to OSBL units closed.
• Take LIC-004 on line and maintain level in VH-0801. Once the normal levels & flow rates
are attained put the controls on auto. Adjust DM water make-up.
• Cut in LP steam slowly to the stripper reboiler E-0802 through FIC-022.Keep the control
valves on the condensate lines LV-032 on manual and route the condensate locally. Excess
pressure on the top is vented from the stripping column & bleeders of PV-045A. Do not
allow the pressure in the stripper columns go to above 0.9 barg.
• Raise temperature at stripper bottom slowly to the desired operating temperature.
• Make up level in the surge drums as required.
• After getting levels in the chimney tray, start the Pump around pumps P-0802 A/B and
adjust FIC-023 & FIC-008/FIC-022 suitably. Adjust TIC-053 for stripper OVHD temperature.

SWS UNIT NO.08
9.2.3. SOUR WATER FEED CUT IN
Check the availability of sour water from various source units.
• Take sour water into the surge drums in co-ordination with the process units and stop DM
water flow. Line up the vents on surge drums to flare and close vents to atmosphere.
• Start diverting Stripper bottom DM water to Waste Water Treatment unit maintaining
proper levels in surge drum, stripper.
• Start Pump around Air Cooler E-0803 and put re circulation into the column through
Pump-around reflux pumps P-0802 A/B. Set the TIC-053 top temperature is to be kept at
90°C. Line up Acid Gas initially to Acid Gas flare.
• Sample and analyze stripped water and adjust the controller for steam to obtain 10 ppm of
H2S and 50 ppm of ammonia in the stripped water. Start sending stripped water to
CDU/WWT/NHT/KHT/GOHT and subsequently Line up stripper Acid Gas to SRU. Ensure
that before diverting acid gas to SRU unit, SRU plant should be ready on all aspect. If SRU
plant is not ready, route acid gas to flare.

SWS UNIT NO.08
10. PLANNED SHUTDOWN

Planned shutdown of the unit may be taken, in case of upstream shutdown activities
causing, no feed available for this unit or for the purpose of routine maintenance, repair
activities of the unit section. While shutting down the unit care should be taken not to admit
air into the system until all hydrocarbons are removed from the system. All related off sites,
utilities and process units should be informed about the shutdown plan well in advance.
Following steps are to be followed for a safe shutdown.
• Inform CDU/WWT/NHT/KHT/AMN/GOHT and Sulfur Recovery unit, off sites and utilities,
WWTP about the impending shut down.
• As the flow of sour water feed to the unit reduces, reduce flow of steam to both the stripper
reboiler.
• Start DM water supply to the surge drum and continue operation of the unit till pressure in
the stripper is adequate to transport water.
• Stop reflux pump and air coolers after the levels in draw off trays are lost.
• Divert stripped water to WWTP.
• Isolate off gas lines from the strippers to SRU and route the gases to acid gas flare.
• Shut off sour water inlet to surge drum.
• When temperature drops to about 60 ºC in the stripper, stop all the pumps and air coolers.
• Isolate acid gas flare from the strippers and surge drum.
• Open vents on surge drum, and stripper column.
• Drain water to blow down drum VH-0802.
• Start steaming of the strippers column and surge drum to make the system gas free before
handing over to maintenance.
Actions of different levels of emergency shutdown are reported in the Cause & Effect
Matrix document (3034-PR-DSH-AA081).

SWS UNIT NO.08
11. NORMAL OPERATION
The normal operating parameters for the Sour Water Stripping Unit are shown in the
Process Flow Diagram (3034-08-ED-PR-PFD-0001 &2).The critical operating parameters
are listed below:
Design
Tag Description Tag No. Unit
Value
SWS feed Flow FI-002 Kg/hr 46907
Operating pressure of Surge Drum
PI-001 barg 1.1
(VH-0801)
Temp. of Sour water feed to Feed
TI-001 °C 54.4
Surge Drum (VH-0801)
Sour water temp. Feed
TI-019 °C 54.4
pumps ( P-0801 A/B)
Stripped water pump (P-
FI-013 Kg/hr 46628
0803 A/B) Discharge Flow.
Stripped water temperature
TI-025 °C 45.0
B/L
Stripped water pressure B/L PI-026 barg 9.4
Sour water stripper OVHD pressure PIC-045 barg 1.1
Sour water stripper OVHD
TIC-053 °C 90.0
temperature

SWS UNIT NO.08
12. EMERGENCY SHUTDOWN

12.1 GENERAL
Emergencies must be recognized and acted upon immediately. Personnel involved in the
plant should carefully study all the emergencies and steps to be undertaken in those
circumstances. Most common emergencies are failure of utilities. Guidelines are given
below to overcome such emergent situations in a safe manner.
The sudden loss of electrical power, instrument air or other utilities could also cause a plant
shutdown. Certain features have been designed in the plant to minimize the likelihood of an
emergency. These include items like spare pumps which can be used in case of equipment
failure.
The following steps are only a general guide for the operating crew, as special problems
may arise at different times, when human judgment, patience and presence of mind
determine the success of the corrective action taken.
12.2 POWER FAILURE
Depending on situation, following actions should be taken as early as possible:
• Close discharge valves of all centrifugal pumps.
• Isolate LP steam supply to the reboiler E-0802 close FV-022.
• Continue to receive sour water in day tank (TK-0801).
• Isolate PV-045A for stopping Sour gas to SRU and route the gas to acid gas flare
through PV-045B.
• If the shutdown is for a longer period, follow normal shut down procedure.
• If any motor trips because of power dip, it should be started immediately.
• When power supply is resumed establishes sour water circulation as per routine
start-up procedure and gradually bring sour water stripper on line.
12.3 STEAM FAILURE
• Stop sour water feed to stripper and route sour water to WWTP.
• Isolate valve in steam inlet to stripper reboiler (E-0802)
• Stop stripper PA pump P-0802 A/B.
• Divert acid gases to flare.


SWS UNIT NO.08
• Start taking DM water in surge drum and keep maintaining its level on manual
mode.
• Route DM water directly to P-0801 A/B i.e. bypass TK-0801 keep on circulating
Stripper bottom water through Start up route to VH-0801. Isolate valve on Stripped
water supply line to OSBL.
If the failure of steam is for a prolonged duration, proceed with the shutdown of the
all SWS as per normal shut down procedure.
After normalization of Steam Supply Cut in Sour water feed as per normal start up
procedure.
12.4 COOLING WATER FAILURE
In case of cooling water failure,
• Water flow to Stripped water trim cooler E-0805 will cease. This will cause the
temperature of stripped water to raise around 60 deg C. The unit will be able to
survive, but cooling water should be restored as soon as possible as high
temperature of water in WWTP is not desired.
12.5 INSTRUMENT AIR FAILURE
In the event of loss of instrument air, the pneumatic instruments will not indicate/record the
correct operating parameters. All the control valves will assure their fail-safe positions.
If the instrument air failure is of small duration (say for a few minutes) it is possible to keep
the unit on stream by taking the various controls on bypass and checking the temperatures,
pressures and levels locally. The control valves should be operated manually by the hand
wheels if provided or the bypass globe valves should be adjusted whichever may be the
case.
It is not advisable to operate plant on such manual mode for longer duration as the
controlling of various parameters become difficult and also it is unsafe. Hence, it is always
advisable to take shut down following normal shutdown procedure in case of instrument air
failure.
12.6 LOSS OF FEED
For failure of Sour Water feed to SWS action to be taken for isolating valve on Sour water
feed line to sour water surge drum. Route DM water supply to surge drum and make up
level in it.

SWS UNIT NO.08
13. SAFETY
13.1 INTRODUCTION
Safety of personnel and equipment is a very important consideration in the operation of the
unit. Though the design of the plant takes care of a number of emergency conditions and
makes the plant operationally safe, proper operating procedures and use of safety
equipment are must for the safe running of the plant and a safe environment to work in.
This chapter contains some safety guidelines, which should be strictly followed in the plant.
13.2 GENERAL HAZARDS IN THE UNIT
All Petroleum products give out vapors in amount depending upon the type of product.
The hydrocarbon vapors also produce Fire and explosion hazards, which are associated
with these vapors under favorable conditions. H2S present in Sour fuel gas feed to the unit
is also very much prone to cause adverse impacts over personnel working in unit.
These Hydrocarbon vapors also produce adverse physiological effects. 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).
13.2.1. SOURCES OF IGNITION
For fire and explosion to occur, three conditions must be necessarily satisfied. These are
availability of combustible material, sufficient quantity of oxygen and a source of heat.
The proportion of fuel in air must be between the explosive limits of the fuel. In free air,
there is no risk of ignition if the hydrocarbon vapor temperature is less than the ignition
temperature. However, in a process unit lot of potential ignition sources are present.
These are described in brief as follows.
• Electrical Apparatus
• Stray Electric currents
• Static Electricity
• Lightening
• Non Electrical sources (Mechanical sparks).
• Auto Ignition

SWS UNIT NO.08
13.2.2. ELECTRICAL APPARATUS
These include all machines, equipment, and fittings, in which conductors are used or of
which they form a part e.g. electric switches, push buttons, sockets, plugs, circuit breakers,
starters, instruments, motors and so on. These may act as a source of ignition by electrical
arcs and sparks or raising the surface temperature of the apparatus above the spontaneous
ignition temperature.
13.2.3. STRAY ELECTRIC CURRENTS
Stray currents may emanate from electric welding machines.
13.2.4. STATIC ELECTRICITY
Examples of electrostatic generation are:
• Passage of liquid through pipes and filters.
• Settling of solid particles in liquids as when rust and sludge particles settle in a
vessel.
• Settling of droplets of one liquid through another, e.g. water droplet separating out
in a tank or a vessel containing petroleum liquid.
• Bubbling of gas through liquid e.g. air trapped in a liquid rising to the surface.
• Splashing by the break u of jets, or bubbles e.g. during splash filling of vessels and
high splash ejection of liquid from nozzles.
13.2.5. LIGHTENING
Lightening can fall on metallic objects such as high stacks, towers, tanks, vessels and tall
buildings. 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 especially
vulnerable to lightening.
13.2.6. NON-ELECTRICAL SOURCES OF IGNITION
• Smoking
• Spontaneous ignition, e.g. thermal insulation of hot pipes which have become
impregnated with oil.

SWS UNIT NO.08
• Pyrophoric Iron: Iron sulphide formed out of contact with air is chemically very active
and when exposed to air it rapidly oxidizes and reaches a temperature sufficient to
ignite a hydrocarbon air mixture.
• Frictional ignition due to impact or rubbing action.
• Falling of iron tools.
• Rubbing of iron tools on concrete or operation of grinding wheel.
13.2.7. AUTO IGNITION
For fire and explosion to occur, three conditions must be necessarily satisfied. These are
availability of 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 vapors is equal to its
ignition temperature, the vapors 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.
The risk of auto-ignition is generally more as the molecular weight of the hydrocarbons
increases. The auto-ignition temperature of some important hydrocarbons is given in table
below.
TABLE-7.1
Product Auto-ignition Temp °C
Hydrogen 589
Ethane 516
Ethylene 450
Propane 466
Butane 430
Pentane 309
Hexane 247
Gasoline 256
Kerosene 254
Lubricating Oil 417
13.2.8. HYDROGEN SULPHIDE HAZARDS
Hydrogen sulphide is present in Sour Water as well as normal flare gas. In Sour Water,
which is fed to Sour Water Stripper Unit the concentrations range is around 2200 ppm.
Hydrogen sulphide is a deadly poison, having a very quick action. Its hazards are
compounded by the fact that the sense of smell is paralyzed once the concentration of H2S

SWS UNIT NO.08
present is high. H2S is also highly flammable with explosion limits between 4 % (LEL) to 46
% (UEL) by volume. Combustion of H2S produces toxic gas sulphur dioxide.
When sampling or purging operations are being carried out on streams carrying H2S,
appropriate precautions must be taken.
13.2.9. PHYSIOLOGICAL EFFECTS
The hydrocarbon vapors which are heavier than air accumulate at low points near the
ground level. The vapors have anesthetics effects. If air with hydrocarbon concentration of
0.1% is inhaled for about 5 minutes the person feels giddy. If concentration increases to
0.5% and a person inhales such air for about four minutes, he exhibits symptoms similar to
alcoholism.
A concentration of 1.0% will cause rapid onset of “drunkenness”, which may lead to
unconsciousness and death if exposure continues. At 2.0% concentration paralysis may
occur rapidly followed by death.
13.2.10. EXPLOSION –FIRE
When the proportion of hydrocarbon in the hydrocarbon – air mixture falls within the
explosive limits (these limits for some important hydrocarbons are given below), an
explosion or fire could occur in presence of source of ignition, such as spark or an open
flame. A hydrocarbon air mixture can sparred on the ground over a considerable distance
and catch fire when in contact with a spark or an open flame.
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 pressures causing damage. One explosion
could initiate another explosion or fire at a distance of ten to hundred meters because of its
physical nature. A fire generally follows explosion.
Explosive Limits of some Hydrocarbons are listed in the following Table.


SWS UNIT NO.08
TABLE-7.2
Lower Explosive Limit (LEL, Upper Explosive Limit

Product
% vol/vol air) (UEL,%vol/vol/air)
Hydrogen 4.1 74.2
Methane 5.3 14
Ethane 3.2 12.5
Propane 2.37 9.5
Butane 1.6 8.5
Pentane 1.45 7.5
Hexane 1.2 6.9
Gasoline 1.3 6
13.3 SAFETY GUIDELINES
The following general safety rules are applicable to plant operations. These must be known
and strictly observed by all personnel.
13.3.1. GENERAL
• Smoking should be permitted only at approved smoking locations.
• If an employee’s clothing become contaminated with acids, caustics, alcohols,

hydrocarbons etc. he must remove clothes immediately and take a shower.
• Defective tools should not be used.
• When using chisels, cold cuts, striking wrenches, hammers or punches, nons-
sparking tools should be used.
• Use appropriate tools for the work involved, i.e. do not use a file for a bar, a hand
wrench for hammer etc. Over–stressing tools or equipment cause serious injuries.
• Safety belts or life-lines shall be used when working 3 meters or more above
ground, where it is not practical to make other provisions to prevent falling.
• Falls are the second largest cause of accidental deaths.
Following acts are to be avoided:
• Failure to look around while going round the plant.
• Running or jumping in work places.
• Standing on boxes, chairs and makeshifts instead of ladders or platforms.


SWS UNIT NO.08
• Neglecting to use handrails and running on stairs.
• Failing to face ladder when carrying objects on the same.
• Tools and materials should not be dropped from heights. They must be carried
down.
• Standing or waling under materials suspended by ropes, chains, or cables should

not be permitted. Stay in the clear until material is well second.
13.3.2. REGARDING ELECTRICAL EQUIPMENT
• Only a qualified electrician should handle the electrical apparatus.
• Use only approved electrical fittings. The covers of electrical fittings in hazardous
areas should be secured properly to avoid entry of explosive gases.
• All electrical equipment’s must be properly grounded.
• An electrical extension wire must not be used if it is in bad condition, laid through
water or in such a manner as to allow motorized equipment to travel over it.
• Employee should regard all electrical wires as live and dangerous.
• Never close a switch or breaker that has been opened unless authorized to do so by
your supervisor.
• All electrical breakers must be de-energized and locked before process equipment
can be worked upon.
• All live fuses, lighting and power cabinets must be kept closed.
• If an electrical power unit motivates moving machinery and if it is necessary to repair

the same then refer to and follow the electrical lock-out procedure laid down by the
plant management.
13.3.3. REGARDING H2S SAFETY
The best method of preventing H2S poisoning is to stay out of the plant areas known or
suspected to contain it. Sense of smell is not an infallible guide to its presence; though the
compound has the distinct and unpleasant odor of rotten eggs, it will in higher
concentrations paralyze the olfactory nerves so the victim cannot smell it.
A good method of prevention is to check systematically the atmosphere of the suspected

areas for the presence of H2S by testing with moist lead acetate paper, or by Tutelary H2S
determination.

SWS UNIT NO.08
Gas masks suitable for use with hydrogen sulphide must be worn during work if exposure to
it is likely to occur. Masks must be frequently checked to ensure they are functional. When
working under conditions of likely exposure, the presence of a second operator is
compulsory.
Connect sampling outlet to container with a copper wire of at least 5 mm diameter.
Following instructions are to be followed.
• Sampling connections must be flushed thoroughly but carefully and slowly, before
Collecting the sample. Spillage must be avoided at all times.
• If a large wrench or other means of leverage is required to open a stuck sample

connection, care must be taken not to break off the connection and create a serious
hazard.
• Gloves and goggles or face shields must be used when drawing samples.
13.3.4. SAFETY RULES FOR PARTICULAR OPERATION
The following safety instructions are for the operations carried out frequently in the plant.
These must, in addition to the General Safety Rules, be understood and observed strictly by
all personnel.
13.3.5. SAMPLE AND PURGE CONNECTIONS
Operator who opens the purge or sample connection should be present till the same is
closed. The plug/ blind if provided should be put back when the operation is complete.
Draining of vessel should not be done unattended. Operator should be present as long as
draining/ venting is going on.
13.3.6. ISOLATION OF SAFETY VALVES
Many safety valves are provided with isolation valves at upstream and downstream of the
safety valve. This is to facilitate the repair of the safety valve. It is important to ensure that
these isolation valves are kept in locked open/ locked closed position as per the P&IDs.

SWS UNIT NO.08
13.3.7. PROCESS EQUIPMENT: VESSEL ETC.
Before opening any equipment, it should be purged to render the internal atmosphere non-
explosive and breathable. Operations to be carried out are:
• Isolation with valves and blinds.
• De-pressurization and draining.
• Replacement of hydrocarbon vapor or gas by steam, water or inert gas.
• Proper isolation and draining of instrument tapping.
• Washing of tanks and vessels with water.
• Ventilation of equipment.
• Opening of top manhole, if present. Testing of inside atmosphere for 02 content any
poisonous gas.
Note: Open a vent on the upper part of the vessel to allow gases to escape during filling
and to allow air inside the vessel during draining. Ensure proper ventilation inside the vessel
by opening all manholes.
13.3.8. PRECAUTIONS BEFORE HANDING OVER EQUIPMENT
A responsible operating supervisor should check following items before equipment is

handed over for maintenance after it has been purged.
• Ascertain that there is no pressure of hydrocarbons in the lines, vessels and

equipment and system is inertized with nitrogen
• Ascertain that equipment is isolated by proper valves and blinds.
• Check that steam injection lines and any inert line connections are disconnected or
isolated from the equipment.
• Put tags on various blinds to avoid mistakes. Maintain a register for blinds.
• Check for pyrophoric iron and if existing keep this wet with water.
• Keep the surrounding area cleaned up.
• Get explosive meter test done in vessels, lines, equipment and surrounding areas.
If welding or hot work is to be done, then also:


SWS UNIT NO.08
• Keep fire-fighting devices ready for use nearby.
• Welding operation to be carried out inside the welding booth.
• Keep water flowing in the neighboring area to cool down any spark bits etc.
• Keep steam lancers ready for use.
After the above operations have been made, a safety permit should be issued for carrying
out the work. A responsible operating supervisor should be personally present at the place
of hot work till the first torch is lighted. Hot work should be immediately suspended if
instructed by the supervisor or on detecting any unsafe condition.
When people have to enter a vessel for inspection or other work, vessel should be first
made free of any inert atmosphere by purging with air to bring normal oxygen level in the
vessel. One person should stand outside near the manhole of the vessel for any help
needed by the persons working inside.

SWS UNIT NO.08
14. ANALYTICAL TESTS


SWS UNIT NO.08
15. ATTACHMENT
15.1 START UP WATER CIRCULATION LOOP


SWS UNIT NO.08
15.2 HEAT AND MATERIAL BALANCE TABLE


SWS UNIT NO.08

SWS UNIT NO.08

SWS UNIT NO.08
REF.No.: 3034 -PR
PR-MAN-AA014-A1

SWS UNIT NO.08
15.3 PRESSURE RELIF VALVE LOAD SUMMARY


SWS UNIT NO.08
15.4 PROCESS FLOW DIAGRAM (PFD)


SWS UNIT NO.08

Operating Manual For Sws Unit No.08: Persian Gulf Star Oil Company REF - No.: 3034-PR-MAN-AA014-A1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operating Manual For Sws Unit No.08: Persian Gulf Star Oil Company REF - No.: 3034-PR-MAN-AA014-A1

Uploaded by

Copyright:

Available Formats

REF.No.

OPERATING MANUAL for SWS UNIT NO.08

A1 24 JUL 2014 FINAL ISSUED Gh.Aghakhani A.Reshad H.Dehghan

Subcontractor Name: NARDIS

OPERATING MANUAL for PAGE 2 OF 48

OPERATING MANUAL for PAGE 3 OF 48

3. BRIEF PROCESS DESCRIPTION 4

4. OPERATING VARIABLE AND CONTROLS 8

8. INSTRUMENTATION AND CONTROL 18

10. PLANNED SHUTDOWN 27

11. NORMAL OPERATION 28

12. EMERGENCY SHUTDOWN 29

14. ANALYTICAL TESTS 40

OPERATING MANUAL for PAGE 4 OF 48

3. BRIEF PROCESS DESCRIPTION

NH3 + H2S NH4+ + HS-

OPERATING MANUAL for PAGE 5 OF 48

• Condensate Distillation units (3 trains)

• Naphta Hydrotreating units (3 trains)

• Kerosene Hydrotreating unit (1 train)

• Gas oil Hydrotreating units (2 trains)

• Sulphur Recovery Unit-TGT (1 train)

• Amine Treating Units (2 trains)

Refer to process flow (3034-08-ED-PR-PFD-0001 &2) and Process and Instrumentation

3.1 SWS FEED SURGE DRUM (VH-0801)

OPERATING MANUAL for PAGE 6 OF 48

3.2 SOUR WATER DAY TANK (TK-0801)

3.3 FEED/BOTTOM EXCHANGERS (E-0801 A/B)

3.4 STRIPPER COLUMN (CC-0801)

OPERATING MANUAL for PAGE 7 OF 48

The column is provided with overhead pump-around circuit consisting of recirculating

The bottom temperature is maintained at a temperature of 127.5 deg C which is governed

3.5 BLOW DOWN DRUM (VH-0802)

OPERATING MANUAL for PAGE 8 OF 48

4. OPERATING VARIABLE AND CONTROLS

4.2 FLOW RATE

5.1 UTILITY SUMARY

Consumption of cooling water, electrical power,steam, condensate; and fuels is tabulated

OPERATING MANUAL for PAGE 9 OF 48

OPERATING MANUAL for PAGE 10 OF 48

OPERATING MANUAL for PAGE 11 OF 48

6.1.1. STARTUP PROCEDURE

• Close all bleeders in suction and discharge lines.

6.1.2. SHUT DOWN PROCEDURE

• Close discharge valve (pump).

6.2 HEAT EXCHANGERS

OPERATING MANUAL for PAGE 12 OF 48

7.1 E-0803 (Pump Around Air Cooler)

E-0803 (Pump Around Air Cooler)

7.2 E-0804 (Trim Air Cooler)

E-0804 (Trim Air Cooler)

OPERATING MANUAL for PAGE 13 OF 48

7.3 CC-0801 (Sour Water Stripper)

CC-0801 (Sour Water Stripper)

7.4 E-0801 (Feed/Bottom Exchanger)

E-0801 (Feed/Bottom Exchanger)

OPERATING MANUAL for PAGE 14 OF 48

7.5 E-0802 (Stripper Reboiler)

E-0802 (Stripper Reboiler)

7.6 E-0805 (Stripper Water Trim Cooler)

E-0805 (Stripper Water Trim Cooler)

OPERATING MANUAL for PAGE 15 OF 48

7.7 DS-0801 (LP Steam Desuperheater)