Document 8RVmyRr9NowBp8yKVyarqoVBK
ABDOO102742
GUIDANCE FOR IMPLEMENTING PROGRAMS FOR OSHA 29 CFR 1910.119
PROCESS SAFETY MANAGEMENT OF HIGHLY HAZARDOUS CHEMICALS
PART THREE OPERATING PROCEDURES
by
PrimaTech
June 10, 1994
Primatech Inc. 445 Hutchinson Avenue, Suite 200
Columbus, Ohio 43235 (614) 841-9800
ABDOO102743
t
GUIDANCE FOR IMPLEMENTING PROGRAMS FOR OSHA PSM
OPERATING PROCEDURES
This document contains information that may assist a company in establishing, or reviewing and updating, the operating procedures element of their process safety management (PSM) program. The information in this document is based upon the U.S. Occupational Safety and Health Administration's regulation, 29 CFR 1910.119, Process Safety Management of Highly Hazardous Chemicals. However, this information may be of use to anyone developing or updating a PSM program for any purpose.
In 1993 the U.S. Department of Labor Occupational Safety and Health Administration (OSHA) commissioned Primatech Inc. to develop a `training material reference manual" related to 1910.119. The purpose of the manual is to provide OSHA's Office of Training and Education with a resource for training federal and state OSHA field officers on enforcing the PSM regulation.
The training material reference manual features an annotated form of the Program-QualityVerification (PQV) inspection checklist originally presented in Appendix A of OSHA Instruction CPL 2-2.45A. Example programs are provided to illustrate the positive and negative indicators of the checklist questions. OSHA has agreed to allow Primatech to make this information available to interested parties. This should in no way be construed as acceptance by OSHA of the suitability of the information or examples provided herein.
The format of this document follows the PQV inspection checklist presented in Appendix A of OSHA Instruction CPL 2-2.45A, often referred to as the "compliance directive". For each question in the PQV inspection checklist, clarification is provided on the checklist item along with positive program indicators and negative program indicators for each question. The positive and negative program indicators are intended to provide ideas for the user to help them in assessing their existing or planned program.
The example programs provided in this document illustrate approaches taken by companies seeking to address the requirements of 1910.119. These examples have not been reviewed and/or endorsed by OSHA and should not be cons* jed as model programs.
The example programs provided herein were developed for specific processes, and are not generic in nature. Since the OSHA PSM regulation is performance-based, readers are strongly encouraged to develop programs tailored to their own covered processes.
1
ADD00102711
%
This document is offered for the user's general guidance only. This document does not attempt to provide any interpretation of the OSHA regulations. Primatech makes no claims regarding the acceptability to OSHA of the information contained herein to OSHA. Consequently, Primatech can accept no liability for any use which the user may make of the information contained herein. Note that the information contained in this manual does not necessarily represent the opinion of Primatech.
2
ABDOO102745
OVERVIEW
This guidance document is arranged in a tabular format. The following is a description of each of the column headings used in the table:
PQV Question
The PQV question is derived from the checklist in Appendix A of the OSHA Compliance Directive (CPL 2-2.45A), which is based on the specific regulatory requirements for the element. Note that the verification portion of the checklist includes questions for records review, on-site conditions, and interviews. In order to avoid unnecessary duplication of information, this guidance document references the checklist questions from the records review section only. Specific questions or concerns from the on-site conditions and interviews sections that are not addressed in the records review section are accounted for in the positive and/or negative program indicators column.
Explanation
The explanation clarifies or provides additional insight into the PQV question. In some cases, the explanation provides an interpretation of the PSM requirement. In no cases should the information contained in this column be viewed as a substitute for the actual regulatory requirement.
Positive Program Indicators
The information included in the positive program indicators column is intended to provide guidance and examples ori what to look for in a well developed program. This column also includes guidance on what to look for when evaluating PSM programs. This column is not intended to contain all conceivable attributes of a good program for all industry types. Rather, it is intended to provide suggestions and ideas on what a good program might include.
i
3
ABDOO102746
Negative Program indicators
The information in the negative program indicators column is intended to provide guidance on possible signs of a poor or incomplete program. This information could be of assistance for identifying potential problem areas when conducting PSM program evaluations. A PSM program that contains one or more of these attributes does not necessarily constitute a poor program. Rather, this information is intended to serve as a guide on what to look for in a less developed program.
It is important for the user of this manual to understand that over 25,000 employers may be covered under the PSM standard. Covered facilities range from large complex chemical, petrochemical, or petroleum facilities, to relatively simple ammonia refrigeration or chlorination systems. This guidance document cannot cover all of the possible ranges regarding the content of PSM program elements in the various industry groups. Additionally, since the PSM standard is a performance based regulation, this guidance document can not address the specific approaches different companies or facilities may choose to implement in complying with the requirements.
In addition to the table, this guidance document contains several helpful appendices, including:
Appendix A - List of Acronyms
Contains description of key acronyms used in the guidance document.
Appendix B - Glossary of Terms
Contains definitions of key terms used in the guidance document.
Appendix C - Technical References
Contains a list of helpful technical references to support the information presented in the table.
Appendix D - Example Program(s)
Contains example(s) of how this PSM element has been adopted. Most of the examples are acutal programs provided by industrial companies.
ABDOO102747
P S M T R A IN IN G M A TE R IA L R E FE R E N C E M A N U A L
Oc X xo 2>
Sa
m
tL
--acs ^- o2
oEa -- 2ue -2 f|
o
o
*2oc -o2" X tl o to -
sf
I*
I rt
O. O
3
5
o
2_o
~
OC X3 o
il
2
a
8
o
Cl
X *Xn O a0 `
0
1
3c
X
X
|
32
o a> 0 a O Qo.
II* D>.^ |3
oIj
2*2u 5.^
o
2a-
2 .
|x S
! s a 2
O i 11 *Co 8ra o.
o 3
i f--
2x
~0 Tc)
i!
It*
8x| -jeS o 2a.
o
il0
P I.O)
Si 1H SIb
ir 1O)
ftCE
u_ a
05 CM
CO
LU
(X
I13
O LU
5 a.
0
_c
li
|21
a- o
2 8o xoo "co
oocs- Eo
2| oE c *1 c
h- co
30_ ^
o 0
-->. XA
w a2a 1co -31O
vc os/
O. j
3 a0
OS
-03 I= p8'S
E
9 x -g 85
2 > os-x c
20
Z0 Zo
2
11 3 OO
| D
~
c 2* 2 .. " S'
1
J (-
*g
S =
X
O Cl 8
X g>
? ! .E &
c
i
j
&E
0
5o=
*o
II n
.'e2 2
u 3 -E
82 ?m
2?
xg
8t
2Q. Uuo.
>*
a. a 0
1?Q.SE
^
gS?
0X
X>
32
2
s(0
J :
* s
I i
^ I
.2 0
E
,,os
X
i
12 0c
02
^ Jxc 23 Cl
s0
.2 x
8D. S
oE c 2
|x 8o Sg>
*b6 z ?S
ni
oC
X>
0
5c8"
B%
3
OS - XT
1 8
xEc
2x-. --_oCs Xoow
co T25 -5
|Z
.2 cCo Eo
^
&l I
os
Z2
*
a
^il3
xa
"I
o
o
cr Q_
o 2
< Jw
a _
V)
cc
2! ft o> ca
LU
Q_
in
O s>
11S
a gX *
u5 n n Z
O3
X a
O>. S. o
a*
E= 2 x
a >-0 3
2o
o
_
o
2 X
ao cc
js 2
o
2o st>a
a*
o
c
I!*
O
x
i*
O
I
o
2
a
ji
PSM TRAINING MATERIAL REFERENCE MANUAL
ABDOO102748
a
o 2
co o- g
S
c5a
5 "g S t5c ce
8 5.2
II StLi
ialE l
c D-
i S.E ?
%
Cat
i:i
in
c
X_o
j- m
J5 ~
c k. a
58 *=5. i!!
OC O
I38o IXQo.I,,|C
21^
o. a c 5 x cl H- o a
o_ ca oE
o c X 3
"28 |
o5
X0
*
oc
!c s s
e
* ^
|ll ou
QB
D
2
s -O
O *I
*S -- ^o
o> o M
oe
1*8
x wE
2y
0
c o
y
_a o^
o ^6 i*;.C . 3 go> H li
a0 ao 0 **
iE
^3 g ci|* c E "I It llcc u a
O
sS
A ft Cl g
y t> x
. c X3- 3O' 0o_
2
3C O' =
IIa - fll 2 ?- 5 a x 21 scoCO I5 3l S 25 II -2 *?L0L5 C eg ^x xco 0CO
3 f | 2 T3> XO ? 8 a c 2 -0LL! 1 8.5 1 c S o >CC
0) ^
9V 52 8-g C ".O2
*3 C
^ o 5
m
cc
x o> --c
D 5
TM cC *O
a
3" O
0 __
x"a
t:
-- 3
0 ao
o o
?c_ 0 .
0
O *D
o
^ Oc
-5 B EO. X-=
x0 O3 oa . e> o>
X- X
c
"0O O
fc .00. `X
Xy
X0 xc
.2 T3
d
B> 3
g
s
3
2
^0
--
x o -m
P
ac
c
E
o~ a2
o>
yX --
i-s I o 2 8s a oo E I E |Z>
i|
Eo
C O'
B
i If 8D y 0 0X q. o . S
' y? iUJ C X0^ aa
c a.
.* 0
O
o
cc
CL
O
p5. EE
" X o
c
o
ill!<
cc
UJ CL
5. Mo
2
TIOC
ll?
s X0_i
c c "x 0g.0-ci c80a>*
X3y2
x&Oc)
=2oC-> 2JT"o>
x
x0
.S02s'%^30 5?EM;
x-S 0
>. O 3
2o ga ?*-
00" Sgo 2*1o -10c
20 1c
e "D h*
H 0* 0 0 c
eg 23
5"8O
O O O E0 50 ??>
3D Ssg oc0 g4x? ?O 15 Ic
5i
Eo x0
|%
8I si
II O0
5. 5
oo ya 80y0Cco -"3DcO3) BC E
IIS y o oy e o o sb* o
> X
c o
0 X
0c 7 0 XO 0 X
O "y
I I I i i
<0
PSM TRAINING MATERIAL REFERENCE MANUAL
oa>
m
O)
o O) tr
LL
O ow>
CO
Lit CC
3 Q
LU
O
o
GC CL
CD
2 t<-
CC
LU CL
O
1
s sa
c
o .
Ia I*
J* a
II If
O3 Es
Ia
rvi 2 E o
ABDOO102749
o. c
$s
I*
Q. 2
c *o s
Cl ." o
I
g-B
SS O
gi
o
8S
o o>
TJ C
2B
fIn a
&m E
?|S
su a
hi .i o
-5 . c ~ >
>
^2c
S
3
B8
28
T> r
rr
O
8o
o a
s
-8 e
S e
S .5ag-d
- x
o ^
8g
s I I
E
S
x
"
c
sI
S'5.
ai !?
*5*
o
I
S
o
<ao
> c II
B
I 8- b E
fS S oo
II
xe
~
II
BO
E
= Bs E .B
-E B i|
2 ' E >
E g o
1 ai:
E8 8 ! ifl
III!
22 8S "S
O Q. e
-I E
I3 In .-
!
=
s
a
*? ooc x
^3
oE *" 3 S' E *?
i!
IIB E
8 c
S
5a
E E
2 & 5 aB. SOn sB w ** &
1 fr*2c
5 5a-so
E Si a> S Co uo bB
O
?
a a
E
o
8
o
c
S'
E
*1C B _c.
O X xs=:
B & *
ao i
gf ac r,
a by
ao
IIIElJ
w
o o
E
o
"> a c
i
I
g.
E
uo g g
Z 2 .2
* BU
a
S
^o
Ia
WB
D
w c **
5 ou ^
S
x 5 II
g> S
g 5
>X
*3 o
1 a__
3
B_ x
j* c 2
B"
8*8 Sub
i S 2 scr c
TJ
g
C
ax
B
|ofC ~
o U
s B
SI
2
_ a C 3 OB
o u
*
2
a
a tj e c S `E
cce* --
g
2
3 cr
*
8
--
B a
^
B9) c
3O o
OB --X > * aa
^U
c
c Oy B x>
goa
2 I si
o B .3 U
Is *1j
- E3
S|
^*5
ts
-eo
!
f
o
a a 1u o_ I
sEi-
g??8
1B
g2
B 3
!!cC^ -ss= 2 2g
iIO
O
B B
>. e
* . a *D
B 6
iE 5 s-r
_0 o 1 53 C
o c=
li a
.
B XB
ii
ca 2
2 *u
B-
BcE o
B * a
ou
is
) B 3
> C 2
SI a
UX
O B c _ *a C B
ag
- B
TS B
B *3
S B --7
o UB
P h'
*8-2a b
SC T3J X--
S T5
:>B C -X
a- E
B^
5cA M ;D
85" 5a-2c u c
g? S o
2ac> u >
n a o OO T1 n TJ
ABDOO102750
PSM TRAINING MATERIAL REFERENCE MANUAL
o Ie?x'!
mi f
[f i m
rs
D O
Sf
Q. ow o
II J? If
s f =5
e r * a >.
D o x-Q 3 >c,, 1 |
*8 J
2S^eox 3 O *
gf *
a. g c
o* S
2r
CL t oe
g *o
111*
i| 3|
?> 7 ^*
1
*8o =
If
11 a.
fl
--
I
f)
?
`a
E .S
ill
HX
O
-
E
E co =a
S 8.
coO
o
^
2
3
>5
55 5
w
O) "35. 11
coo _-
co S
es
.= "O
. C
o /D
u o
C0 80
ci If 12 o
O) E
e5
iA 2
?cc
LL
o
:Q.
IIoc\^
3 3-' u --
:L Q. a
x
* "2
9
c
l|
|i o
_
0u _-' 3 S
* c : c a
m -- o
IIw
UJ cc 3 D
LU
o'0
= "
c5 c
2a
s
*2
& ?
1 " go
o g
2S a T3 X *D
E
*2
a a
c o
w
o co
* c
%> -2E
o
o
cOcQ_
* X --
a e
T)
05 2 )
a o
30 X O
0 o
aX
o f4t)
< 1 8 cCC 2 UJ
O S' ...CL
c -2
c 2 E
2i
=
X
" 9i
O (
*5 j= 3 o **
Eo 0
0 c o
5 'o
c
a o
3 JBC a
o aX
3 uO
M
x
&s
>i2
3 * g.
o 2 e;sa
e=I
E S * o
Egg
0-
1O -J a o. 2o *-
Si
x--
a> o
3
Z
OO
O
x
<
3
_ 3O ra o -O
e2
-o o 3
g * i
Si*
>-- "O O "O X cr x
"1
co
-2o
1|
a
*5*
m --S cE
^ E
> T>
O
3C V -3
II 3 o _
.
O if
O
O a.
Oe)
oH
_ V 28 5To>
3 O'
T> x ^ C
^ C "O _ 0 > tC 3
Is a. j#
ll s
za E
x _o
o --
22
0*
2
r
O
e
o
c-
05
-ec aw
o^
0
n
81 o E
& _& c *o
^
Oc c
go S -s
cc >.
5
929
--
2
r
s
c
S
T>
50
|
X
o
g
--
^i55-
I S
0^0
*5 O i o 5
a O' ,,
III
C 3 O
<?5
ABDOO102751
PSM TRAINING MATERIAL REFERENCE MANUAL
x3
11 ??
C0 ,, *E
81
16O ^
5.2
f
| .2
g.?S s si
S E
2JO)
O s
cn
LL
u 05 L co
LU
IIICC
3
D
IILU
5 x.x 0> S
jc
2
ce
uo oo
5"
g
a.
2v 2e OI
2 >s. I 0
5 1*-
c t
~2 x
Q.
^ 0
?
gE
"1
g -E
PX
0
0
2
> * E cP 0
E
x
*c
X -
X
E >. * -o
f>) Bo
rE
2
c
o
? >. 2
2 SZ w
c JH M x
8 11 !* I
s
SXo3 >Ei
c0 sOs
O)
E ^ ? "i
-g
5 1 2.
00o CO
2 5 s 8 -*1p o.
*0 _ o E a.
tO
0 xQ.
CD 0>
c
o 0 ax x-
0
0 E
~ * II
Xa
0
x*
5. ce
o
c-
0 ~ Oo*- 0n
ao2c
E>*
II %
C 2" tj
flj i
oO x 0 *.
?X
0
Xa
0
o2
o
cO
-x
o
I 5
>
X
Xac Xac
a
c0
i?
_5C_5
X0
C
-s
>
0
h-
a
e X
> 0
o> c
X >,
c 0*
S| ft!
in
0. 00 *o; x O C
s5 0 o
c^ 00 _ x 0
a3 os 9|f :*
300
1o 1x co
a2 >
< a
0
o X OX a? a c0
|si
x
3o
t 2xCc
.
Co 3
1Ex
0
XK
=8g
S o8.
0> O
gf g-E &
c
1 .3 0
Is? 0
XX
x1
* il H
1st | &!
e. io
2?-=-
x5
! S I c
*O
0
u O
i
u.
O
o
ir
CL
O
1< cXr
CC LU
=o
OCL "x oE a0
a
Xo >-
* 2* S
Uj III
xO
_
ft
X
O0 0
a cr> a > S &2
x a~ x O oS
SE
I 1I1 II 2^
"2003 "o5 2
1 -sc
a>
Q. X
?s
1 x s tl
oE
2
x^ c_
1 5
Ea
lie
>. " a 0 _ 2>. co ?c x x go
E o
|f
** o
in
ABDOO102752
PSM TRAINING MATERIAL REFERENCE MANUAL
h M "l 11111111111111
D Jt H !l
s . t US
Jce
I!2 s.2 a
o C C
* 83
ajj.i
O E
oo i 2 !E K -sSg
o 3 o
--o a o gc
is I* i s
3 ~
D. p
E23 UJ a. 3
2 T> 3 o 0
h. w
O.
#1
s
C TJ --
o>
I3
23
oS 0
ae e o
a 1~ g*
o' O)
DC LL
O CC\DJ^
CO
LU DC
E C Q.
8| 3? 10 c Js> 8&
Sc
1c 5
oC>
o *
c
5 I
t ?i 3|-
|1
sI
0
OO
E*> 5c |s a8g 05 -
0? Sp
E-C
"O o> c
00
H
g o fc o
8 >-S. E U
P 5oS
o
E
c 05
cS
P
3 oa
o
Q a3
9 s
o LU
En 3t
8 o
2 a.
a2 O
O
o
DC
Q_
* 5
CD =6 -
y
c oc
E
c 'w
o 0
< J2o *51I
DC
LU
O :f I ? --CL
:C 3 E *
: C '.3
E
0O
SE
co >
3 * O^
PO
>.
m 0o
3?;
E o
>c
i? .
8
*O" 3t
C
O P
T3
C 0
0 3CL -K
e0 o0 *s
~SpPo
0
c
0
o o
c o0
we
CL
c o0
c0 ?o 00
Ea
it
"2
e5 v
0. 9P
2 5 a.
8|
a
r
iI
i-g-2 Q. -o O O 0
25
Ol 0
i2
0
O)
> o
P
.E 0 O
0 5 a
II S
*o 1
a.E
^o gE
ABD00102753
PSM TRAINING MATERIAL REFERENCE MANUAL
If
ill
4 Q. X) 5 E
:;i
> u
c _o
f o1 c
I
f i !
si I
o. S. a
.p5
a> c
E
? 8. >.
O o^
753 ,,
T,
aa
2 .
x-- o g Tt 'a
_ A2 uO
. _
III
It l = J5! -S EC2 30cf ci i5sExi
o>
c X
x5
X v
a. o
o >;
-a.
w
ao
x--
n o
0g E
o> s
-S*S 5i --o .-I2f C .
E
x-- *or
c 3
E *
rr
&
o Ts
51 X
<0 33 O
*>
115 tl S
O2 U8I
3O *D O
S*
< aQ. O a a oO .
Ae k *0 Ilf fst oA S3-
2g
3 OC
TJ O' Ol 3M
g
Q- J -2
"S S =S
2 rx o t:
oil a0 TJ O _c o> c 00 cX >> 0 Xc 0 0(1
Ili Co
o o
n Is s
g o 1 5 si 2
ai * 11 =6
-oXI_= I-on*O^2
O C O O D.
f
8 -2fi
'a "g Ilf s o> 3 2
I!
5c
c
2
8
S
5*g g*
ao
* Elr c
2 o = E s
o" S' -
5.
o.
*
3
c. cfot I S'?.
O - X
to . i *c5 I
B 2
5S s2 2
g S'
ot 0 *.
ai
o X Ego
X 'go ?2 J, fc
t
~
8,2-g
.
E
1? Io*2u
E8
Jag
u (0 d
11 E! S0c0C ^*.|>0~-Tco ?1
cS
s
c
5E >*
^E
fg
Si
a. m
E X
*oS EEo 5*
o
;
*o
"O
s
o
*
>
<
a>
xs
o o
?! 5o Io
_ 23 K ? ?5. Sgf
si
i
-5
.g
3D ^3 1 52.
O
1
2=
g
5.
^s
s
&
w
O _c ' 5>
2.
*D a5--
s
E
|
c
II2-5.S*
?!
v* --
CL
o
*r
0O _^ --
| s w
< . c c
CC UJ
CL
>-- 0
2^
*5S Ea
O 1 1I8
0^*0
a
XMc
a
42
3
> 0s
T> 3
8 O
A
VO 0
V 3 O O O
Q ft
X
'
.c= *f>t c 3
2
8 c
a 0 & u
a. _ 0
Q. DC
Cl
O 0 E s. O
3o
l!
II
2o %S
t;
e
II 2 2 S
"i . o c-
2 ^ ?JO- c
3
Cg
X
t 3X
2
a o -- >. o ^ x"
O--
5
"3
g.*o
11
a> 2
S 2 O XT r* *1 O 3 - 3
*
o
e
2Z
o
&
o
ifO 8l-EQ.-s
O O3-' a= UJ u.
Ea o
PSM TRAINING MATERIAL REFERENCE MANUAL
ABDOO102754
I I_ao
-g
r
>
o
^ 11
o
* 3 "D V*
1
fg i!
II 73
S| *
Q. PC
I1
ws ?o
O
cg g *s
S-Sl : s- it
Jj> O
Pi ^s g | 1
E!
| E!
to oo ou
S "C E
jis
!8I 5 .
0
1a
8 i
EE go
o u
c ~g0
c. X
5 9- a .2 5
?S
tr - ^ ~c
c Ox So
3 5c
o o
O
o
O
7
9C
JJ ^9 it
00
I E If
00
$E
ii0>
o ai
cr
LL
o t iw0>
CO LU
cc D Q
ID
15
c
5
73 X
S-2
ao ^o
X _c
T
o2a 22
je o "
-- * o c o_ I)
2 tl
o s
c
3
J
S
t:
a c
C
^?ccoo 0
S
u2"
5.
I--2 IccC~o Xm
73 o
S- ?1
0 73 s ~
a " S* - *o Z,,
5
"O
0
0
3= O
C 0o
x* o
o >
o-- C ?
3 O 4t 5. 2
5x6
o
22
ga
O
73
cO
C oc
O
C o
I ss s.E00
g
x
S S: a
0.0
a 0
a
!> a
S
a
E 3 E _c E
01c co
5 t0o Qo.
a
_ac
Q. 3 C C E _D.
S
C
I
So
0 O
O 06 73 0
CEo*>|.
_, --
00.x05"
O
o
a:
o. ii
o 5E 2
<cc i 8
o IILU
CL
73 3^
51
E 5.->
*5 38
CO
s I
So s
1
J*C *0
O *o
J 8. 55
o >
ao 2 Eta. o* ao.
0a 73 5 5
25
cX
I* 1 if
x O. 73 n ' . cC0 e> x 5 0 X
pe-*
. to:
o
c
O 0
Cl
a2
5i3So 2co Cac.
jOO
5O) 3c
Q. 3
O
82 I5 IO
O
c >. o
Sgw '*0
08 20 5|
3 o
X^6o
5 xo
t 8 o
5 E5 a
So.c a 5
*
m
N
ABDOO102755
APPENDIX A
List of Acronyms
i
i
13
ABDOO102756
LIST OF ACRONYMS
AIChE * American Institute of Chemical Engineers
ANSI*
American National Standards Institute
API *
American Petroleum Institute
ASHRAE * American Society of Heating, Refrigeration and Air-Conditioning Engineers
ASME *
American Society of Mechanical Engineers
ASTM
American Society for Testing and Material
AWS *
American Welding Society
BFD
Block Flow Diagram
CCPS *
Center for Chemical Process Safety
CGA *
Compressed Gas Association
CMA *
Chemical Manufacturers Association
DIERS
Design Institute for Emergency Relief Systems
EPA Environmental Protection Agency
FEMA
Federal Emergency Management Agency
FMEA
Failure Mode and Effects Analysis
FTA Fault Tree Analysis
HAZOP
Hazard and Operability Study
HHC
Highly Hazardous Chemical
IDLH
Immediately Dangerous to Life and Health
14
ABDOO102757
1IAR * ISA LC LD MSDS NFPA * OSHA P&ID PEL PFD PHA PSM PQV SOCMA SOP STEL
International Institute of Ammonia Refrigeration Instrument Society of America Lethal Concentration Lethal Dose Material Safety Data Sheet National Fire Protection Association Occupational Safety and Health Administration Piping and Instrument Diagram Permissible Exposure Limit Process Flow Diagram Process Hazard Analysis Process Safety Management Program-Quality-Verification Synthetic Organic Chemical Manufacturers Association Standard Operating Procedure Short Term Exposure Limit
* Mailing address and telephone numbers included
15
ABDOO102758
Referenced Agency Addresses and Phone Numbers
AlChE American Institute of Chemical Engineers 345 East 47th Street New York, New York 10017 Phone: 212-705-7338
ANSI American National Standards Institute 11 West 42nd Street New York, New York 10036 Phone:212-642-4900
ASHRAE American Society of Heating, Refrigerating and Air-Conditioning Engineers 1791 Tullie Circle, N.E. Atlanta, Georgia 30329 Phone: 404-636-8400
ASME American Society of Mechanical Engineers 22 Law Drive P. O. Box 2300 Fairfield, New Jersey 07007-2300 Phone: 800-843-2763
AWS American Welding Society 550 N.W. LeJeune Road Miami, Florida 33126 Phone: 800-443-9353
CCPS Center for Chemical Process Safety of the AlChE 345 East 47th Street New York, New York 10017 Phone: 212-705-7319
16
Referenced Agency Addresses and Phone Numbers (Continued)
CGA Compressed Gas Association 1725 Jefferson Davis Highway, Suite 1004 Arlington, Virginia 22202 Phone: 703-412-0900
CMA Chemical Manufacturers Association 2501 M Street, N.W. Washington, D.C. 20037 Phone: 202-887-1100
MAR International Institute of Ammonia Refrigeration 1101 Connecticut Avenue, N.W., Suite 700 Washington, D.C. 20036 Phone: 202-857-1110
ISA Instrument Society of America 67 Alexander Drive P.O. Box 12277 Research Triangle Park, North Carolina 27709 Phone: 919-549-8411
NFPA National Fire Protection Association 1 Batterymarch Park Quincy, Massachusetts 02169 Phone: 800-344-3555
17
ABDOO102760
APPENDIX B
Glossary of Terms
18
ABDOO102761
GLOSSARY OF TERMS
BLOCK FLOW DIAGRAM or BFD1 A diagram used to show the major process equipment and interconnecting process flow lines as well as flow rates, stream composition, temperatures, and pressures. The BFD is intended as a simplified diagram.
CHECKLIST2 Detailed list of desired system attributes or steps for a system or operator to perform. Usuaffy written from experience and used to assess the acceptability or status of the system or operation compared to established norms.
CONSEQUENCE2 The direct, undesirable result of an accident sequence usually involving a fire, explosion, or release of toxic material. Consequence descriptions may be qualitative or quantitative estimates of the effects of an accident in terms of factors such as health impacts, economic loss, and environmental damage.
DECISION TREES4 Decision trees are a special case of event tree models used to guide the user through multiple questions and provide a course of action based on the outcome of all of the questions. They provide no logical method of choosing the initiating event.
ELECTRICAL ONE-LINE DIAGRAM1 A diagram including legend of the electrical power distribution system that could contribute to a highly hazardous chemical release showing such items as power consumers, the chain of supply back through starters, distribution centers, substations to the main feeder, emergency power supply, and connections to various components. For complex systems, the one-line diagram may be a group of drawings.
FACILITY3 The buildings, containers and equipment that could reasonably participate in a catastrophic release as a result of being physically interconnected or of their proximity and in which dangerous substances are used, stored, manufactured, handled, or moved.
19
ABDOO102762
FAILURE MODE AND EFFECTS ANALYSIS or FMEA1 A specifically designed method to identify the conceivable ways that a highly hazardous chemical equipment or its components can fail and the effect of the failure on the system with respect to a release. The failure and effects are determined in a study of updated piping and instrument diagrams that describe the facility taking into consideration process chemistry,, standard operating procedures, maintenance procedures, operator job descriptions, process flow diagrams, inventory tabulations, electrical one-line diagrams and other documents. The resulting qualitative analysis is translated into a quantitative FMEA when probabilities of the failure of components are assigned. The results of the FMEA are reported for a unit or system of a facility on an FMEA table. The results are entered on a FMEA table for each equipment item or component studied are as follows: the identification number of the item, the name of the item, the other equipment potentially affected with the equipment identification number and the effect of the failure on that equipment, a classification of the criticality ranking of the failure based on quantity or rate of the potential release, the probability of the failure and the suggested action in terms of equipment or procedure to prevent the failure or to mitigate the results of the failure.
FAULT TREE ANALYSIS or FTA1 The analysis of the logic diagram constructed from a study of the updated piping and instrument diagrams that describe the facility taking into consideration process chemistry, standard operating procedures, maintenance procedures, operator job descriptions, process flow diagrams, inventory tabulations, electrical one-line diagrams and other documents. The logic diagram is called a fault tree and represents a qualitative analysis of the hazards. Results of the FTA are reported for a unit or system on a table. Entered on the table are the descriptions of the various combinations of equipment or procedural failures that can lead to a release. The combinations are determined by solving the fault tree logic diagram for the minimal cut sets, that is, the smallest combination of equipment or procedural failures, which if all occur, will result in the "top event", that is the highly hazardous chemical release. The table is also entered with a criticality ranking based on the quantity or rate of the potential release, a probability for the respective failures and the suggested action in terms of equipment or procedure to prevent the failure or to mitigate the results of the failure. The analysis of the logic diagram includes the identification of "minimal cut sets." When probabilities are assigned to each element of the event sequence, a qualitative fault tree is obtained which gives the probability or frequency of occurrence of the release.
HAZARD2 An inherent physical or chemical characteristic that has the potential for causing harm to people, property, or the environment.
20
ABDOO102763
HAZARD ANALYSIS1 A systematic identification of the potential conditions that may result in an EHS accident
HAZARD AND OPERABILITY STUDY or HAZOP1 A systematic study of updating piping and instrument diagrams that describe the highly hazardous chemical facility taking into consideration process chemistry, standard operating procedures, maintenance procedures, operator job descriptions, process flow diagrams, chemical inventory tabulations, electrical oneline diagrams and other documents. The study is performed by a multidisciplinary team to identify hazard or. operability problems that would result in a highly hazardous chemical accident. Deviations from the design value of key parameters (flow, temperature, composition, time, quantity, etc.) of each segment of the highly hazardous chemical facility and its procedures are studied using guide words (such as, more of, less of, none of, part of, more than and other) to control the examination and evaluation. The study team shall consist of trained personnel knowledgeable in the technology and operations, such as process chemistry, the design of the system, the procedures of its operation and maintenance, and the related codes, standards and practices. In addition, the study team shall have technical expertise to answer most questions of the review without resorting to further expertise. The study team shall include a study leader specifically qualified for his or her leadership role by training or previous experience in HAZOP studies and a team secretary who shall record the results of the study. Persons who occupy these team study positions shall be technically trained and be available for the duration of the study. Results of the HAZOP study shall be reported by tabulation for a unit by key equipment, such as vessels or pipelines, and process parameter. The results are entered on the table as follows: guide word, causes of the deviation, consequences of the deviation in terms of a potential release, the criticality based on the quantity or rate of potential release and the suggested action in terms of equipment or procedure to mitigate the deviation.
HIGHLY HAZARDOUS CHEMICAL or HHC3 A substance possessing toxic, reactive, flammable, or explosive properties.
HUMAN ERROR2 Actions by or failures to act on the part of designers, operators, managers, or other individuals that may contribute to or result in accidents.
MATERIAL SAFETY DATA SHEET or MSDS1
21
ABDOO102764
A document which describes, at a minimum, the chemical and physical properties and the physical and health hazards of a substance.
ABDOO102765
MODIFICATION1 Any change in existing equipment or procedures that would require a change in process safety information and/or operating procedures. Modification does not include routine maintenance or replacement in kind.
OPERATOR2 An individual responsible for monitoring, controlling, and performing other tasks as necessary to accomplish the productive activities of a system. Often used in a generic sense to include people who perform various tasks (e.g.; reading, calibration, maintenance).
PIPING AND INSTRUMENT DIAGRAM or P&ID1 One or more detailed drawings including legends and citations of referenced documents showing: every item of highly hazardous chemical equipment and its identification number (including installed spare equipment); every pipe size, flow direction, identification number and identification of ANSI piping specification and break between piping specifications; symbols and identification of every instrument including instrument function to show trips and interlocks represented in accordance with Instrument Society of America standards or a standard adequate for the conduct of a safety review or hazard analysis with an appropriate symbol legend shown, every valve, the failsafe position of control valves or non-hand operated valves in the case of instrument air or power failure; steam traps; representation of insulation or heat tracing of piping, highly hazardous chemical equipment and instruments; sizes of all important equipment nozzles with location shown schematically to reflect function and elevation, such as, drains, vents, flushing connections and steam connections; references to inter-facing with other diagrams describing process, service, treatment, disposal, or utility systems; data on type, size, and set pressures of every relief valve and relieving device; instruments to monitor early detection of abnormal conditions or a highly hazardous chemical release; where critical, the relative elevations between equipment and of key piping; notes or symbols on such items as slope of critical piping to avoid pockets, or, where critical symmetrical piping; notes on each item of highly hazardous chemical equipment, such as, material of construction, design temperature, design pressure, design thermal duty of heat exchangers, design capacity and dynamic head of rotating equipment, etc.
PRELIMINARY HAZARD ANALYSIS2 A technique that is derived from the U.S. Military Standard System Safety Program Requirements. Focuses in a general way on the hazardous materials and major process areas of a plant, and is often used as a precursor to further hazard analyses.
23
-ABDOO102766
PROCESS CHEMISTRY1 The chemical reactions which are relevant to possible scenarios of highly hazardous chemical releases, including information on raw materials, intermediates, products, and waste products.
PROCESS FLOW DIAGRAM or PFD1 A diagram including a legend of a facility which depicts the use, generation, storage or handling of a highly hazardous chemical showing items of equipment (groups of duplicate equipment may be represented by one symbol if desired), flow of material from item to item, simplified basic control loops or major control schemes, points of discharge to the environment, and showing or crossreferencing documents which give details of material balance, flows, raw materials, products, intermediates, treatment chemicals, operating conditions of temperature, pressure and steam characteristics, operating cycles and batch sizes where applicable. A process flow diagram includes, or references, a block flow diagram that depicts the receipt, handling and storage steps at the site of shipping containers of the highly hazardous chemical.
PROCESS SAFETY MANAGEMENT2 The application of management systems to the identification, understanding, and control of process hazards to prevent process-related incidents and injuries.
REPLACEMENT IN KIND1 The replacement of existing highly hazardous chemical equipment with identical or equivalent highly hazardous chemical equipment, and installation according to criteria for design and operation.
RISK2 Combination of the expected frequency (events/year) and the consequence (effects/event) of a single accident or a group of accidents.
STANDARD OPERATING PROCEDURE1 The document setting forth the operating procedures covering all details of the operation involving highly hazardous materials that are currently in effect at the facility.
TRUTH TABLES4
24
ABDOO102767
A listing of all combinations of the states of basic events, the resulting occurrence or non-occurrence of a top event, and the corresponding probabilities for the combinations.
25
mnninm?
WHAT-IF CHECKLIST1 A method of hazard analysis based on a systematic study of updated piping and instrument diagrams that describe the highly hazardous chemical facility taking into consideration process chemistry, standard operating procedures, maintenance procedures, operator job descriptions, process flow diagrams, inventory tabulations, electrical one-line diagrams and other documents. The study is performed by a multidisciplinary team to identify hazards or operability problems that could result in a highly hazardous chemical accident. The study is composed of a comprehensive list of questions prepared in advance from study of documents by team members either in conference or independently usually corresponding to their individual background. The study team shall consist of trained personnel knowledgeable in the technology and operations, such as process chemistry, the design of the equipment, the procedures of operation and maintenance and the related criteria for design and operation. In addition they shall have technical expertise to answer most of the questions of the review without recourse to further expertise. The team shall include a person assigned, to lead the study and a person to record the results who are technically trained and will be available for the duration of the study. Results of the study shall be reported for a unit on a table. The results are entered on the table as follows: the "what if' question and its corresponding consequence/hazard, the criticality based on the quantity or rate of the potential release and the recommended action in terms of equipment or procedure to mitigate the consequence/hazard.
1. New Jersey Toxic Catastrophe Prevention Act, N.J.A.C. 7:31, New Jersey Department of Environmental Protection and Energy, June 18, 1993.
2. Guidelines for Hazard Evaluation Procedures. 2nd. ed., Center for Chemical Process Safety of the American Institute of Chemical Engineers, 1992.
3. Process Safety Management of Highly Hazardous Chemicals, 29 CFR Part 1910.119, Occupational Safety and Health Administration, February 24, 1992.
4. Reliability Engineering and Risk Assessment. Ernest J. Henley and Hiromitsu Kumamoto, Princeton-Hall, Inc., 1981.
26
ABDOO102769
APPENDIX C
Technical References
OPERATING PROCEDURES "Standard for MSDSs," ANSI RP 2400.1 "Procedures for Welding or Hot Tapping On Equipment Containing Flammables," API Publication 2201, Third Edition, October 1985. "Sizing, Selection, and Installation of Pressure Relieving Devices," Part 1, API RP 520, July 1990. "Guide for Pressure Relieving and Depressuring System," API RP 521, November 1990. "Venting Atmospheric and Low Pressure Storage Tanks (Nonrefrigerated and Refrigerated)" Third Edition, API Std 2000-82, (R 1987). "Overfill Protection from Petroleum Storage Tanks" First Edition, API RP 2350-87. "Management Practices, Self-Assessment Process and Resource," API RP 9000. "Safe Maintenance Practices in Refineries," API RP 2007, 1983. "ASME Boiler and Pressure Vessel Code, Section VIII, Division I - Pressure Vessel Requirements," American Society of Mechanical Engineers, New York, NY, 1968. Guidelines for Hazard Evaluation Procedures. 2nd ed., Center for Chemical Process Safety of the American Institute of Chemical Engineers, 1992. Plant Guidelines for Technical Management of Chemical Process Safety. Center for Chemical Process Safety of the American Institute of Chemical Engineers, 1992. "OAQPS Control Cost Manual," EPA 450/3-90-006, January 1990, U.S.E.P.A., Office of Air Quality Planning And Standards, Research Triangle Park, North Carolina, 27711. "A Guide to Good Practices for the Operation of an Ammonia Refrigeration System," MAR 1983. "Guide for Venting Deflagrations," NFPA 68-1988.
27
ABDOO102770
utual Loss Prevention Data
F
ABDOO102771
OPERATING PROCEDURES (cont'd.) "Standard for MSDSs," 29 CFR 1910.1200 "Confined Space Entry Program," 29 CFR 1910.146 'The Control of Hazardous Energy (Lockout/Tagout) 29 CFR 1910.147 "Hot Work Fire Prevention and Protection," 29 CFR 1910.252 WAC 296-67-021 Operating Procedures WAC 296-67-054 Hazard Communication WAC 296-67-075 Air Contaminates WAC 296-67-300 Hazardous Waste Operations and Emergency Response WAC 296-67-145 Confined Spaces WAC 296-24-110 Lockout/Tagout
29
ABDOO102772
GENERAL REFERENCES
Ammonia Plant Safety fand related facilities!, vol. 23, American Institute of Chemical Engineers, 1981.
Ammonia Plant Safety (and related facilities!, vol. 24, American Institute of Chemical Engineers, 1984.
Ammonia Plant Safety fand related facilities), vol. 27, American Institute of Chemical Engineers, 1987.
Ammonia Plant Safety fand related facilities), vol. 28, American Institute of Chemical Engineers, 1988.
Ammonia Plant Safety fand related facilities!, vol. 31, American Institute of Chemical Engineers, 1988.
"Guidelines for Safe Automation of Chemical Processes," American Institute of Chemical Engineers, 220p.
"Guidelines for Investigating Chemical Process Incidents," American Institute of Chemical Engineers, 347p.
"Guidelines for Auditing Process Safety Management Systems," American Institute of Chemical Engineers, 136p.
"Management of Process Hazards," American Petroleum Institute, Recommended Practice 750.
"Process Safety Management (Control of Acute Hazards)," CMA.
Chemical Manufacturers Association (CMA's Manager Guide), First Edition, September 1991.
The Revised Field Operations Manual (FOM)," OSHA Instruction CPL 2.54B, June 15, 1989.
"State Plan Policies and Procedures Manual," OSHA Instructions STP 2.22A, Ch-2, January 29, 1990.
"Integrated Management Information Systems (IMIS) Forms Manual, Chapter V " OSHA Instruction ADM 1-1.12B, December 29, 1989.
30
ABDOO102773
3n of Operations with Catastrophic Potential,' OSHA Instruction 5, 1988. nent Guidelines for Compliance," OSHA 3133; U.S. DOL, 1992. -nent," OSHA 3132; U.S. DOL, 1992. am Management Guidelines," U.S. DOL, 1989. Systems," June 1988; U.S. EPA, Office of Solid Waste and Washington DC 20480. ix," Dow Chemical Co., May 1988. * * A New Approach," National Safety Council, 1983. ament Resources from the American Institute of Chemical ustrial Hygienists. James A. Gideon and Thomas W. Carmody, ane Association Journal (53), June 1992. Safety Performance," Report A-3, The Business Roundtable. es for Contractor Safety and Health," Texas Chemical Council. rocess Industries," Volumes 1 and II, Frank P. Lees, Butterworth,
ng Design for Process Safety," 500p.
ABDOO102774
APPENDIX D
Example Programs
The following examples illustrate approaches taken by companies seeking to address the Operating Procedures requirements of 29 CFR1910.119. These examples have not been reviewed and/or endorsed by OSHA and should not be construed as model programs. Primatech makes no claims regarding the acceptability to OSHA of the information contained herein. The example programs provided herein were developed for specific processes, and are not generic in nature. Since the OSHA PSM regulation is performance-based, readers are strongly encouraged to develop programs tailored to their own covered processes.
CONTENTS D-1 Operating procedures - amine unit (shut-down) D-2 Operating procedures - amine unit (start-up) D-3 Operating procedures - crude unit (start-up) D-4 Operating procedures - crude unit (emergency procedures) D-5 Operating procedures - chemical transfer process
32
ABDOO102775
I I )
D-1 Operating Procedures - Amine Unit (Shut-down) The following is an example of operating procedures used in a petroleum refinery. The procedures outline the specific steps to be taken for the shut-down of an amine unit. It includes safety requirements, special tools or equipment required and special considerations for the safe shutdown of the unit.
33
ABDOO102776
refinery
NAME op PROCEDURE:
SHUT-DOWN OF THE NORTH AMINE UNIT
A. PURPOSE:
TO PROVIDE PROCEDURES FOR A SAFE SHUT DOWN OFTHE NORTH AMINE UNIT.
B. REFERENCES:
P&ID'S PROCESS FLOW DIAGRAM
#4874-5-10-011-1 * 4874-5-10-011-2 * 4874-5-10-011-3 * 4874-5-10-011-4
U 4874-5-10-011-5 n 4874-5-10-011-6 * E-11 838-60-0.101
C. APPROVALS:
COMPLEX SHIFT SUPERVISOR A-CREW
COMPLEX SHIFT SUPERVISOR C-CREW
COMPLEX SHIFT SUPERVISOR 8-CREW
COMPLEX SHIFT SUPERVISOR D-CREW
COMPLEX SUPERVISOR
1
ABD00102777
SAFFTY REQUIREMENTS-
1. Follow all refinery safety policies and procedures during shut down of the North Amine Unit.
2. All personal protective eauipment must be worn, where applicable.
3. Ascertain that H,S alarm system is operable and SC8A breathing apparatus units are available and ready to use.
4. Check that all fire fighting eouioment is in the correct location and reaoy for service.
5. Scaffolding mustbe installed at predetermined locations and a portable scaffold available for unit technicians to safely gain access to valves and eQuipment.
6. Full Body Harness must be worn when Scaffolding or Platforms are not available above 4 feet.
SrSOALTOPlS QR EQUIPMENT REQUIRED:
1. 18, Chemical dram hoses for draining Amine & condensate
2. 5. 3/4* check valves and 5. pressure regulators set at 10 psig. 3. 5. green N7 hoses. 4. 1, stripping pump and 4, 3* x 20* lengths of reinforced vacuum hose.
5. 1. PortaScaffold. PE-SHUTOOWN PROCEDURES AND SPECIAL CONSIDERATIONS:
1. Work list on specific items that involve entry, draining, etc., should have been gone over thoroughly, (on site), with the Unit Supervisor. Console Shift Supervisor, and the Maintenance Supervisor in charge to review any item that may need darification.
2. A current blind list that applies to the North Amine Unit must be issued to the Maintenance department.
3. A master blind list will be kept available and up to date by the Sulfur Recovery Unit Senior Technidan in charge of the North Amine Unit shut down.
4. Maintain level in Lean DBA Surge Tank, 10-F-20, at 4 feet.
5. Check that all the Lean Amine from the Lean Amine Pumps 10-G-21ABC is going throuQh the Lean Amine Coolers. 10-E-23A/B. and 8* bypass is dosed.
6. Assure that level in Amine Sump, 10-F-21, is pumped down, line up 10*
2
ABDOO102778
G-24 to pump back to 10-F-20 and block in discharge back to Rich Amine line D/S of H.l.C-250.
7. Have filter elements available on hand to do complete filter change out for Lean Amine Filter. 10-J-20 & Amine Sump Filter, 10-J-22.
8. Review Toxic Gas Procedure and hazards of H,S with all unit personnel.
9. With the North Amine Unit shutting down it will be necessary to have
the Unsaturate Gas Plant line up the Amine system to the East and West Amine Trains.
10. North Sulfur Unit will no longer have add gas supply from the North Amine Unit.However, add gas can be routed from the east or west Amine units to keep the North SRU operating if desired.
11. North Amine Unit will be circulated until unit is cool.
12. Drain all Amine to closed amine sewer. (Do not drain Amine to the OWS. Utilities cannot treat amine at the Waste Water Treatment Rant.)
13. Unit will be deoressured. steamed out to gas free and water washed to remove sludge deoostts from equipment.
T4. Personnel will be familiar with physical locations of shutdown lines, drains and vents in order that the unit will be shut down safely and efficiently.
15. Run chemical drain hoses to the spedfie locations as described in section G. sub-section 3. Do not hook up hoses at this time.
16. PREPARE UNIT FOR SHUTDOWN:
a. Rich DEA Rash Drum. 10*0-20. From the Master BlindList removedrain spec blinds
per the following:
(1) 3. 2* and 1, 4* blinds at gate valves on bottom drains to Closed DEA Sewer for Rich DEA Rash Drum. 10-D-20.
(2) 1. 2* blind at gate valve on bottom drain to the Closed DEA Sewer for the Entrained Amine Separator, 10-D-49.
(3) Install 0-100 psig pressure gauge on D/S ball valve for P1C-250B control loop.
b. Lean/Rich Amine Exchangers. 10-E-20A/D.
From the Master Blind List remove drain following:
blinds per the
(1) 2, 2" blinds at gate valves for tube side drains to Closed DEA Sewer for Lean/Rich Amine Exchangers. 10-E-20A/D.
(21 2, 2* blinds at gate valves for shell side drains to
3
AfiDOO 102779
Closed DEA Sewer for Lean/Rich Amine Exchangers. 10-E20A/D.
c. Regenerator Reboiiers. 10-E-22A/B.
Fromthe Master the following:
Blind List remove
drain spec blinds per
___ ID .3* blind at gate valve for shell side common inlet drain to the Close DEA Sewer for Regenerator Reboilers. 10-e22A/B.
___ (2) 2* blind at gate valve for reboiler common outlet drain to
the Closed DEA Sewer forRegenerator
Reboiiers. 10-E-
22A/B.
d. Regenerator Ovhd Accumulator, 10-0-22.
From the Master Blind List remove drain spec blinds per the following:
___ (D 2* blind at gate valve for ' bottom drain to Closed DEA Sewer for Regenerator Ovhd Accumulator. 10-0-22.
___ (2) 1 1/2" blind at gate valve for drain to OWS for IT-261 &. LG-558 level bridle on 10-0-22.
e. Regenerator Reflux Pumps. 10-G-20A/B and Regenerator Ovhd Hydrocarbon Pump,10-G-22A.
From the Master Blind List remove drainsoec blinds per following:
the
___
ID 3/4* blinds at gate valves for drains to OWS for 10-G20A/B.
____
(2) 1 1/2' blind at gate valve for drain to OWS for 10-G-22A.
17. Install N, hoses with check valves and regulators set at 15nsin at following locations:
____
a. 3/4* bleeder at U/S of P1C-250A control valve.
____ ___
b. 3/4*U/S bleeder for PIC-253A control loop off of 10-D-22.
c. 3/4* bleeder U/S of F1C-258 control valve for Lean Amine spill back to 10-F-20.
d. 3/4* high point vent on suction line for 10-G-26A. Lean Amine Filter Pump.
G. NORTH AMINE UNiT SHUTDOWN:
1. Reduce Rates And Amine Circulation:
4
ABDOO102780
Iff
a. Notify the Utilities section of the reduction in 40* steam usaoe and condensate production.
b. Notify the Console Shift Supervisor for the FCC and the Night Supervisor of the planned Amine Unit shutdown.
c. Have the Saturate Gas Plant. Unsaturate Gas Plant. Merox and
C.H.O Unit slowly reduce the total Lean Amine charge rate to 45
M B/D to their respective contactors and
absorbers. This will
lower the amine circulation on the East and West Amine Units to
accommodate the Unsaturate Gas Plant Amine Absorber, 5-0*6 when
they switch to the amine headers from the East and West Amine
units. As circulation is adjusted the Amine Surge & Mix Tank,
10-F-1, level will fluctuate.
d. Close console monitoring of the North Amine unit and the East and West Amine unit must be done during the bypass of the North Amine Lean to Rich piping.
e. When the total am'ine circulation is reduced to 45 M B/D to the East & West Amine Units, have the PCC Console Supervisor direct the Sr. Tech and Process Technicians to switch 5-D-6 from the North Amine Unit to the East and West Amine Units oer procedure.
f. When the switch is complete and circulation is being maintained through the 6* bypass, start reducing the circulation with HIC2SQ and F.V-251 at a rate of 10 M B/D per hour down to 13-15 M B/D.
0- When the Rich Amine Row RC-251 to the DEA Regenerator has dropped to 20 M B/D shut down one Lean Amine Pump, 10-G-21ABC.
h. Insure that F1C-25B is spilling back more Lean Amine to 10-F-20 as amine circulation is lowered.
i. When amine circulation has been reduced to 13 M B/D. the Norm Amine Unit will be at minimum circulation.
J- Put steam/feed controllers on ratio control . for the Regenerator
Reboilers.
10-E-22A/B and set it at 1.0. This will reduce
steam automatically as rate is reduced with FV-251
k. Continue to circulate the amine unit in this manner until PIC253A is dosed and Accumulator pressure starts to fall. This will indicate that Acid Gas production has stooped.
I. Close the acid gas butterfly valve D/S of P.V-253A control looo on acid gas piping to the North Sulfur at battery limits.
m. Set PV-253B at 11-15 psig to vent excess pressure to the LP flare for Regenerator Ovhd Accumulator, 10-D-22.
n. Close 2* gate valve D/S of LV-250 for Hydrocarbon from Regenerator Ovhd Accumulator. Put 10-G-22A in the off position.
5
ABDOO102781
o. Lower level to 0V. on LT-250 block in the 3* battery limits valve for hydrocarbon line to F.C.C unit (or Coker) from 10-0*20, when hydrocarbon has been displaced from the level glass.
p. Maintain PIC-250 at 60 psig by allowing* fuel gas to control 10D-20 pressure from P.V-250B.
q. Leave LT-251 for the Rich DEA Bash Drum, 10-D-20 set on cascade mode with FV-251 on the control console, this will control the level in the Rich DEA Rash Drum and maintain a somewhat stable Rich Amine Feed to the DEA Regenerator, 10-D-21. If LT-251 level starts to become erratic HlC-250 can be closed down to' reduce tne amount of rich amine to 10-D-20.
2. Reduce Temperature to Cool Down the Unit:
a. When 35 pstg steam flow is at 10-15 M LB/HR for each FT-252 & F7- 259 to 10-E-22A/B, take steam
control valves off ratio control and slowly reduce the steam flow in manual to bom reboiiers.
b. Lower level slowly to 10*/. in 10-E-22A/B Regenerator reboiiers. LT-252A & LT-252B making sure that process gases do not blow through to the Lean DEA Surge Tank. 10-F-20.
c. Adjust variable speed fans for 10-E-21A/B as necessary to keeo uvhd temp at 115'F per Tl-258.
d.
Close 1 1/2" reflux bleed line to 11-G-30,
D/S of discharge
lines for the Regenerator Reflux Pump, 10-G-20A/B.
e. Block in condensate supply line to 10-M-20 desuperheater.close 1 1/2* gate valve for 150# velocity steam to 10-M-20 desuoemeater.
f. At this time close off all steam to 10-D-22A/B Regenerator
Reboiiers. Block in RC-252 & RC-259 steam contrr; valves ano
IIC-265 level control loop for
10-D-23 condensate pot. crack
open 3* condensate valve to OWS U/S of
UC-265 level control
valve.
g. When no more reflux is being produced, pump me level LIC-253 from the Regenerator Ovhd Accumulator. 10-D-22 to the regenerator and shut down the Regenerator Reflux Pumps 10-G20A/B when pumps lose suction.
h. With N, injection hoses installed at low point bleeder U/S of
PIC-253A control valve, slowly start to pressure up me entire Amine system to 10 psig.
i. Circulate the amine through the system until reboiier outlet temperatures fall below 125'F per Tl-256.
j. When reboiler outlet temperatures have fallen below 125'F shut
6
ABDOO102782
down 10-G-21 ABC Lean Amine Pumps.
k. When LT-251 level for 10-D-20 reaches 0*/. and level glass indicates 0*/.- Line up 10-0-20 to displace the remainder of amine bv opening the top T drain valves from the stilling well, main compartment to the rich amine outlet section of 10-D-20. Keep drain line dosed to the Closed DEA Sewer.
l. Crack open 2" drain valves for tube side inlets on 10-E-20A/D if drain valves are gassing through then dose the 1 1/2" ball
valve at battery limits for fuel gas make up to Rich DEA Rash Drum, 10-D-20. Open PIC-250B to 100*/. and* depressure the fuel gas line from battery limits into the Rich DEA Rash Drum, 1Q-D20.
m. Monitor the local 0-100 psig gauge installed on the 3/4" D/S
ball valve on
P1C-250B control looo. wnen the local pressure
gauge has eoualized with
PT-250 transmitter for the Rich DEA
Rash Drum close the 1 1/2" gate valve D/S of PIC-250B central looo for Fuel Gas make-up to 10-D-20.
n. Close 12" butterfly valve for Lean DEA inlet to Lean QEA Surge Tank 10-F-20 after tne Regenerator Reboilers, 10-D-22A/B have stopped gaining level.
o. Open the 6* gate valve for the Filtered Lean Amine jumpover to the spill back line to the Lean DEA Surge Tank. 10-F-20.
*(
p. Close the 3. 6" gate valves for Rltered Lean Amine to the suction lines to the Lean Amine Pumps, 10-G-21ABC.
q. Close 3. 10" suction butterfly valves at 10-F-20 for the Lean Amine Pumps, 10-G-21ABC.
r. Close 10" D/S butterfly valve and 6" bypass valve at RC-25B Lean Amine Spill Back control loop.
s. Close 10" butterfly valve at battery limits for LeanAmine To Units.
t. Close 10" butterfly valve at battery limits for Rich Amine to 10-D-20 Rich DEA Rash drum.
u. Close 3" gate valve at battery limits for Amine Rash gas to F.C.C unit lor Coker) from 10-D-20.
V. Continue filtering amine through the Lean Amine Filter system during the unit draining process.
3. Prepare To Drain Down Unit:
a. There are no provisions for pumping out the amine unit. It must be drained through the dosed DEA sewer system to the Amine Sump. 10-F-21 and pumped to the Lean DEA Surge Tank. 10-F-20.
7
ABDOO102783
b. Proceed to the following steps .to prepare equipment for draining.
m Rich DEA Flash Drum, 10-D-20.
Install chemical drain hoses on low point bleeders end route to Amine Sump, 10-F-21 per the following:
(a) 3/4* bleeder D/S of HIC-250 control loop Rich DEA to 10-D-20.
lb) 3/4" bleeder at battery limits U/S of 3'* isolation valve for liquid hydrocaroon to FCC/Coker.
(c) Install chemical drain hose to 3/4" ball valve U/S of fuel gas makeup PIC-250B and route to 3/4" bleeder D/S of PSV-10067 to the LP Rare.
(d) 3/4" bleeder at battery limits D/S of 14* butterfly valve for Rich DEA to 10-D-20.
(e) 3/4" bleeder at battery limits U/S of battery limits isolation valve lor PIC-250 Amine Rash Gas to the FCC/Coker unit.
(2) Regenerator Ovhd Accumulator. 10-D-22.
Install chemical drain hoses on low point bleeders and route to Amine Sump. 10*F*21 per the following:
(a) 3/4" bleeder D/S of UC-254. Regenerator Reflux to OEA Regenerator. 10-D-21.
(b) 3/4" bleeder D/S of P1C-253A and 14" check valve on actd gas line at battery limits.
(c) 3/4" bleeder D/S of PIC-253B control valve on acid gas line at battery limits.
(31 Lean DEA Coolers. 10-E-23A/B.
Install chemical drain hoses on lowpoint bleeders route to Amine Sump. 10-F-21 per the following:
and
(a) 3/4" low point bieeoeron shell side of
cooler,
10-E-23A/B.
Lean OEA
tb) 3/4" bleeder for Lean Amine to unitsat battery
limits U/S of 10" butterfly valve for Lean Amine to units.
(cl 3/4" bleeder O/S of FIC-258 for Lean Amine spill back to 10-F-20, Lean DEA Surge Tank.
8
ABDOO102784
Lean/Rich Exchangers; 10-E-20A/D.
Install chemical drain hoses on low point bleeders and route to Amine Sump, 10-F-21 per the following:
(a) 3/4* bleeder D/S of FV-251 DEA Regen Feed control valve.
Ibl 3/4* bleeder U/S of UC-252 Regen Reboiler level control valve.
(c) 3/4* high point vent U/S of 12* butterfly valve for Lean Amine to 10-F-20 Lean DEA Surge Tank.
(5) Amine Sump Pump, 10-G-24 discharge line.
Install chemical drain hoses on 3/4" bleeder and route to the Amine Sump, 10-F-21 per the following:
(a) 3/4* bleeder on filter outlet piping at the Rich Amine line O/S of HIC-250.
(6) Install Chemical drain hoses on the vent and drain manifold to the LP Rare per the following:
(al Rich DEA Rash Drum, 10-0*20.
1) 3/4" ball valve U/S of fuel gas make-up PIC2506 and route to the 3/4* bleeder 0/S of PSV-10067 to the LP Rare.
2) 3/4* bleeder at battery limits U/S of battery limits isolation valve for PIC-250A Amine Rash Gas to the FCC/Coker.
3) 3/4* bleeder at battery limits U/S of 3* isolation valve for liquid hydrocarbon to the FCC/Coker.
4) 3/4* bleeder on common 2* drain piping to the Dosed DEA Sewer for the Entrained Amine Separator. 10-0-49.
b. Regenerator Overhead Accumulator. 10-0-22.
1) 2. 3/4* bleeders on discharge line of 10-G22A back to D/S side of UC-250 control loop and HIC-250 control looo.
2) Remove 1 1/2* drain detail D/S of 1 1/2* gate valve on drain piping to the OWS for LT-262 & LG-558 level bridle assy. Install 3/4" chemical hose to drain Hydrocarbon side of
9
ABDOO102785
10-D-22 to the IP Rare.
3) ,
Remove the 1 1/2* drain detail D/S of the 1
1 /2" gate valve on drain piping to the OWS
for the Regenerator Ovhd Hydrocarbon pumc.
10-G-22A. Install 3/4* chemical hose
to
drain the Hydrocarbon side of
10*0*22
to the LP Flare.
4. Drernino Down Of Unit:
a. Special Consideration prior to Oraining down the unit.
(1) Verify that alt battery limit isolation valves have been closed as outlined in section G.
12) Flag off area around the North Amine Unit - USE THE BUDDY SYSTEM DURING ALL DRAINING. Note: Have extra SCBA air packs available at the unit.
(3) With N, injection hoses installed at low point bleeder U/S of PIC-250A control valve, slowly start to pressure up the entire Amine system to 15 psig.
(4) When N, pressure has been established and is maintaining 15 psig on PT-250 for 10-D-20, Rich DEA Flash Drum. PI-251 for 10-D-21. DEA Regenerator, PT-253 for 10-D-22, Regenerator Ovhd Accumulator. Check valve position for PIC-253B on the control console, if valve is ooen set PIC* 253B up to 20 psig to stop excess flaring.
Note: (5)
Unit draining must be monitored so 10-F-20. Lean DEA Surge Tank & 10-F-21. Amine Sump, does not over fill. Adjust unit draining to Closed DEA sewer to keep level below 80*/.. Assure that 10^3-24 DEA Sump Pump is working properly.
b. Draining Eauipment Per The Following:
Note: Do not overfill the Amine Sump. 10-F-21 and the Lean DEA Surge
Tank.
10-F-20.
11) Rich DEA Rash Drum. 10-0-20.
(a) Crack open 3. 2* bottom gate valves and 1. 4* sortom gate valve and the 4s common drain valve to start draining the Rich DEA Rash Drum, 10*0*20 to the Closed DEA sewer.
(b) Crack open and drain level bridles for LT-251, LT-
250, and
LG-562 for Rich DEA Rash Drum to the
Closed DEA Sewer.
(c) Open HIC-250 control valve to 100*/. on the console
10
ABDOO102786
and crack open 8" bypass valve. Open 3/4' i0w point
bleeder D/S of
HlC-250 control loop to start
draining down Rich Amine line through attached
chemical hose to Amine Sump. Note: Check drain
hose at Amine Sump if hose is blowing gas block in
3/4" bleeder at HIC-250.
(d) Open 3/4" ball valve on D/S side of PIC-250B control loop, and the 3/4" gate valve D/S of PSV10067. Depressure remainder of fuel gas line from bartery limits through the attached hose to the LP flare. When PIC-250B fuel gas line is depressured close 1 1/2* U/S and D/S* ball valves and 1 1/2" bypass valve on the control loop to isolate fuel gas line.
(el Open 3/4* bleeder at battery limits D/S of 14" butterfly valve for Rich DEA to 10*0*20 and drain down through attached chemical hose to the Amine Sump.
(f) Open 3/4 bleeder at battery limits U/S of 3" gate valve for liquid hydrocarbon to the FCC/Coker from 10*0*20 and DRAIN DOWN THROUGH ATTACHED CHEMICAL HOSE TO THE VENT AND DRAIN MANIFOLD TO THE LP FLARE. Note: Check drain hose at vent and drain manifold if hose is blowing gas block in 3/4* bleeder at battery limits.
(g) Crack open 3/4" bleeder atbattery limits U/S of 3* isolation valve for Amine Flash Gas to FCC/Coker unit and DRAIN DOWN THROUGH ATTACHED CHEMICAL HOSE TO THE VENT AND DRAIN MANIFOLD TO THE LP FLARE. Note: Check drain hose at vent and drain manifold if hose is blowing gas block in 3/4" bleeder at
battery limits.
(21 Entrained Amine Separator. 10*0-49.
(a) Crack open 2* gate valve on bottom of Entrained Amine Separator, 10-D-49. Drain the Amine Interface to the Closed DEA Sewer until the level sight glass shows only hydrocarbon is present. CLOSE OFF THE COMMON DRAIN UNE TO THE CLOSED DEA SEWER AND FINISH DRAINING THE HYDROCARBON THROUGH THE VENT AND ORAIN MANIFOLD TO THE LP PURE. Note: If drain sounds tika gas is blowing throuQh block in 2" bottom drain to LP Hare.
(b) Crack open and drain LT-259 LEVEL BRIDLES FOR 10D-49 TO THE VENT AND ORAIN MANIFOLD TO THE LP
. FLARE.
(cl Monitor Amine Sump, 10-F-21 level U*254 on the
11
ABDOO102787
console and in the field. running in automatic and constant level. Note: Do Sump.
Verify that is able to not overfill
1Q-G-24 is maintain a the Amine
(3) Lean/Rich Exchangers. 10-E-20A/D.
la) Crack open 2. 2* gate valves to drain tube side of Lean/Rich Exchangers, 10-E-20A/D to the Ciosea OEA Sewer.
(b) Ooen Regenerator feed control valve FIC-251 to 1007, and crack open 8* bypass valve. Crack open 3/4* O/S bieeoer on F1C*251 control valve and drain through attached chemical hose to the Amine Sump, 10-F-21. Note: Check drain hose at Amine Sump if hose is blowing gas block in 3/4" bleeder.
(c) Crack open 2. 2* gate valves to drain shell side of Lean/Rich Exchangers. 1Q-E-2QA/C to the Closed DEA Sewer.
Id) Open UC-252 control valve from the console to 1007., crack open 10* bypass. Crack open 3/4* bleeder U/S of UC-252 control valve, drain through attached chemical hose to the Amine Sump. Note: Check drain hose at Arrne Sump H hose is blowing gas block in 3/4" bleeder.
lei Ooen 3/4*high point vent U/S of 12" butterfly valve for Lean Amine to 10-F-20. drain through anacned chemical hose to the Amine Sump. Note: Check drain hose at Amine Sump, if hose is blowing gas block in 3/4" blearer.
(4) DEA Regenerator. 10*0*21.
(a) Crack open and drain LT-253 & LG-556 level bridles to the Dosed DEA Sewer.
Note: (b)
Unit draining must be monitoredso 10*F*20. Lean
DEA Surge Tank & 10-F-21. Amina Sumo, do not
overfill.
Adjust unit draining to Closed OEA
Sewer to keep level below 80"/..
(5) Regenerator Reboilers, 10-E-22A/B
(a) Crack open 3* gate valve to drain common shell side inlet of the Regenerator Reboilers. 10-E-22A/B and DEA Regenerator. 10-0-21 to the Closed OEA Sewer.
(b) Crack open 2s gate valve to drain common shell side outlet of the Regenerator Reboiiers, 10-E-22A/B to the Amine Sump.
12
ABDOO102788
ini Ooen The 2` sort-up eaualizing line between the shell inlet and the shell outlet of the Regenerator Reboilers. 10-E-22A/B.
id) Crack open and drain LT-252A/B level bridles for Regenerator Reboilers. 10-E-22A/B to the Closed DEA Sewer.
(6) Regenerator Ovhd Accumulator. 10*0*22.
lal Crack, open 2' bottom gate valve to drain Regenerator Ovhd Accumulator, 10*0-22 to the Closed OEA Sewer. Note: If gas is blowing through to OEA Sewer, block in drain.
(b) Crack open 3/4*gate valve to drain acid gas line at battery limits O/S of P1C-253A control looo. drain through attached chemical hose to the Amine Sump. 10-F-21. Block in when draining is complete.
<c) Ooen 1 1/2* gate valve to drain level column assy, for UC-262 on hydrocarbon side of 10-D-22 to the VENT AND DRAIN MANIFOLD TO THE LP FLARE. Block in when drain is blowing gas.
Id) Open 3/4* gate valves to drain LT-253 & LG-557 level bridle assy, to the Dosed DEA Sewer.
lei Open 3/4* gate valves to drain LT-263 & LG-567 level bridle assy, tothe Closed DEA Sewer. Block in when draining is complete.
(f) Crack open 2. 3/4" bleeders for case drains to Regenerator Reflux Pumps. 10-G-20A/B and drain down to the Oily Water Sewer. Note: If gas is blowing through to the Ofly Water Sewer block in case drains.
<g) Open 2. 3/4* gate valves for warm up bypasses around check valves for 10-G-20A/B, drain discharge piping to the OWS Sewer. Note: If gas is blowing through to the 03y Water Sewer block in ease drains.
th) Open 1. 3/4* gate valve on hydrocarbon piping from
10-G-22A backto D/S
side of LIC-250 for
hydrocarbon withdrawal to the FCC/Coker unit,
DRAIN THROUGH THE ATTACHED CHEMICAL HOSE TO THE
VENT AND DRAIN MANIFOLD TO THE LP FLARE. Block in
whan draining is complete
lil Open 1, 3/4* gate valve on hydrocarbon piping froiT 10-G-22A back to D/S side of HIC-250 for Rich DEA to 10-0-20. DRAIN THROUGH ATTACHED CHEMICAL HOSE
13
ABDOO102789
(j)
(k) (!) Note: (m) (nl (o) (p)
TO THE VENT AND DRAIN MANIFOLD TO THE LP FLARE. Block in when draining is complete.
Crack open 3/4,* case drain bleeder and 1 1/2* gate valve on suction tine to Regenerator Ovhd Hydrocarbon Pump. 10-G-22A and DRAIN THROUGH THE VENT AND DRAIN MANIFOLD TO THE LP FLARE. Note: If gas is blowing through to the Oily Water Sewer block in case drains.
Open 1, 3/4* gate valves for warm up bypasses around check valves for 10-G-22A. DRAIN DISCHARGE PIPING TO THE VENT AND DRAIN MANIFOLD TO THE LP FLARE.
Crack open 3/4* bleeder U/S of FIC*254 control valve for Regenerator Reflux to 10-D-21 and drain through attached chemical hose to the Amine Sumo. Crack open 2* bypass for FIC-254 control loop.
Monitorthe Differential Pressure across the Filters 10-J-22. 10-J-20 & 10-J-21. when the DP exceeds 25 p&sg remove the filter from service and replace the filter elements per the procedure.
Continue draining the unit. When N, appears at each sight glass bulls eve. dose each dram valve on equipment to maintain N, pressure on the unit at 15 psig. Do not allow excess N, to blow to the Amine Sump or LP Flora.
When amine has been drained from the unit, go through once more and check every piece of eouipmem to verify that unit is drained. Leave drains dosed after checking drains.
After unit has been assured to be liouid free, stop N, injection at PIC-250A control valve. PIC-253A
control loop off of
10*0-22. slowly reduce the
set point of P1C-253B down to 5 psig on the console
to depressure the unit. Note: Do not depressure
the unit through open bleeders to the atmosphere,
high concentrations of H3s are still present in all the
equipment.
(71 Shut Down Lean PEA Filter System. 1QJ20 & 100-21:
Note:
The Lean Amine niter System has been used to help filter out any solids that may have been drained to the Closed OEA Sewer or the surge tank during the draining seouence of the Amine shutdown. Note: The Lesn Amine FBter system can be taken out of service prior to shut down, or can be left
14
ABDOO102790
circulating if no repair work is to ba done.
(a) Slowly reduce F1C-255 flow on the control console
to '2 M B/D through the Lean Amine Filter System,
then shut down
10-G-26A, Lean Amine Filter
Pump.
(b) Close the 8" .butterfly valve at 10-F-20 for the suetion line to 10-G-26A.
(cl Close the 8" return butterfly valve for the Spill Back line to the Lean DEA Surge Tank, 10-F-20.
(a) Draining Down 10-J-20 & 10-J-21 Filter System:
(1) Start N, injection to high point vent at 10-G-26A Lean Amine Riter Pump. Verify that pressure gauge on inlet to 100-20 is good, replace if necessary. Monitor loeal pressure gauge on inlet to 10-J-20, maintain under 10 psig by adjusting pressure regulator on the N, hose.
(2) Crack open 3/4" gate valve to drain 10-G-26A, Lean Amine Filter Pumpto the Closed DEA Sewer.
(3) Crack open 3/4* bleeder U/S of FIC-255 control valve for Lean Amine to 10-J-20 and drain through attached chemical nose to the Amine Sump.
(4) Ooen FIC-255 control valve on the console to 100*/, and open the 4* bypass for FIC-255.
(5) Open the 1 1/2* bottom gate valve to drain 10-J-20 Lean Amine Rter to the Dosed DEA Sewer. (When N, is blowing through to the Dosed DEA Sewer, dose the 1 1/2" drain valve.)
(6) Open the 1 1/2* bottom gate valve to drain 10-J-21 Lean Amine Carbon Rter to the Dosed OEA Sewer. ( When Ns is blowing through to the Closed DEA Sewer, dose the 1 1/2* drain valve.
(71 Start N, injection to 3/4* bleeder D/S of line
strainer on
10-J-21.
(8) Open the 3. 6* gate valves for carbon filtered lean amine from 10-J-21. Drain through to suction lines for the Lean Amine Pump**-, 10-G-21ABC to the Dosed DEA Sewer.
b. Lean Amine Pumps. 10-G-21ABC.
(1) Open 3. 3/4* gate valves to drain pump cases for 10-G-21 ABC to the Dosed DEA Sewer. Insure that the 3. 10* pump suction butterfly velvet are open.
IS
ABD00102791
(2) Open 3. 3/4* gate valves for warm uo bypasses around check valves for 10-G-21A5C, dram discharge piping to the Closed DEA Sewer.
C31 Open 3. 3/4* gate valves to drain suction lines U/S of 10-G-21ABC to the Closed DEA Sewer.
0
14) When N, is biowino through to case drains and suction drains "for 10-G-21ABC. close off 3. 3M* gate valves for case drams and suction drains to the Closed OEA Sewer, this will help and force N, to sweeo amine liouid from the 10-E-23A/B, Lean Amine Exchangers.
(5) Verify that 8" butterfly valve is dosed next to 10-P-20. Lean DEA Surge Tank. Open 3/4* gate valve to drain FIC-258 Spill Back control looo through the attached chemical hose to the Amine Sumo.
(6) Ooen FIC-258 Spill Back control valve on the console to 100V.. crack ooen the 6* bypass for FIC258 control looo.
c. Lean DEA Coolers. 10-E-Z3A/B.
(1) Ooen 3/4* gate valve to drain shell side outlet, through attached chemical hose to the Amine Sumo.
(21 Ooen 3/4* gate valve U/S of 10* butterfly valve at battery limits to drain Lean Amine piping through attached chemical hose to the Amine Sump.
(31 Crack open 8* bypass on Lean Amine around 10-523A/B. Lean Amine Coolers.
(4| When N, apoears at low point drain for 10-5*23A/B. Lean Amine Coolers and at battery limits bleeder, close off drains until valves are just open slightly to keep N, purge on Lean Amine piping and coolers.
(51 Once the Lean Amine section of the unit is drained, go through once more and check every piece of eauipment to verify that unit is drained.
(61 Ooen the 1 1/2* bottom gate valve to drain 10-J-21 Lean Amine Carbon Filter to the Closed DEA Sewer. ( When N, is blowing through to the Closed OEA Sewer, dose the 1 1/2" drain valve.
171 Stan N, injection to 3/4* bleeder D/S of line
strainer on
1Q-J-21.
(8) Ooen the 3. 6* gate valves for carbon filtered lean
16
ABD.00102792
amine from 10-J-21. Drain through to suction lines for the Lean Amine Pumps, 10-G-21ABC to the Closed DEA Sewer.
d. Drain 10-F-21 Sump Filter System Discharge Line.
(1) Pump the level in the Amine Sump. 10-F-21 until a low level of- 10V, is reached on U-254' then shut down 10-G-24, Amine Sump Pump. Close .the 2" inlet and the 2" outlet valve for the Amine sump Filter. 10-J-22.
(21 Close the 2* gate valve D/S of the check valve for filtered amine from 10-P-21 to the Lean DEA Surge Tank. 10-F-20.
(31 Open the2* jumpover around 10-G-24
discharge
check valve. With the 2a gate valve closed for the
filtered amine to the D/S side of HIC-250. drain
down the amine piping back into the Amine Sump, 10*
F-21. Drain until the local pressure gauge on 10-
G-24 reads 0 psig.
(4) Crack open the 3/4* bleeder D/S of the 2* check
valve on the filtered amine from the Amine Sumo to
the Rich Amine Line D/S of HIC-250. Drain to the
Closed DEA Sewer. When the discharge fine is
drained, line the discharge line baek up to
10*
F-ZO.
INSTALL ISOLATION BLINDS:
To isolate the unit from the rest of the refinery the following Blinds will be installed from the Master Blind List at battery limits.
1. Liauid Hydrocarbon to the FCC/Coker.
2. Rash Gas tothe FCC/Coker units. 3. Rich Amine. 4. Lean Amine. 5. Acid Gas D/S of PIC-253A control looo. 6. Make-up Fuel Gas P1C-250B double block and bleed. 7. Regenerator Ovhd Accumulator Bleed Line to the Amine Acid Gas KO Drum
.11-0-30. PREPARE UNIT FOR STEAM OUT:
1. From the Master Blind List remove tower blinds Per The Following: a. Rich DEA Rash Drum. 10-D-20.
17
ABDOO102793
(1) 2* blind for 40 psig steam to bottomof vessel. (2) 3* blind for vent on top of vessel. b. Entrained Amine Separator. 10-0-49. (1 I 2* blind for 40 psig steam'to bottom of vessel. c. DEA Regenerator. 10-D-21. (1) 3* blind for 150 psig steam to bottom of tower. (2) 3" blind for top vent on tower. d. Regenerator Ovhd Accumulator. 10-0-22. (1) 2* blind for 40 psig steam to bottom of vessel. (2) 2" blind flange for top vent of vessel. 2. Have a 150 psig steam supply connected to piping per the following:
a. Rich DEA Rash Drum. 10-D-20. (1) 3/4* bleeder U/S of PIC-250A control loop.
b. Regenerator Ovhd Hydrocarbon Pump. 10-G-22A. HI 3/4* suctipn bleeder U/S of pump, install 150 psig steam hose.
c. Regenerator Ovhd Reflux Pumps. 10-G-20A/B. (11 2. 3/4* suction bleeders U/S of pumps, install 2. 150 psig steam nose.
d. Lean Amine Pumps. 10-G-21ABC. (1) 3. 3/4* suction bleeders U/S of pumps, install 3. 150 psig steam hose.
e. Amine Sump Pump. 10-G-24. (11 3/4* bleeder on 2* jumpover D/S of 10-G-24, install 1. 150 psig steam hose.
3. Condensate Wash ofRich DEA Hash Drum. 10-0*20. a. The Rich DEA Rash Drum. 10-0*20. will be condensate washed prior to the Steam Out Procedure, to dilute any sludge deposits that remain on the bottom of the vessel. To do this it will be necessary to install condensate hoses from discharge side of 10-G-23A/B. Condensate Pumps to the following locations:
18
ABDOO102794
(1) 3/4* battery limits bleeder 0/S of 10" butterfly valve for Rich DEA to 10-0-20.
(2) Close 2. 8" Rich OEA inlets to tube side of 10-E-20A/D.
b. When condensate hoses have been installed and drains have verified as being dosed, start condensate wash to Rich DEA Rash Drum, 10-D-20.
(11 Start condensate to Rich DEA tine at battery limits, fill from battery limits through H1C*250 control loop and into 10-D-20.
(2) Ooen 3/4" cold condensate to LG-562. LT-250, LG-550, IT-
251,
LG-551 level bridle assy, flush into vessel side
of 10-0-20-
13) When all condensate connection have been turned on to 10D-20, fill for 2 hours.
14) After 2 hour fill, stop condensate flush to Rich DEA line, and LG-562 level glasses drain 10-0-20 and 10-0-49 through bortom drains, slowly to the Amine Sump. 10-F-21.
(5) Open 2. 8* butterfly valves to inlet of tube side of the Lean/Rich Exchangers, 10-E-20A/D. drain down inlet pioing to the Closed OEA Sewer.
(6) With the Rich OEA Rash Drum. 10-D-20 draining down diluted sludge deposits to the closed DEA Sewer, monitor the differential pressure across the Amine Sump Riter, 10-J-22. When the OP is 25 psig across the filter, stop draining down 10-D-20 and take 10-J-22 out of service and replace filter elements per the procedure.
(7) When 10-0-20 is drained, remove condensate hoses from Ricn DEA piping at battery limits, reinstall chemical hose at battery limits that was used during the unit draining process. Drain down the Rich OEA piping control loop to the Amine Sump, 10-F-21.
STEAM OUT QE UNIT:
1- Steam Out Of Hydrocarbon Rash Drum. 10-0-20.
Note:
When the steam out sequence starts, all steaming out of vessels. lines, pumps, etc. wfll be steaming to the Amina Sump. IO-f-21. and condensate will be pumped to the Lren OEA Surge Tank. Do not overfill the Amine Sumo or the Lean DEA Suroe Tank, watch levefr doseW.
The sump pressure wfll need to be monitored dosely by the local pressure gauge installed on Net line to the Amine Sump Carbon Rter, 10-J-25. sdfust
drains and bleeders on equipment to prevent over pressuring as
19
ABDOO102795
needed to keep PSV-10055 from relieving to the atmosphere.
a. Start steam purge to 10-D-20, open 2a steam at bottom of vessel ana at steam hose connected to PIC-250A control looo.
b. Start steam purge to 10*0-49. open 2* drain slightly to steam out and drain condensate.
c. Crack open and steam out level bridles for LT-259 & LG-565 for 10*0*49 to the Closed OEA Sewer.
d. Open HIC-251 on too of 10-D-20 steam to LP flare for 2 hrs.
e. Open 2a and 4* drains on 10-0*20 as needed to drain condensate from vessel. Do not leave drains open unattended.
f. As 10*0*20 starts to heat up and build pressure, steam out to battery limits to Rich OEA piping, Rash Gas to FCC/Coker and Liguid Hydrocarbon to FCC/Coker.
0- Crack ooen and steam out level bridles for IT-251. LT-250 and IG`562 for Rich OEA Rash Drum to the Dosed OEA Sewer.
Steam Out Of 10E-20A/0 Lean/Rieh Exchangers And 10P-21 PEA Regenerator;
a. After 10*0*20 has been steaming for 2 hours, open 2. 8* butterfly valves on tube aide inlets for 10*E*20A/D Lean/Rich exchangers.
b. Dose 4* gate valve 0/5 of HIC-251 to the LP flare and start
steaming from
10*0*20 through exchangers and Rich Amine feed
line to 10-0-21, open 2a drain lines U/S of 10-E-20A/D to Closed
OEA Sewer as needed to drain condensate out.
c. Open 3a 150 psig steam to DEA Regenerator, 10-0-21, steam
through
10-E-22A/B reboilers to shell side inlets to 10-E-
20A/D Lean/Rich exchangers.
d. Ooen 2. 2" shell side outlet drains on 10-E-20A/D and steam through to the Dosed OEA Sewer. Ooen 3/4* low ooirn bleeder U/S of UC-252 control valve.fLeave 10* D/S butterfly valve dosed for LV.252 ur.til overhead circuit is steam purged.)
t. Open and steam through the 2a equalizing line for stan-up between the inlet and outlet amine lines to and from 10-E-22A/6.
f. Crack open and steam out level bridles for IT-258 & LG 556 for 10-D-21 to the Dosed DEA Sewer.
0- Drain condensate through low point drains until dry steam is present at 2a dirain D/S of 10-E-22A/B, and at 3a bottom drain U/S of 10-E-22A/B.
20
ABD00102796
h. Crack open steam to the Regenerator Reboiiers. 10*D*22A/B Through F1C-252 & F1C-259 control valves to keep reboilers warm, drain out the condensatethrough the 3" drain to the OWS U/S of UC-265.
Steam Out Of 1Q-E-21A/B Overhead Condensers And 1Q-D-22 Reoeners^r Overhead Accumulator
a. Steam from 10-D-21 will start to heat up the 10-E-21 Overhead
Condensers. leave fans off during steam purge and louvers
dosed.
Steam coils can be put in service to help in
preventing condensation through the condensers during steam
purge.
b. Open the 2* gate valve for the 40 psig steam out to the
Regenerator Ovhd Accumulator, 10*0*22. steam and condensate
should stan to appear at
10*0*22. crack open case drains
on 10-G*20A/B and 10*G*22A as needed to drain condensate out.
Set PtC-2538 control valve on the console down to 2 psig.
c. Stan steam purgeto suctions of 10^G*20A/B Regenerator Reflux
Rumps. Partially close off 4* suction plug valves for botn pumos. This will force steam through F1C-254 control loop for Regenerator Reflux to the OEA Regenerator, 10-D*21.
d. Stan Steam purge to suction of 10-G-22A Regenerator Ovhd Hydrocarbon Pump. Partially dose off 3* suction gate valve. Open the 1 1/2* gate valve for hydrocarbon to the 0/S side of
L1C-250 control loop. Purge through discharge of 10-G-22A to the battery limits 0/S of UC*250 Hydrocarbon to the PCC/Coker. VERIFY THAT THE VENT AND DRAIN HOSE IS CRACKED OPEN TO THE LP FLARE. When the steam is dry or chemical drain hose is hot going to the LP Rare at battery limits, dose down on the 1 1/2* gate valve until the valve is just cracked open on the alternate hydrocarbon piping to the 0/S side of UC-250 control loop.
e. Open 1 1/2* gate valve to purge hydrocarbon pipinQ from
discharge of
10-G-22A back to Rich OEA piping. Leave the 1
1 /2* gate valve for the alternate hydrocarbon piping cracked
open to steam out both sections of discharge piping.
f. Open 3/4* gate valves to steam out LT*253 & LG-557 level bridle assy ana drain to the Closed DEA Sewer.
g. Open 3/4* gate valves to steam out LT*253 & LG-567 level bridle assv and drain to the Dosed OEA Sewer.
h. When Regenerator Ovhd Condensers. 10*E*21A/B and Regenerator
Ovhd Accumulator. 10*0*22 are hot and pressure is building on
the system, set
P1C-2S3B at 5 psig to vent to the LP flare as
needed to hold pressure on unit. Steam to the LP Rare for 2 hours.
i. After unit has been steaming to the LP flare for 2*3 hours.
Dose the steam sources for unit steaming until the unit has
depressured down to under 1 PSIG. then install isolation blinds as they appear in order in Section K below.
j.
Prior toopening vessel
top vents, dose isolation valves per
21
ABDOO102797
the following:
(1) Rich DEA Rash Drum, 10*0-20.
(a) 2. 8" butterfly valves U/S and D/S of PSV-10067.
(bl 2. 8* butterfly vaives U/S and D/S of PSV-10068. tc! 4* gate valve on U/S side of HlC-251. (21 DEA Regenerator. 10*0*21. (al 1, 6" U/S gate valve and 1, 8* butterfly valve D/S
of PSNM0053A. (bl 1. 6" U/S gate valve and 1. 8" butterfly valve D/S
of PSV-10053B. (3) Regenerator Ovhd Accumulator. 10*0*22.
la) 10* U/S & D/S butterfly valves and 8" bypass valve on PIC-2538 to the LP flare.
(bl 14" U/S & D/S butterfly valves and 14* bypass valve for PIC-253A.
k. Prior to opening vents, install flare blinds from the Master Blind List per the Following: (1) Rich DEA Rash Drum, 10-D-20. (al 8* blind U/S of PSV-10067. (bl 8* blind U/S of PSV-10068. (c) 4* blind U/S of HlC-251 control valve. (2) DEA Regenerator, 10*0*21. (al 6" blind U/S of PSV-10053A. (bl 6* blind U/S of PSV-10053B. (31 Regenerator Ovhd Accumulator. 10*0*22. (al 10" blind 0/S of PIC-253B control valve. Install blind on U/S side of D/S 10* butterfly valve. (bl 8* blind on U/S side of bypass to the LP Rare for P1C-253B.
1. When isolation valves have been dosed and LP Rare blinds have been installed, the vessel top vents can be opened and the unit 22
ABDOO102798
steam out to the atmosphere can proceed. Unit technician and stand by person will use SCBA to open vessel top vents per the following:
U1 3* gate valve on top of Rich DEA Rash Drum, 10-D-20.
(2) 3" gate valve on top of DEA Regenerator, 10-D-21.
(3) 2" gate valve on top of Regenerator Ovhd Accumulator, 10* D*22.
(4) Crack open 1 1/2* gate valve to steam out level column
assy for
UC-262 on hydrocarbon side of 10*0*22 to
the OWS.
m. When vessel vents have been ooened on 10*0*20, 10*0*21 and 10*0* 22. Open 3/4* bleeder D/S of PIC*253B control valve to steam to
the atmosphere. n. Open LV.252 control looo and start steam purge to high point
vent on Lean Amine inlet piping to 10*F*20. Lean Amine Surge Tank.
4. Steam Out Of 10G-21ABC Lean Amine Pumps & 10E*23A/B. Lean Amin# Cooler.
a. Verify that 10-F-20 Lean Amine Surge Tank is isolated as described in section G of the Unit Shutdown and N, is holding positive pressure on 10-F-20.
b. Close cooling water inlet and cooling water outlet on 10** 23A/S Lean Amine Coolers and drain down.
c. Open 150 psig steam to suction of 10*G*21ABC and purge through suction piping out warm*uo jumpover to the Closed DEA Sewer.
Open discharge butterfly valves and purgethrough discharge piping to 10-E-23A/B. Lean Amine Coolers. Leave 8* bypass piping around coolers cracked open to battery limits bleeder.
d. Ooen F.V.25B control valve for Lean Amine spill back to 10*F*20. steam purge out to 0/S bleeder on control looo.
e. Alternate discharge location of the Amine Sump Pump. 10-G-24 back to the 3/4* bleeder at the Rich Amine Line and to the Lean DEA Surge Tank.
f. Continue steaming the Amine Unit to the atmosphere for 4*6 hours until it has been determined that all -ystems have been steamed.
5. To verify _that__the unit has been thoroughly steamed out an, H*S_eheck will be _done _bL. a Fire & Safety inspector wearing Fresh Air on the following!
a. Top vent on 10-D-20.
23
ABD00102799
b. Top vent on 10-D-21.
c. Top vent on 10*0*22.
d. When it has been determined through testing that the unit is virtually H,S free, the unh steam out sequence is considered complete. Note: If H,S testing indicates that H,S content is not at safe level continue to steam unit untH it is at a acceptable level.
e. After testing on unit vessels indicate that H,S is at a safe level shut off all steam sources that were used for steaming, open all low point bleeders to drain down and depressure the unit.
6. Orain Down Amine Sumo Filter System:
a. Manually start OEA Sump Pump, 10*G*24 run until sump is emoty. When 10*G*24 looses suction shut down the pumo. Close the 2" gate valve D/S ofcheck valve at 10-F-20 for filtered amine from IO-F-21.
b. Open 1 1/2* gate valve to drain 10*J*22. Amine Sump Filter.
c. Open 3/4* low point bleeder D/S of 2* filter bypass to drain down filter outlet piping.
d. Open 2* jumpover around discharge check valve on IO-G-24, DEA Sumo Pump to drain discharge piping back to Amine Sump.
e. Open 3/4* bleeder to drain 10-J-21 filter outlet piping at Rich Amtne Line at South end of Unit. Drain through the attached chemical hose to the Amine Sump.
f. When the pressure drops to 0 psig on the local pressure gauge for 10X3*2 - dose the 2* jumpover around the check valve for 10-G-24.
g. When the Amine Sump Filter System is drained proceed with the N, purge sequence.
7. Steam Purge Of The Amine Sump Filter System:
a. The Amine Sump Filter, 10-J-22 will not be steam purged the ftter elements cannot tolerate the high steam temperature. To protect filter elements from damage, dose the 2* inlet and the 2* outlet valve to 10-J-22. Amine Sump filter and then open the 2* filter bypass valve.
b. Start steam injection to 3/4* bleeder on 2* jumpover D/S of 10* G*24, steam from discharge of 10X3*24 through the bypass around the Amine Sumo filter, 10-J-22 out to the 3/4* low point bleeder
24
ABDOO102800
U/S of 2" gate valve for discharge to 10-F-20.
c. Verify that the 2m gate valve is dosed for 10-G-24 pump discharge to the Rich DEA piping D/S of HIC-250. Steam through 10-J-22 outlet piping to 3/4* low point bleeder D/S of 2* filter bypass and the 3/4" bleeder for 10-G-24 discharge back to the Rich DEA piping at the south end of the unit. Drain condensate through attached chemical hoses to the Oily Water Sewer.
d. When 10-J-22 is hot and steam is blowing through to Amine Sump from low point bleeder O/S of 2* filter bypass, and at discharge piping back to Rich DEA line, crack open the 2* bypass to purge bypass line.
e. After all the liouid has drained and steam is present at low
point bleeders stop steam injection at 10*<3*24 DEA Sump Pump and
remove steam hose on
10-G-24 discharge line.
f. Open 2" jumpover around 10-G-24 discharge check valve and drain piping back into the Amine Sump.
g. Filter is now ready to be isolated and filter elements can be removed for change out.
DEA REGENERATOR. 10-0-21. CONDENSATE WASH:
Close isolation valves per the following:
1. Regenerator Reboilers. 10-E-22A/B.
a. 18* butterfly valve on 40 psig steam to PIC-255 and deoressure the steam system to the Regenerator fleboiiers. 10-E-22A/B.
2. All other isolation valves have been dosed as described in section G of the unit shutdown.
a. 10* burterftv valve at battery limits for Rich Amine to the Rich DEA Rash Drum, 10*0-20. {Isolation blind was installed in section H.)
b. 10* butterfly valve at battery limits for Lean Amine to units. (Isolation blind was installed in section H.)
c. 14* butterfly valve D/S of PIC-253Acontrol loop on add gas piping to the North Sulfur at battery limits.
d. 12* butterfly valve forLean DEA inlet to the Lean DEA Surge Tank, 10-F-20.
e. 11/2* bail valve at battery limits for fuel gas make-up to 10D-20.
f. 3*gate valve at battery limits for Amine Rash gas to the
FCC/Coker from
10-D-20. (Isolation blind was installed in
25
ABDOO102801
section H.l
g. 3* gate valve for Liouid Hydrocarbon to the FCC/Coker units from 10-0*20. {Isolation blind was installed in section H.)
3. All other isolation valves have been dosed and blinds have been installed as described in section J of the unit shutdown.
a. Rich DEA Rash Drum, 10-D-20.
(1) 2. 8" butterfly valves U/S and D/S of PSV-10067.
(2) 2. 8* butterfly valves U/S and D/S of PSV-10068.
(3) 4- gate valve on U/S side of HIC-251.
b. OEA Regenerator. 10-0-21.
(II 1. 6* U/S gate valve and 1, 8" butterfly valve D/S of PSV10053A.
(2) 1. 6" U/S gate valve and 1, 8' butterfly valve D/S of PSV10053B.
c. Regenerator Ovhd Accumulator. 10*0-22.
(II 10* U/S & D/S butterfly valves and 8* bypass valve on PIC253B to the LP flare.
(21 1 112m Regenerator Ovhd Accumulator Bleed Line to the Amine Acid Gas KO Drum. 11-0*30.
4. Conoensete Wash of the DEA Regenerator. 10-D-21
a. The DEA Regenerator, 10-0-21 will be condensate washed to remove any amine deposits that may exist on the trays that were not removed during the steaming saauence.
b. A stripping pump will be installed to pump from the bottom of the DEA Regenerator bade to The Regenerator Ovhd Accumulator, 10*0*22. Regenerator Reflux Pumos, 10-G-20A/B will be used to pump condensate back to the DEA Regenerator.
5. Prepare Unit For Condensate Wash Per The Following: a. Have Maintenance install tower isolation blinds per the Master Blind List.
b. Have Maintenance install condensate wash tie-ins as shown on Master Blind List.
c. Check to insure all bleeders are dosed on 10-D-22. 10-G-20A/B.
26
ABDOO102802
10-G-22A, and 10*0*21 after tower isolation blinds and wash connections are installed.
6. Prepare For Condensate Fill:
a. install 3* suction hose from strippinQ pump to 3* drain from DEA Regenerator bottoms.
b. Install 3* discharge hose from' stripping pump to top 2* vent on the Regenerator Ovhd Accumulator, 10-0*22.
7. Condensate Fill For Wash:
a. Open 2" gate valve for cold condensate make-up on 10-E-21, Ovhd condenser outlet line to Regenerator Ovhd Accumulator, 10*0*
22.
b. Start filling the accumulator with condensate, when 507, level has been established on UC-253. start 10-G-20A/B Regenerator Reflux Pumos and pump condensate back to the regenerator. Continue to fill the Regenerator until a 50*/, level in the Regenerator bottoms has been established on U-258.
c. When 50*/, level has been maintained in the accumulator and
regenerator, close 2* cold condensate make-uo to 10-0-22. start
circulation through the stripping pump ' and back to the
accumulator.
Add condensate as necessary to stabilize levels
after circulation has been started.
d. Maintain condensate circulation for 2 hours before sampling.
e. Take a samcie of the wash to the Water Lab to check the ph, sulfides, and CODs.
If the PH is between 5-12. and
If the sulfides are less than 100 mg/I, and
If the CODs are less than 2000 mg/1,
then the wash can be drained to the oily sewer. If the sample
fails any of these criteria, continue to circulate and add condensate for dilution.
When samoies results meet the above criteria. shutdown circulation and notify utilities that the OEA Regenerator will be drained to the Oily Water Sewer.
Once the OEA Regenerator is drained. the unit is ready for Maintenance.
ENVIRONMENTAL. SAFETY AND HEALTH CONSIDERATIONS:
27
ABD00102803 1. Rich Amine TRN# 360917*00. 2. Lean Amine TRN* 341925-00. 4. Sulfur Unix Feed Gas TRN# 360024-00. 3. Amine liouid solutions must be drained to the Closed DEA Sewer. NEVER
ALLOW AMINE TO ENTER THE OILY WATER SEWER.
28
ABDOO102804
D-2 Operating Procedures - Amine Unit (Start-up)
i i i i i i i
The following is a petroleum refinery operating procedure for initial start-up of an amine unit. It includes safety requirements, special tools or equipment required, normal and critical operating parameters, and special considerations for the safe start-up of the unit.
i 34
ABDOO102805
REFINERY
NAME OF PROCEDURE:
INITIAL START-UP OF THE NORTH AMINE UNIT
A. PURPOSE:
TO PROVIDE PROCEDURES FOR A SAFE START-UP AND OPERATION OF THE NORTH AMINE UNIT.
B. RErS=rNCS:
P&IC'S
# 4874-5-10-011 -1
* 4874-6-10-011-2
tt 4874-5*10-011-3 # 4874-5-10-011-4
4874-5*10-011-5
tt 4874-5-10-011-6
PROCESS FLOW DIAGRAM * E-11838-60-0101
C. APPROVALS:
COMPLEX SHIFT SUPERVISOR A-CREW
COMPLEX SHIFT SUPERVISOR D-CREW
COMPLEX Sn;.-: SUPERVISOR B-CREvV
COMPLEX SHIFT SUPERVISOR C-CREW
COMPLEX SUPERVISOR
ABDOO102806
D. SAFETY REQUIREMENTS:
1. Follow all refinery safety policies and procedures during stan-up and operation of the North Amine Unit.
2. All personal protective equipment must be worn, where applicable.
3. Ascertain that H,S alarm system is operable and SCBA Breathing Apparatus Units are available and ready for use.
4. Check that all fire fighting equipment is in the correct location and ready for service.
5. Scaffolding must be installed at predetermined locations and a portable scaffold available for unit technicians to safely gain access to valves and equipment.
6. Full Body Harness must be worn when Scaffolding or Platforms are not available above 4 feet.
E. SPECIAL TOOLS OR EQUIPMENT REQUIRED: 1. 4. 3/4" check valves. 2. 4, control regulators set at 25 psig. 2. 4. N, hoses. 4. 7. Chemical handling hoses. 5. Portascaffold.
F. PF.E-START-UP PROCEDURE & SPECIAL CONSIDERATIONS FOR INITIAL START-UP:
____ 1.
All utility line commissioning has been completed, and in service per procedure.
2. __ 3.
Water wash all process lines to remove foreign material. Chemically clean and then flush with condensate the entire Amine System.
____ 4.
Unit is under N, blanket at 5 psig to eliminate oxidation.
____ 5.
All pumps, drivers and fans have been checked off on Equipment List forcorrect rotation and lubrication.
____ 6. Assure that all Start-Up Filters and Strainers are in place.
_____ 7. ____ 8.
9.
All control valves have been checked of: on Instrument.Equipment List for free travel and calibration from control console.
Instrument loops, alarms, and interlocks are in working order, and have been checked off on Instrument Equipment List.
Cooling water exchangers have been passivated and cooling water circulation has been established through all cooling water exchangers per Exchanger List.
ABDOO102807
10. Personnel will be familiar with phvsicsl locations of stan-up lines, drains & vents m orcer tr.s: the unit can be brought on stream safely snd efficiently.
11. Master blind list and lock out/tag out list are to be reviewed by Unit Supervisor, Console Shir. Supervisor and Sr. Process Tech.
12. The Console Shift Supervisor and Sr. Process Technician will assure that all flows are lines up correctly and that all blinds have been removed or installed as required by the blind list in this Procedure Manual.
13. The Lean DEA Surge Tank, 10-F-2G. and Fresh Dea Storaoe Tank, 10*F-22. will be under a N, blanket following the initial wash and chemical cleaning operation.
14. Verify that unit is lined up to feed the Unsat Gas Plant. Verify that Rich and Lean Amine header block valves to the CHD/SGP located in the ICP at the Unsat Gas Plant battery limns are closed.
15. NOTE: The North Amine Unit will not reouire steam out for initial Start-Up since the unit was cnemically cleaned, purged, pressure tested, and N, blamceted to prevent oxidation. However, during subseouent start-ups. steam will be used to prepare the unit for start-up. air freeing, and pressure testing the unit prior to start-up. To accomplish this, use the steam out procedure as directed below.
15. For Initial Stan-Up, proceed to section J.
ISOLATION BUNDS:
Note: To isolate the unit from the rest of tne refinery the following Blinds should have been instaflea from the Master Blino Lis: at battery limits.
1. Liquid Hydrocarbon to the FCC.'Coker.
2. Rash Gas tothe FCC.'Coker units. 3. Rich Amine.
4. Lean Amine.
5. Acid Gas D/S of PIC-253A control loop.
6. Make-up Fuel Gas PIC-2503 double block and bleed.
7. Regenerator Ovhd Accumulator Bleed Line to the Amine Acid Gas KO Drum, 11-D-30.
a. Prior to steaming the unit, close isolation valves per the following:
U) Rich DEA Rash Drum. 10-D-20.
(a) 2, 8* butterfly valves U/S and D/S of PSV-10067.
lb) 2. 8" butterfly valves U/S and D/S of PSV-10068. (c) 4" gate valve on U/S side of HlC-251.
ABDOO102808
(2) DEA Regenerator. 10-D-21. (a) 1, 6" U/S gate valve and 1, 8" butterfly valve D/S of PSV-10053A. (b) 1, 6' U/S gate valve and 1, 8" butterfly valve D/S of PSV-10053B.
(3) Regenerator Ovhd Accumulator. 10-D-22. (a) 10* U/S & D/S butterfly valves and 8* bypass valve on PIC-253B to the IP flare. lb) 14" U/S &. D/S butterfly valves and 14* bypass valve for PIC-253A.
b. Prior to steaming the unit, install flare blinds from the Master Blind List per the Following: (1) Rich DEA Rash Drum. 10-0*20. (a) 8* blind U/S of PSV-10067. (b) 8* blind U/S of PSV-10068. (c) 4* blind U/S of HIC-251 control valve. (21 DEA Regenerator. 10-D-21. la) 6* blind U/S of PSV-10053A. (bl 6" blind U/S of PSV-10053B. (3) Regenerator Ovhd Accumulator, 10-D-22. (a) 10" blind D/S of PIC-253B control valve. Install blind on U/S side of D/S 10" butterfly valve. (b) 8* blind on D/S side of bypass to the LP Flare for PIC-253B.
PREPARE UNIT FOR STEAM OUT:
1. From the Master Blind List remove blinds per the following:
a. Rich
DEA Rash Drum. 10*0*20.
(1) 2" blind for 40 psig steam to bottom of vessel.
(21 3" blind for vent on top of vessel.
(3) 3. 2* and 1, 4* spec blind at gate valves on bottom drains to the closed DEA Sewer.
b. Entrained Amine Separator, 10-D-49.
(1) 2" blind for 40 psig steam to bortdm of vessel.
12) 1, 2" blind at gate valve on bottom drain to the closed DEA Sewer.
A
ABDOO102809
c. Lean/Rich Amine Exchangers, 10-E-20A/D. ID 2. 2* blinds at gate valves for tube side drains to closed DEA Sewer Lean/Rich Amine Exchangers, 10*E*20A/D. (2) 2, 2" blinds at gate valves for shell side drains to closed DEA Sewer fcr Lean/Rich Amine Exchangers, 10-E-20A/D.
d. DEA Regenerator, 10-D*21. ID 3* blind for 150 psig steam to bottom of tower. 12) 3" blind for top vent on tower.
e. Regenerator Reboilers. 10-E-22A/B. ID 3* blind at gate valve for shell side common inlet drain to the closed DEA Sewer for Regenerator Reboilers, 10-E-22A/8. (2) 2* blind at gate valve for reboiler common outlet drain to the ciosea DEA Sewer for Regenerator Reboilers, 10-E-22A/B.
f. Regenerator Ovhd Accumulator. 10-0*22. (1) 2' blind for 40 psig steam to bottom of vessel. (21 2* blind flange for top vent of vessel. (3) 2" blind at gate valve for bottom drain to Closed DEA Sewer for Regenerate Ovhd Accumulator, 10-D-22. (4) 1 1/2" blind at gate valve for drain to OWS for IT-261 & LG-558 level bridle on 10-D-22.
g. Regenerator Reflux Pumps. 10-G-20A/B and Regenerator Ovhd Hydrocarbon Pump,10-G-22A. (1) 3/4* blinds at gate valves for drains to OWS for 10-G-20A/B. 121 1 1/2" blind at gate valve for drain to OWS for 10-G-22A.
h. Lean Amine Filter. 10-J-20. (1) 11/2 blind at gate valve for bottom drain to the Closed DEA Sewer. (2) 2" blind at gate valve for 40 psig steam to 10-J-20.
i. Lean Amine Carbon Filter. 10-J-21. (1) 1 1/2* blind at gate valve for bottom drain to the Closed Dea sewer. (2) 2" blind at gate valve for 40 psig steam to 10-J-21.
5
ABD00102810
j. Amine Sump Filter, 10-J-22. (1) 1 1/2* blind at gate vaive for boTtom drain to the Closed DEA Sewer. (2) 1" blind at gate vafve for 40 psig steam to 10-J-22.
2. Install chemical drain hoses and route to the Oily Water Sewer per the following:
a. Rich DEA Flash Drum, 10-D-20. (1) 3/4* bleeder at battery limits U/S of 3" isolation valve for liouid hydrccarocr. to the FCC/Coker. (2) 3/4* bleeder at battery limits D/S of 14* butterfly valve for Rich DEA to 10-D-20. (31 3/4" bleeder at battery limits U/S of isolation valve for PIC-250A Amine Flasn Gas to the FCC/Coker. (41 3/4" bleeder U/S of 2" gate valve for Amine Sump Pump, 10-G-24 discharge back to the Rich DEA piping D/S of HIC-250 control valve.
b. Regenerator Qvhd Accumulator, 10*0-22. (1) 3/4* bleeder D/S of P1C-253A and 14" check vafve on acid gas line at banerv limits. (21 3/4" bleeder D/S of P1C-253B control valve on acid gas vent line to the IP Rare.
c. Lean DEA Coolers. 1Q-E-23A/B. (1) 3/4" bleeder for Lean Amine to units at battery limits U/S of 10" bunerfly valve.
3. Have a 150 psig steam supply connected to piping per the following: a. Regenerator Ovhd Hydrocarbon Pump, 10-G-22A. (1) 3/4" bleeder on discharge side of pump, install 150 psig steam hose. b. Regenerator Ovhd Reflux Pumps, 10-G-20A/B.
(11 2, 3/4" bleeders on discharge side of pump, install 2. 150 psig steam hose.
c. Lean Amine Pumps. 10-G-21ABC. (1) 3, 3/4" bleeders on discharge side of pump, install 2, 150 psig steam hoses.
d. Amine Sump Pump. 10-G-24. (1) 3/4" bleeder on 2" jumpover on discharge side of pump, install 40 psig steam hose.
6
ABDOO102811
STEAM OUT OF UNIT:
1. Steam Out Of 1Q-G-24 Amine Sumo Pump- IO-F-24 Amine Sumpr .
Note:
When the steam out sequence starts, all steaming out of vessels, lines, pumps, etc. will be steaming to the Amine Sump, 10-F-21, and condensate will be pumped to the Lean DEA Surge Tank. Do not overfill the Amine Sumo or the Lean PEA Suroe Tank, watch levels closely. The sump pressure will need to be monitored closely by the local pressure gauge installed on inlet line to the Amine Sump Carbon Filter, 10-J-25. adjust drains and bleeders on equipment to prevent over pressuring as needed to keep PSV-1005S from relieving to the atmosphere.
a. The Amine Sump Filter, 1O-J-22 will not be steam purged. The filter elements cannot tolerate the high steam temperature. To protect filter elements from damage, dose the 2" inlet and the 2* outlet valve to 1Q-J-22, Amine Sump Filter.
b. Start steam injection to 3/4* bleeder on 2" jumpover D/S of 10-G-24. steam from discharge of 10-G-24 through the bypass around the Amine Sump Filter, 10-J-22 out to the 3/4" low point bleeder U/S of 2* gate valve for discharge to 10-F-20.
c. Verify that the 2* gate valve is dosed for 10-G-24 pump discharge to the Rich DEA piping D/S of HIC-250. Steam through 10-J-22 outlet piping to 3/4" low point bleeder D/S of 2* filter bypass and the 3/4" bleeder for 10-G-24 discharge back to the Rich OEA piping at the south end of the unit. Drain condensate through attached chemical hoses to the Oily Water Sewer.
d. When 10-G-24 discharge piping is hot and steam is blowing through to Amine Sump from low point bleeder D/S of 2" filter pypass, and at discharge piping back to Ri< DEA iine, close off all bleeders and vents and pressure system to 10 psig using loca, pressure gauge on inlet to 1Q-J-22 Amine Sump Filter. Check system over for leaks.
e. If no leaks are found deoressure filter system to 5 psig and remove steam hose on discharge line.
f. Filter is now ready to be N, purged and put in service per procedure.
2. Steam Out of the Rich DEA Rash Drum. 10-0-20.
a. Start steam purge to 10-0*20. open-2" steam at bottom of vessel.
b. Stan steam purge to 10*0-49, open 2" drainslightly to steam out anddrain conoensate.
c. Crack open and steam out level bridles for LT-259 & LG-565 for 10-D-49 to the Closed DEA Sewer.
d. Crack open top vent on 10-D-20 to steam to the atmosphere.
e. Open 2" and 4" drains on 10-0-20 as needed to drain condensate from vessel. Do not leave drains open unattended.
f. As 10-D-20 starts to heat up and build pressure, steam out to battery limits to Ric' DEA piping. Flash Gas to FCC/Coker, and Liquid Hydrocarbon to FCC/Coker.
7
ABD00102812
0. Crack open and steam out level bridles for LT-251, LT-250 and LG-552 for Rich DEA Flash Drum to the Closed DEA Sewer.
3. Steam Out Of T0-E-20A/D Lean/Rich Exchangers And 10-0-21 DEA Regenerator-
a. After 10-D-2Q has been steaming for 2 hours, open 2. 8" bunerfiy valves on tube side inlets for 10-E-20A/D Lean/Rich exchangers.
b. Close 3* top vent on the Rich DEA Rash Drum, 10-D-20. Start steaming from 10-D-20 through exchangers and Rich Amine feed line to 10-D-21, open 2" drain lines U/S of 10*E*20A/D to Closed DEA Sewer as needed to drain condensate out.
c. Open 3" t50 psig steam to DEA Regenerator, 10-D-21, and crack open the 3" top vent, steam through 10-E-22A/B reboilers to shell side inlets to 10-E-20A/D lean/Rich exchangers.
d. Open 2, 2" shell side outlet drains on 1Q-E-20A/D and steam through to the Dosed DEA Sewer. Open 3/4* low point bleeder U/S of LIC-252 control valve. (leave tQ" D/S butterfly valve dosed for IV.252 until overhead circuit is steam purged.)
e. Open and steam through the 2s equalizing line for start-up between the inlet and outlet amine lines to and from 10-E-22A/8.
f. Crack open and steam out level bridles for LT-258 & LG 556 for 10-D-21 to the Closed DEA Sewer.
g. Drain condensate through low point drains until dry steam is present at 2" drain D/S of 10-2-22A/8, and at 3" bortom drain U/S of 10-E-22A/B.
h. Crack open steam to the Regenerator Reboilers, 10-D-22A/B through FIC-252 & FIC-259 control valves to keeo reboilers warm, drain out the condensate through the 3* drain to the OWS U/S of LIC-265.
4. Steam Out Of 10-E-21A/B Overhead Condensers And 10-0-22 Regenerator Ovrhp*ri Accumulator:
a. Close the 3* top vent on 10-D-21. Steam from 10-D-21 will start to heat up the 10-E-21 Overhead Condensers. Leave fans off during steam purge and louvers closed. Steam coils can be put in service to help in preventing condensation through the condensers during steam purge.
b. Open the 2" gate valve for the 40 psig steam out to the Regenerator Ovhd Accumulator, 10-D-22. steam and condensate should start to appear at tO-D-22. crack open case drains on 10-G-20A/B and 10-G-22A as needed to drain condensate out.
c. Open the top vent on 10-D-22 and steam to the atmosphere adjust 40 psig steam as necessary to 10-D-22 to keep pressure under 25 psig on PT-253 transminer.
d. Purge through the 3/4" bleeder on acid gas piping D/S of PIC-253A control looo to the Oily Water Sewer. Steam purge through to the 3/4" bleeder D/S of PIC-253B control valve to the Oily Water Sewer.
e. Starr steam purge to suctions of 10-G-20A/B Regenerator Reflux Pumps. Partially dose off 4" suction plug valves for both pumps. This will force steam through FIC-254 control loop for Regenerator Reflux to the OEA Regenerator. tO-D-21.
8
ABD00102813
f. Start Steam purge to suction of 10-G-22A Regenerator Ovhd Hydrocarbon Pumo. Partially close off 3* suction gate valve. Open the 1 1/2" gate valve for hydrocarbr'' to the 0/S side of UC-250 control loop. Purge through discharge of 10-G-22A to 3/4" battery limits bleeder D/S of UC-250 Hydrocarbon to the FCC/Coker. When trie steam is dry at battery limits close down on the 1 1/2* gate valve until the valve is just cracked open on the alternate hydrocarbon pipinQ to the D/S side of 1)0-250 control loop.
q. Open 1 1/2* gate valve to purge hydrocarbon piping from discharge of 10-G-22A back to Rich DEA piping. Leave the 1 1/2* gate valve for the alternate hydrocarbon piping cracked open to steam out both sections of discharge piping.
5. Steam Out Of Lean Amine Section:
a. Verify that 10-F-20 Lean Amine Surge Tank and 10-F-22 Pure Amine Tank are blocked in and N, is holding positive pressure on both.
b. Open LV-252 control loop and start steam purge to high point vent on Lean Amine inlet piping to 10-F-20, Lean Amine Surge Tank.
c. Close cooling water inlet and cooling water outlet on 10-E-23A/B Lean Amine Coolers and drain down.
d. Open 150 psig steam to suction of 1O-G-21 ABC and purge through suction piping out warm-up jumpover to the Closed DEA Sewer. Open discharge butterfly valves and purge through discharge piping to 10-E-23A/B. Lean Amine Coolers. * Leave 8" bypass piping around coolers cracked open to battery limits bleeder.
e. Open FV-25B control valve for Lean Amine spill back to 10-F-20, steam purge out to D/S bleeder on control loop.
f. Open suction gate valve and start 40 psig steam to 10-G-26 steam through suction piping out warm-up jumpover to the Closed DEA Sewer. Open discharge gate valve and FV-255 control loop and steam out to 3/4" high point vent on the Lean Amine Filter, 10-J-20.
g. Stan 40 psig steam to 10-J-20 filter. Open the 1 1/2* drain valve to the Closed DEA Sewer as necessary to drain out condensate.
h. Purge from 10-J-20 to high point vent on 10-J-21, Lean Amine Carbon Filter. Stan 40 psig steam to bottom of 10-J-21, Lean Amine Filter. Open the 1 1/2" drain or. 10-J-21 to me Closed DEA Sewer as necessary to drain out condensate. Steam purge through 10-J-21 to filter outlet piping to the suction of the Lean Amine Pumps, 10-G-21 ABC.
i. Continue to steam purge unit to the atmosphere until it has been determined that all systems have been steamed and air freed. Close all bleeders, drains and vents on equipment. Open HV-251 off 10-D-20, Rich DEA Rash drum and PV-253B off 10-D-22, Regenerator Overhead Accumulator. When purging is complete block in HV-251 off 10-0-20 and PV-253B and pressure up system to 25 psig. Go over the whole unit carefully checking for obvious leaks. Note? May need to connect N, to 10*0*22, Regenerator Ovhd Accumulator, to get the pressure up to 25psiQ on unr
Q
ABD00102814
J- ~===ARE UNIT FOR N- PRESSURE TEST:
____ 1-
The unit will be pressurized by installing N, hoses with control regulators set at 25 osig at 4 different locations. Pressure will be monitored by PT-250, PT-251, and PT-253. In the event of over pressuring, unit pressure will be lined up to vent excess pressure through PIC-250,
PIC-253A out open bleeders D/S of the control loops to the atmosphere inside unit battery limits.
Proceed to following steps th prepare equipment for N, pressure test.
a. 10-D-20 Rich DEA Rash Drum.
HI Open all vessel trim per the following:
2, 2* gate valves on level bridles for IT-251, LG-551, LT-250. and LG-550 assy.
2, 2* gate valves on sight glass bridles for LG-552. LG-566, and PT-250. 1 1/2* gate valve for PT-250 transminer. (21 Close all vessel trim per the following:
3. 2" and 1,4" bonom drain valves to amine sump, 3/4" gate valves for coid condensate flush to level bridles LT-250 & LT-251.
3/4" gate valves for cold condensate flush to LG-562, LG-566 to closed DA sewer.
3* gate valve for top vent.
2" 40psig steam valve to steam coil and 2" condensate return from steam coil.
2* 40psig steam valve for purge to bonom of 10-0-20.
(3) Open Qll.&rocess lines per the following:
10" butterfly valves for HIC-250 and crack open bypass.
2" and 3* gate valves on P1C-250A off gas to FCC/Coker and crack open bypass.
2" and 3" gate valve on LIC-250 liquid H.C. to the FCC/Coker unit and crack open bypass.
2. 8* butterfly valves for PSV 10067 & PSV 10068.
4" gate valve for HIC 251 to the LP flare.
6* gate valve from bottom of 10-D-20 to inlet of 10-D-49. 1/2" hex valves for FT-251 Rich DEA flow transmitter.
ABD00102815
(4) Close ail process valves per the following: 1 1/2" pate valve D/S of PIC-250B control loop for fuel gas to 10-0-20. 2" gate valve from 10-J-22 to D/S side of HIC-250 Rich DEA control loop. 1 1/2" gate valve D/S of UC-250 form 10-D-22.
b. 10-0-49 Entrained Amine Separator. (1) Open All Vessel trim per the following: 2. 2' gate valves on level bridle LT-259 & LG-565. (2) Close all vessel trim per the following: 2* bottom drain valve to dosed amine sewer. 3/4" gate valve for cold condensate flush to LT*259 & LG-565 bridle assy to closed DEA sewer. 2* 40 psig steam purge ne.
c. 10-D-21 DEA Regenerator. 11) Open all vessel trim per the following:
2, 2" gate valves for LT-258 & LG-556 on bottom of tower.
2. 2* gate valves for PT-2501 & PDT-252 pressure Transmitters. (2) Close all vessel trim per the following:
3* isolation gate valve for 150 psig steam purge to bottom of tower. 3" gate valve for too vent on tower. 3/4- gate valve for cold condensate to flush LT-256 level bridle to dosed DEA sewer. 3* gate valve for drain piping to dosed DEA sewer on tower drain on common inlet line to 10-E-22A/B, Regenerator Reboilers. (3) Open all process lines per the following:
2. 10" isolation gate valves for FV-251 and 8* bypass valve. 2. 6" isolation gate valves for PSV 1005* A & PSV 10053B.
d. 10-0-22 Regenerator Ovhd Accumulator. U) Open all vessel trim per the following: 2, 2" isolation oate valves on level bridle for LT-253 and LG-557. 2* isolation gate valves for level bridle LT-262 and LG-558.
11
ABD00102816
2. 2* isolation Qate valves for level bridle LT-263. 2, 2* isolation gate valves for level bridle LG-567. Isolation gate valve for PT 253 pressure transminer and P.I-555 local pressure indicator.
(2) Close all vessel trim per the following: 2* drain to closed DEA sewer. 2" drain from bonom of vessel and install blind flange. 1" gate valves for Cold Condensate flush header to flush level bridles for LT-262. LT-263. LT-253 and LG-567. 1 1/2* gate valve for drain to oily water sewer from LT-262 level bridle. 2* 40psig steam valve for steam purge to bonom of vessel. 3/4* drains from 10-G-20A/B and 10-G-22A to oily water sewer. 2" gate valve for cold condensate make-uc to 10-D-22.
13) Open all process lines per the following:
2, 14* bunerfly valves for PV-253A acid gas line to the SRU, and 14* bypass
bunerfly valve. Row taps for FT-253 transminer. 1,14* U/S bunerfly valve for PV-253B vent to the LP flare. Note: Leave 8" bypass closed during pressure test.
2, 4" suction plug valves to 10-G-20A/8 Regenerator Reflux Pumps.
2. 3" discharge plug valves for 10-G-20A/B. 1/2* hex valves for flow tap for FT-254 transminer. 2, 3* valves for FV-254 control loop and 2* crack open bypass valve for Regenerator Reflux to 10-D-21. 3" suction valve to 10-G-22A Regenerator Ovhd Hydrocarbon Pump. 1 1/2* discharge gate valves for 10-G-22A. (41 Close all process lines per the following: 1 1/2* gate valve on bleed line from 10-G-22 Reflux piping to 11-G-30A/B Amine Sour Water pumps.
2, 10* bunerfly valves for PIC-2538 control loop and 8* bypass butterfly
valve.
-------
ABD00102817
e. 10-E-22A Regenerator reboilers. (11 Open ail vessel trim per the following;
2, 2' gate valves for level bridle LT-252A and LG-554.
(2) Close all vessel trim per the following;
1" gate valve for cold condensate flush to LT-252A and LG-554.
2* gate valve for draining shell side of 10-E-22A/8 Reboilers to the closeo DEA sewer. f. 10-E-22B Regenerator reboilers. Ill Open all vessel trim per the following: 2. 2" gate valves for level bridle LT-252B and LG-555. (21 Close all vessel trim per the following: 1" gate valve for cold condensate flush to LT-252B and LG-555. g. 10-E-20A/B Lean/Rich Exchangers. (11 Open all process valves per the following:
2, 8* Rich DEA tube side inlet butterfly valves and 2, 8" Rich DEA tube sia, outlet gate valves on 10-E-20A/D. 2, 10" Lean DEA shell side inlet butterfly valves and 2. 10' Lean DEA shell side outlet butterfly valves on 10-E-20A/D.
2, 12" butterfly valves for LV-252 control loop and crack open 10* bypass
butterfly valve. 2, 1 1/2' gate valves for PSV-10069 and PSV-10070 on tube side of 10-E-20A/C.
(2) Close all process drain valves per the following: 2* drain to closed DEA sewer on Rich DEA inlet to tube side of 10-E-22B. 2* drain to closed DEA sewer on Lean DEA outlet side of 10-E-22B. 2* drain to dosed DEA sewer on Rich DEA inlet to tube side of 10-E-22D. 2" drain to dosed DEA sewer on Lean DEA outlet side of 10-E-22D.
h. 10-E-21A/B Regenerator Ovhd Condensers. U) Open all process valves per the following: 6, 8* butterfly valves on inlet side of Ovhd Condensers. 4, 8* gate valves on outlet side of Ovhd Condensers.
12
ABD00102818
(2) Close all process drain valves per the following: 6. 3/4* bleeder valves on inlet lines to condensers D/S of blind locations. 4, 3/4* bleeder valves on outlet lines from condensers U/S of,biind locations.
10-E-23A/B Lean DEA Cooler. HI Open all process valves per the following:
2. 1/2* hex valves to F7-258 flow transmitter.
1.12' butterfly valve for Lean DEA inlet from shell side of 10-E-23A. 1, 12" butterfly valve for Lean DEA outlet from shell side of 10-E-235.
2, 1/2" hex valves for F7-256 flow transminer.
1/2* hex valve for PT-256 and PI-599 local pressure indicator.
2, 8* bunerfly valves for FV-258 control loop, and crack open 6" bypass
bunerfly valve. 1Q-F-20 Lean DEA Surge Tank. ID Verify that all vessel trim is closed per the following:
12' Tank inlet bunerfly valve from 10-E-20A/D Lean/Rich exchangers. 2" gate valve for filtered DEA from 1Q-F-21 Amine sumo. 3" drain to closed DEA sewer. 8" bunerfly valve for Lean DEA spill back. 3* gate valve for Fresh amine from 10-F-22 and 3* gate valve for pumped low pressure condensate to 10-F-20. 8" tank outlet bunerfly valve for suction line to 10-G-26, Lean DEA Filter Pump. 3, 10' tank outlet bunerfly valves for suctions lines to 10-G-21ABC. Lean Amine Pumps. (2) Open all process valves per the following: 3. 10' suction bunerfly valves at Lean Amine Pumps. 10-G-21ABC. 3. 10* discharge bunerfly valves for 10-G-21ABC. Lean Amine Pumps. (3) Close all process valves per the following: 3/4* high point vents and case drains to closed DEA sewer for 10-G-21ABC Lean Amine Pumps.
ABD00102819
i6* gate valve for carbon filtered Lean Amine to 1O-G-21 spill back to 10-F-2D
Lean DEA Surge tank.
i
(3) Close all process drains and utility systems per the following:
i2. 1 1/2" gate valves for high point vent and vessel drain to closed DEA
Sewer.
2" gate valve for 40psig purge steam to 10-J-21.
i
2" gate valve for cold condensate flush to 1Q-J-21. Condition of Battery Limits Isolation valves.
I
i(11 Verify that battery limits valves are property positioned per the following:
3" gate valve for liquid hydrocarbon to FCC/Coker from 10-0*20 Rich DEA Rash Drum. (Closed)
3" gate valve for off gas to FCC/Coker from 10-D-20 Rich DEA Flash Drum. (Closed)
10* butterfly valve for Rich DEA to 10-D-20 Rich DEA Rash Drum. The blind
i i
at battery limits will be removed and the 10' butterfly valve will be opened to include new Rich DEA piping for Nt pressure test.
i
14* butterfly valve D/S of PIC-253A at battery limits for acid gas to North Sulfur Recovery unit and acid gas to and from East & West Sulfur Recovery Units. (Closed)
I
10* butterfly valve for Lean Amine to units. The blind at battery limits will
ibe removed and the 10" butterfly valve will be opened to include the New
Lean Amine piping for N, pressure test.
i3' gate valve for Fresh Amine from 10-F-22 Fresh Amine Tank to 10-F-20
Lean DEA Surge Tank. (Closed)
Install N, hoses with check valves and control regulators at the following locations. 11) On low point bleeder at HIC-250 amine control valve to 10-D-20. (2) On low point bleeder at FlC-251 control valve to DEA Regenerator.
i
r
(3) High point vent on 10-G-20A Regenerator Reflux Pump. (41 High point vents on 10-G*21ABC Lean Amine Pumps.
i
(5) High point vent on 10*G-26. Lean Amine Filter Pump.
The following valves can be opened to avoid over pressuring during the N, pressure test.
(1) The 3/4* high point vent at battery limits D/S of PIC-250A on off gas line to FCC/Coker.
i
i
*
ABDOO102820
(2) The 3/4" high point vent D/S of check valve from PIC-253A control loop.
(31 Install 0-60psig pressure gauge in 3/4" battery limits bleeder for Lean Ar to units.(Gauge will be used only for the N, pressure test and will be remove prior to Amine fflU
N. PURGE DF LEAN AMINF FILTER SYSTEM:
Note: The Lean Amine Filter System will not be steam purged, because the filter elements for 10-J-20 cannot tolerate the high temperature.
1. Open suction gate valve and start N, to 10-G-26 purge through suction piping out warm-uc jumpoverto the Closed DEA Sewer. Open discharge gate valve and FV-255 control loop ano purge out to 3/4" high point vent on the Lean Amine Filter, 10-J-20.
2. N, purge through to 10-J-20 filter. Crack open the 1 1/2* drain valve to the Closed OEA Sewer as necessary to displace air from the system.
3. Purge from 10-J-20 to high point vent on 10-J-21, Lean Amine Carbon Filter. Ooen the 1 112* drain on 1O-J-21 to the Closed OEA Sewer as necessary to displace air from the system.
4. Purge through 10-J-21 to the 3/4" bleeder D/S of the line strainer on the filter outlet pining to the suction of the Lean Amine Pumos, 10-G-21ABC.
5. Crack open the 3. 6* gate valves for filtered Lean Amine on the suction lines for the Lean Amine Pumps. 10-G-21A8C.
NITROGEN PRESSURE TEST:
1. Verify that all vents, drains and low bleeders are dosed on all eouioment.
2. Make sure FIC-258 spillback is blocked in at Lean DEA Surge Tank,l0*F*20.
3. With N, injection hoses installed at the following; HlC-250 low point bleeder, 10-G-20 Regenerator Reflux Pump high point vent, low point bleeder on FiC-251 control loop. 1O-G-26, and 1O-G-21 ABC high point vents, slowly start to pressure up entire Amine system up to 25 psig: (Do not open and N, pressure test 10-F-20.)
4. Close off N, injection hoses when N, pressure has been established and is maintaining 25 psig on the following; PIC 250 for 10-0-20, H.C. Rash Drum, Pl-251 for 10-D-21 DEA Regenerator. PIC-253 for 10-D-22, Regenerator Ovhd Accumulator, and D/S of 10-E-23A/B at battery limits.
5. Check unit carefully with snoop. If no leaks are found, depressure unit and leave a slight positive N, pressure on the unit while unit isolation blinds are removed per unit blind list.
6. Once Blinds are removed, N, pressure the unit to 5 psig.
10-F-20. LEAN DEA SURGE TANK FILL:
1. Refer To Fresh DEA Unloading Procedure for 10-F-22 and N, purge procedure for 10-F-22 prior to filling. Fresh DEA will be unloaded from a tank truck into the Fresh DEA Tank, 10-F-22, located in the East Amine Unit and will be pumped into the Lean DEA Surge Tank 10-F-20 by 10-G-25 transfer pump.
17
ABDOO102821
Steam coils should be activated in the Fresh DEA Tank. 10-F-22, to hold the DEA temperature at approximately 110'F. Condensate will be added to 10-F-20 to mix and produce a strength of 25 weight */. per procedure.
Steam coils should be placed in service in the Lean Amine Surge Tank 10-F-20 to hold the 25 Weight V. temperature at approximately 110*F per TI-265.
Vessel Preparation & Line Uo For Circulation:
a. Check the entire unit to ascertain that all vent and drain valves are closed and that bull plugs are installed at all locations. Confirm that all control valves ooerate properly per Instrument Check List.
b. Line Up The Unit Per The Following:
(t) Check that the 6* Rich Amine header to Lean Amine header bypass line is open at the Unsat Gas Plant battery limits.
(2) Check that Uouid Hydrocarbon line from Rash Drum 10-D-20 is blocked in at LV-250 control loop. PV-250A in the off gas line from 10-D-20 should be placed in service at 60 psig. Notify the FCC to line up to take 10*D*20. Amine Rash, open battery limit valves when FCC is ready to take Amine Rash Gas. (Note Leave PV-250B control loop blocked in.)
13) Check that battery limits block valves are open on both the Rich and Lean Amine to the units.
(4) Set PV-253B in regenerator accumulator 1O-D-22 off gas line at 2 psig to the LP flare. Leave PV-253A to the sulfur unit closed.
(5) Verify that FV-258 Lean Amine spill back control loop is closed going back to 10-F-2Q Lean OEA Surge Tank.
16) Close Bypass valve on 10-E-23A/B Lean DEA Cooler.
North Amine Unit Filling:
a. Line up 10*F*20 Lean Amine Surge Tank to the suction of the Lean Amine pumos 10G*21ABC. Verify that the 3. 6" oate valves D/S of the Lean Amine Rlter SvsTPm rr> the suctions are closed. Start 10-G-21C turbine pump on slow roll (per turbine start up procedure) crack open the discharge valve. This will start to fill the Lean Amine header to the battery limit gate valves at the USGP through the bypass valve at battery limits and return to the Hydrocarbon Rash Drum, 10-D-2C. through HlC-250 control valve for the Ricr*. Amine line. Bloc., m tube and shell siaes of 10*E*20A/D Lean/Rich exchangers.
b. Maintain Hydrocarbon Rash Drum pressure at 60 psig, using HIC-251 to vent off excess N, to the LP flare.
c. The Lean Amine Riter System may now be filled and placed in service. Refer to procedure for 10-J-20 & 10-J-21 prior to start-up.
til Open the 8" butterfly valve at the Lean DEA Surge Tank, 10-F-20 for the suction to 10-G-26.
ABD00102822
12) Open FJC-255 Control valve on the control console to 20*/,. Start 10-G-25. Lean Amine filter Pump slowly open the discharge valve to start filling r Lean Amine filter, 10-J-20, open the 3/4* bleeder to displace tne N, to v Closed DEA Sewer.
(3) When 10-J-20 is full close the high point vent and continue filling the Lean Amine Carbon Filter, 1C*J*21, ooen the 1 1/2* high point vent valve to displace th N, to the Closed DEA Sewer.
(4) Once the Lean Amine Carbon Filter, 10-J-21 is full, close the 1 1/2" top vem valve to the Dosed DEA Sewer.
(5) Open the 8* butterfly valve for the 10-G-21ABC spill back line at the Lean DEA Surge Tank, 10-F-20.
(6) Open the 6" gate valve for the filtered amine to the spill back line to the Lean DEA Surge Tank, 10-F-2Q.
(7) When the Lean Amine filter piping is lined up to the spill back line to 10-r-20. open the discharge valve for 10-G-26 the rest of the way and raise FICUSS on the console to 2 M 8/D.
(8) Monitor the differential pressure across both filters during the unit start-up phase.
When a normal level (50*/,, is established in the Hydrocarbon Flash Drum. 10*D:20, shut down the Lean Amine pump 10-G-21C, and check the liouid level in the Lean Amine Surge Tank, 10*F*20. If level ts below a half tank.make up some additional 25*/, solution to bring the level up back to 50V,.
Commission PV-250B fuel gas control valve to 10-D-20 and set P1C-250B at 60 psig.
When the preceding steps have been taken to establish an Amine level and fiasn Drum pressure, the Lean Amine pump 10-G-21C may again be started to fill the remainder of the unit.
With 10-G-21C running, open tube side inlet and outlet butterfly valves on 10-E-20A/D and start filling 1G-E-20A/D Lean Rich Amine exchangers on tube side. N, will vem out PIC-2S3B to the LP Flare.
When 10-E-2QA/D Lean Rich Amine exchangers are full amine will appear at FlC-251. Periodically check open low point bleeder at control loop for amine use container to catch sample to verify amine is present at control loop.
With Amine at F1C-251, start closing down control valve from console. This will help to maintain LT-251 for 10*D*20 Hydrocarbon Flash Drum.
If level in 10*0*20 Hydrocarbon Rash Drum starts ;o drop, close down on FIC-251 to keep level constant. Monitor level in 10-F-20 Lean DEA Surge Tank, and shut down 10-G-21C when low level alarm is activated.
The Amine Solution will now be entering the DEA Regenerator 10-D*21, at Tray 23. Amine will flow down the tower to the bottom of the regenerator and to the Regenerator Reboilers, 10*E*22A/B. LT*252A/B will indicate when amine is present in reboilers. Continue to fill OEA Regenerator, 10-D-21, and Regenerator Reboilers. 10*E*22A/B, until 80*/, level is reached on LT-252A/B.
19
ABDOO102823
l. When regenerator reboilers 10-E-22A/B are full, ooen inlet butterfly vaive for Lean DEA Surge Tank, 10-F-20. Verify that 10-F-20 N, Blanketing system is venting properly. Open 10-E-20 A/D shell side inlet and outlet valves to start to fill the Lean Amine side of 10-E-20A/D Lean Rich exchangers. When 10-E-20A/D are full amine solution will appear at LV-252. Periodically check low point bleeder on control loop for amine, use container to catch sample to confirm amine is present at control loop.
m. As amine starts to enter 10-F-20, Lean DEA Surge Tank, the level will start to stabilize, verifying that amine is returning from the regenerator. The system is fuil when the level in 10-F-20 remains constant.
NORTH AMINE UNIT START-UP:
1. With the Lean Amine Pump 10-G-21C turbine running at slow speed, open the discharge
avalve fully and start adjusting steam to turbine to increase speed and Amine circulation. When
10-G-21C is running at full RPM, set FV-258 at 5 M B/D to spill back to 10-F-20, Lean Amine
Surge Tank.
2. Set H.C. Flash Drum, LT-251, on cascade control with FV-251 in the feed line to 10-D-21 Regenerator at 15 M B/D. Adjust H.V.250 manually to keep constant flow of amine to M
10-D-20. Rich DEA Flash Drum.
3. Set LV-252 D/S of 10-E-20A/D from 10-E-22A/B reboilers on automatic control. (Set level
at 50*/..)
4. Check the entire North Amine Unit and systems for leaks and proper operation of equipment.
5. With circulation established and all systems functioning properly, the next step will be to activate the reboilers 10-E-22A/B and heat up the unit. This must be done very slowly to eliminate any condensate buildup and accompanying water knock. Steam and condensate alines must be checked during the heat up for expansion clearance. Note: Commission the North SRU condensate system per the startup procedure.
a6. On condensate Pot 10-D-23, open the 1" equalizing line between 10-E-22A/B. Ooen 2. 5" gate valves on bottom of tube side outlets for steam side of 10-E-22A/B Reboilers. Activate auto vent valves for non-condensibles for equalization lines for 10-E-22A/B. Open the 3" gate valve to the OWS U/S of LV-265 control loop. (Leave D/S gate vaive closed going to acondensate system during heat up phase of steam system.)
7. Check that TV-252 in the pumped low pressure condensate line to desuperheater 10-M-20
ais blocked in, PV-255 control valve in the 40 psig steam line to desuperheater 10-M-20 is set
at 20-30*/. open and FV-252 and FV-259 in the steam supply lines to reboilers 10-E-22A/B
are on manual control in the closed position.
t
8. With one Technician stationed at the main block valve in the 40 psio steam line to this
system, very slowly crack open valve enough to start a small flow of steam. Leave the blocx
valve in this position until system begins to heat up.
i
9. As the steam lines to the reboilers heat up and condensate draining to the OWS through the trap out lines U/S of FV-252 & FV-259 control loops reaches a minimum, the block valve in the main steam supply may be slowly opened.
10. At this time FV-252 and FV-259 in the reboilers supply lines can be slowly opened to start a steam flow through 10-E-22A&B. Activate PV-255 control valve, and set steam pressure at 35psig.
ABDOO102824
11. When PV-255 control valve is in service, set the minimum steam flow at 5 M LB/HR to the reboilers with FV-252 and FV-259. Open the pumped low pressure condensate to TV-2r" and place in service. Open 150psig velocity steam to 10-M-20 desuperheater (Set TV-2 to control at approximately 2B0*F.l
12. The condensate from 10-D-23 will continue to drain to the sewer until the system is completely hot. At that time slowly open LV-265 control loop, to send condensate from the reboilers to the condensate system and close the 3* pate valve U/S of LV-265 to the OWE. Place LV-265 on automatic control on the console when the condensate is flowing to the Condensate System.
13. With the steam pressure and temperature on control, slowly increase the steam flow oi manual control to 10-E-22A and 1O-E-228 to raise regenerator's bottom temperature over 2-3 hr. period to approximately 260*F.
14. Control the Lean Amine Temperature from Coolers 10-E-23A/B at 115-120*F by adjusting the 8* bypass valve.
15. As the regenerator's overhead temperature reaches 200*F, the louvers on the overhead condensers 10-E-21A/B should be opened. Fans can be started to maintain condenser outlet temperature at 115*F. Place TIC-272 and TIC-274 in automatic to control variable speed of 10-E-21 A/Bfans.
16. When a liauid level builds in the Regenerator Overhead Accumulator, 10-D-22. reflux pump 10-G-20A/B may be staned.and LIC-253 and FV-254 placed in service to control the level in 10-0-22 at 50V..
17. With the North Amine Unit circulating 15 M B/D and the unit is up to temperature, start 2nd Lean Amine Pump, 10-G-21 ABC. Slowly start to raise the amine circulation rate to 35-40 M B/D over a 2 hr. period to the North Amine Unit.
18. The North Amine Unit will be lined up to supply lean amine to the USGP and send rich amine from the USGP back to the North Amine Unit. This will reduce the amine circulation to the East and West Amine Units. Close monitoring on the console for all three amine trains will be needed during the USGP switch to the North Amine Unit.
19. As the amine becomes rich with H,S, the overhead system pressure will increase due to the unit stripping H,S out of the Rich Amine. The overhead accumulator 1Q-D-22, has been venting to the LP flare through PV-253B since the amine unit was started and circulation was established. H,S will be venting to the LP flare, so venting should be eliminated as soon as possible due to the environmental concern.
20. When a level builds in H.C. side of 10-D-20, notify the FCC to line up to take hydrocarbon from 10-D-20. When FCC is ready to take hydrocarbon, open battery limits valves and put LT-250 on cascade with LV-250. Set level at 50V. and line up to pressure to the FCC/Coker.
21. The North Amine Unit will normally feed the North Sulfur Unit. However for Initial Start-uo. Acid Gas from the North Amine Unit will be sent to the East and West Sulfur trains. To do this it will be necessary to open the acid gas "jumpover* from the North Amine Unit and North Sulfur Unit to the "crossover* line between the East and West Amine Units. Slowly open the acid gas to the East or West Sulfur Furnace, it will take a short amount of time for the Sulfur Furnaces to adjust for the increase in acid gas. Avoid sending a surge of acid gas to the East or West Sulfur Units by opening the acid gas valves from the North Amine too quickly.
21
ABDOO102825
22. When acid gas is lined up from the North Amine Unit to the North Sulfur or the East or West Sulf; units, the acid gas venting will be eliminated. Set PV-253 at I8psig on 10-D-22 to keep flare vaiv closed so all the acid gas produced from the North Amine Unit will go to the sulfur units.
NORMAL OPERATING PARAMETERS:
NORTH AMINE UNIT
1. 35psig Steam Temperature To 10-E-22A/B Reboilers.
280*F
2. Rich Amine Temperature From 10-0*20 H.C. Flash Drum. 125*F
3. Regenerator Bottoms Temp. From 10-D-21.
20*F
4. Rich Amine Feed Temp. To 10-D-21 Regenerator.
212*F
5. Lean Amine Tower Bottoms To 10-F-20 Surge Tank.
170*F
6. Regenerator Tower 10-D-21 Overhead Temp.
237*F
7. Overhead Condensers 10-E-21A/B Outlet Temp.
115*F
8. Lean Amine Temperature To Units.
115'F
9. H.C. Flash Drum Pressure 10-D-20.
60 psig
10. Amine Regenerator 10-D-21 Top Pressure.
15 psig
11. Amine Regenerator 10-D-21 Bottom Pressure.
19 psig
12. Overhead Accumulator Pressure 10-0-22.
13 psig
13. 40psig Steam Let Down Pressure, To 10-E-22A/B Reboilers. 35 psig
14. Lean Amine Pressure Before 10-E-23A/B coolers.
270 psig
15. Lean Amine Pressure After 10-E-23A/B coolers.
260 psig
16. Refer to Process Flow Diagram E-11838-60-0101 for further process flow information.
EMERGENCY OPERATING/ SITUATIONS:
1. Loss of Instrument Air: In the event of a complete instrument air failure all control valves will fail in the safe position, so that the charge to and the flow from ail vessels will stop. Steam to the reboilers 10-E-22A/B will be shut off and pressure control valves will open on 10-0-20 and 10-D-22 to the LP flare.
2. Loss of Power An automatic reacceleration program has been designed to automatically restart the North Amine Unit pumps when power is restored within 5 seconds, after a power failure.
3. Flanoe Leak: Large or small amine leaks can not be tolerated. These leaks contain H,S and must be reoaired Quickly to keep the amine from reaching the oily water sewer. All precautions must be taken to prevent the escape of H,5 into the atmosphere. H,S is a personnel safety hazard and an environmental problem.
ABDOO102826
Q. CRITICAL OPERATING LIMITS-
1. Maximum steam temperature to 10-E-22A/B___ 284*F. 2. Low level in 10-F-20 Lean Amine Surge Tank i 3 feet. 3. High concentration of hydrocarbon in Rich Amine. 4. Sudden changes in amine circulation rate.
DEVIATION \. High steam temp, to
10-E-Z2A/B.
2. Low level in 10-F-20 Lean Amine Surge Tank.
CONSEQUENCES
1. Amine degrades at temp, above 284#F, causing the amine to decompose and form a corrosive product.
1. Loss or erratic Lean Amine flow to units. Damage to Lean Am;.*.* pumps 10-G-21ABC from cavitation.
STEP TO CORRECTIONS/AVOID
1. Ascertain that condensate is lined up to 10-M-20 desuperheater, and that TV-252 control valve is working properly. Adjust TV-252 set point to 2S0'F on control console.
1. Verify LT-252A/B for 10-E-22A/B reboilers are controlling properly and not holding Amine in reboilers.
2. Stan adding condensate to 10-F-20 to increase level.
3. High concentration of hydrocarbon in Rich Amine.
1. Amine unit upset from tower carryover and high pressure and temperature.
2. High arrvunts of hydrocaroon in the acid oas from the Amine Unit will effect the Sulfur Recovery Units performance.
3. Check with amine users possible trouble with amine levels in contactors or absorbers pulling to hard on lean amine to try and satisfy their needs.
t. Contact Amine users immediately to have levels checked in contactors and absorbers to find where hydro carbon is coming from.
2. Bypass The Ts Gas Unit if problem cannot be resolved quickly.
3. Vent Acid Gas to the LP Rare through PV-253B off the top of 10-D-22 Overhead Accumulator or HIC-251 on the Rich DEA Rash Drum, 10-D-20.
4. Shut down the Sulfur Recovery Unit.
23
ABDOO102827
DEVIATION
4. Sudden changes in Amine circulation rate.
CONSEQUENCES
1. Row increase to above design rates.
2. H,S stripping from amine reduced due to erratic flows to the DEA Regenerator tower.
3. Higher than design acid gas rates to the Sulfur Recovery Units.
STEP TO CORRECTIONS/AVC
1. Contact amine users to chec that vessels are being blown down, and levels are being controlled properly.
2. Take FV-252 and FV-259 steam control valves off steam/feed ratio control end set steam rate to control in auto to keep a constant stear flow to the Amine Reboilers.
1. Monitor Sulfur Units carefully by:
a. Watching for acid gas knockout drum for carryover.
b. Monitoring air demand so r proper amount of air is fed the sulfur furnaces.
* . SAFETY RELIEF SYSTEMS AND THEIR FUNCTIONS:
(1) There are two safety relief valves on 10*0*20 H.C. Flash Drum. Both are set to relieve to the Low pressure flare at 95 psig. HV-251 on 10*0*20 can be manually opened at the control console to control drum pressure.
(2) 10*0*21 Amine Regenerator has two safety relief valves that protect the tower from over pressuring, both are set to relieve at 50 psig.
(3) On 10*0*22 Overhead Accumulator, PV-253 is set for 18 psig and will automatically start venting Acid Gas to the flare to control the pressure on the North Amine Unit.
(4) N, is supplied to the Pure Amine Tank. 10*F*22, and to the Lean Amine Surge Tank, 10-F-20. Both are under local pressure control from the refinery N, system. This N, blanket is provided to prevent oxidation of the amine solution. 10-F-20 is equipped with a safety relief that is set to 10* WC. it will relieve if PCV*568 fails to open to the 10*J*23A/B carbon filter system.
ENVIRONMENTAL-SAFETY AND HEALTH CONSIDERATIONS:
(1) Pure Amine TRN# 812958-00 (2) Rich Amine THN# 360917-00 (3) Lean Amine TRNtf 341925-00 (4) Sulfur Unit Feed Gas (Acid Gas) TRN# 360024*00
ABDOO102828
D-3 Operating Procedures - Crude Unit (Start-up) The following is a normal operating procedure for a crude unit start-up, generally found in a petroleum refinery. The procedures outline the necessary steps needed for the safe start-up and continuous operation of the unit, including safety requirements, special tools or equipment required, normal and critical operating parameters and emergency conditions or situations.
35
ffIffffIffI V E K K K K IE IIII
ABDOO102829 REFINERY
riw.ewwic . mu i*ww
Page
: 1 of 15
Issued : 11/23/92
Revised : l2/02'92
NORMAL OPERATING PROCEDURE FOR CRUDE UNIT START-UP
A. PURPOSE To establish a standard with this orocedure. considered necessary for the safe stan-uo ana continuous operation of the Crude Unit.
B. REFERENCES 1. P & ID drawings: 4350-R-1 *010, R-V-011A, R-1-011B, R-1-012 R-13-013. R-13-014, R-13-015. 2. Unit Description Manual 3. Emergency Procedure Manual 4. Unit Procedure Manual
C. APPROVALS
Complex Shift Supervisor A*Shift
Complex Shift Supervisor C*Shift
Complex Shift Supervisor B-ShifT
Complex Shift Supervisor D*Shift
Complex Supervisor
ABDOO102830
Page Issued Revised
: 2 of 15 : 11/23/92 : 12/02/92
SAFETY REQUIREMENTS
1. Wear reouired personal protective eouipment (PPE).
2. Foilow Lock Out/Tag out procedures llOTO).
3. Foilow established refinery safety practices, take ail personal safety precautions curing unit start-up.
SPECIAL TOOLS OR EQUIPMENT REQUIRED 1. Valve wrenches. 2. Temporary scaffolding. 3. Safety harness for working above 4 feet. 4. Air. steam & chemical hoses. 5. N2 hoses with Dixtox connections. 6. Copper tubing and compression fittings.
PRESTART-UP PROCEDURE
1. Remove Blinds.
2. Open reouired valving.
3. Steam air free and gas purge.
4. Pressure test eouipment.
5. Commission Utility Systems.
6. Check Power eouipment.and Control instrumentation.
------- **'
------
-* --
START-UP PROCEDURE
After initial checks are complete and the unit is sectionally divided, there are certain reouired
steps which must be acted on in seouence to each section. It is not intended that each unit
section be placed in service as it is listed. tt's~possibte that several steps may be on-going at
the same time.
' .--'SrrrO
' -
Stan-up consists of the following major steps;* ~ ` t
* Steam Out
- Crude Line and product toCrude Exchangers.
* Steam Out
Desalter.
* Steam Out
- Crude Heaters and Atmospheric Tower.
* Pressure Test
* Atmospheric Section.
C3* B2
ABDOO102831
Page issued Revised
: 3 of 15 : 11/23/92 : 12/02/92
" Fuel Gas Purge
Atmospheric Section.
* Crude Flow
Exchangers. Desalter. Heaters, and Atmospnenc Tower.
* Fuel Fire
Atmospheric Heaters (System dry out and heat uoi.
* Steam Out
Vacuum Heater. Vacuum Tower and Flow circuits.
* Pressure Test
Vacuum Section.
* Fuel Gas Purge
Vacuum Section.
~ Gas Oil Circulate
Vacuum Tower, Heater, and Row circuits.
* Fuel Fire
Vacuum Heater (System dry out and heat uo).
- Reouced Crude Flow Raise Heater outlet temperatures, and establish a normal vacuum tD bring Vacuum side on stream.
* Products/Rundown Increase charge rates and temperatures to bring products on specification. Change product rundowns to storage.
ATMOSPHERIC AND VACUUM TOWER STEAMOUT
1. Make certain that all reauired blinds are swung open or removed.
2. Block in each atmospheric heater control valve and bypass. Open 150# tube steam into the outlets of 13-E-1QA & C. and steam backwards through the hot oil preheat exchangers, desalter, and the desalter preheat exchangers.
Steam throuoh all preheat train exchangers and desalter first.
3. When a good flow of steam is showing from the exchanger drains and desalter vent, close off on the backflow and begin to direct steam flow into each atmospheric heater pass. Steam initially from east to west, starting witn F01020 C/V and bypass.
Check each heater outlet bleeder for dry steam from the bottom north deck
4. At this same time, light two burners in each atmospheric heater box to begin dryout and assist with heatup.
5. Stan boot steam into Atmospheric Tower and allow steam to blow from tower top vent.
6. Steam through all control loops (including bypasses), pump circuits, exchangers, and side strippers.
7. Steam flow should carry through the 1-E-21 overhead bundles into the accumulator.
A targe amount of condensate will form in the accumulator across the 1-E*21's.
When a water level forms in the 1-D-7 boot. line-up and pumpout to the SW rundown.
ABDOO102832
Procedure : #01-001
Page
: 4 of 15
Issued
: 11/23/92
Revised : 12/02/92
8. Begin a direct flow of 150* tube steam into the Vacuum heater charge ime. Steam each vacuum heater pass. Steam initially from south to norm, starting with FI3058 C/V and bypass.
Check each hearer outlet bleeder for dry steam from the bottom east qec<
9. At this same time, light two burners in each Vacuum Heater box to begin
dryout and
assist with heatup.
10. Steam through ail control loops (including bypasses), pump circuits, ana exchangers. Allow steam to blow from tower top vent.
11. Steam flow should carry through overhead system (ejector condensers) into seal drum.
While The unit is steaming, check flanges for leaks, and finish opening all remaining block valves for operating equipment or at relief valve*:
12. When dry steam is showing at nearly all locations, close all bleeders, vems, and allow steam pressure to reach 20# PSIG on both Atmospheric and Vacuum towers.
Check all flanoes for leaks.
13. Use Nj to air-free purge 1-G-1A/8 compresspr system, 1-E-14 Discharg Coolers, and the 1-D-9 Discharge Separator.
14. When unit steam purge and pressure testing is complete, open fuel gas into 1* D-7 Accumulator and maintain 5# Psig pressure on the atmospheric overhead. Likewise, open fuel gas into 13-D-11 Seal Drum and maintain 5# Psig on vacuum system. (Fuel gas blowdown line from 1-D-16 may provide enough gas volume to maintain the pressure on 1-D-7).
Bleed H.O from all low point bleeders, pump cases, and equipment drams
except the Desalter. Leave a slight water level in VP-6 between LC-01501 and V* trvcpck tap. ..
START RAW CRUDE INTO PREHEAT TRAIN
15. Contact Oil Movements to start one crude pump lined up through P01001. Fill entire preheat preheat train and both atmospheric heaters with inlet to Atmospheric Tower. (Include; desalter, crude booster pumps, exchanger bypass loops, and each individual pass flow control loop and bypass.)
Crude charge pump(s) should provide the necessary volume and pressure for the initial fill. Do not exceed 50-0m B/D of cold crude flow. A higher rat* may flood the atmospheric tower.
E33 C33
CS3 G33
AaBbDuOuuOi1u0z2o83j3j
Procedure : #01-001
Page
: 5 of 15
issued : 11/23/92
Revised : 12/02/92
16. Open 1-B-1A/B pass flow controllers IF01005 thru 20) separately. Mane certain tnat each Pass shows a positive flow, and pressure at the Iood.
it will be necessary to start a crude booster pump at the desalter to assist the filiing process. Commission P01001 and re-adjust heater pass flows after starting 1-G-2.
17. When a bottoms level is established in 1-D-l, start 1-G-12A/B and Dump L01007 to Virgin Sloo. Set L01007 instrumentation to control FO1015 IResic to storage). (Slop return; l-G-12 -> 13-E-10`s. 13-E-5*S. F01015. resio line to B/L jumoover).
With tr:s circulation in progress, continue draining excess water from all low points, alternate spare pumps, open and fully flush all by-pass lines, leaving . valves slightly open.
18. Begin raising transfer line temperatures of the Atmospheric Heaters about 100'F per hour. Make sure a good steam flow is showing from the exhaust mufflers to the super heater coils of each heater.
19. Stan injection of Stripped sour water into the preheat tram IF01002), ano at the Oesalter (F01039). Energize the electrodes to tne Desalter grids ana also staa pumping cemuisifying chemical. Establish a 50*/. water level in 1-D-6.
TOWER HEAT-UP, CIRCUIT FLOWS AND REFLUX ESTABLISHED
As heater outlet temperatures increase along with atmospheric tower overhead, fans will be started on 1-E-21 condensers to provide temperature and pressure control. Begin overhead chemical injection when top temperature exceeds 250*F.
20. When gasoline and water levels are establish in the Overhead Accumulator ano
Boot, line-uo 1 -G-3 reflux pumo and 1 -G-15 sour water pump. Commission 1C-
01503 to displace sour water to the sour water rundown. Stan 1-G-3 ano
reflux Atmospheric Tower to maintain a top temperance of 150*F.
Commission F01031 to control reflux rate, line-up and stan 1-G-a S.R.
Gasoline pump to control 101001. Commission
F01030
to control flow off-spec product to slop.
Continue draining free water from P/A circuit tow points. Use caution to avoid drawing a flow of hot liquid into a line packed with water when staning a P/A or product pump.
21. As tower temperatures increase on tower, stan P/A circuits.
22. As levels establish in side strippers, start product pumps to draw small accumulations to Virgin slop.
23. Start-up the overhead compressor(s) as P01009 spillback closeure will dictate the need.
Crude feed rate should be at this rime around 100m B/D.
ABD00102834 VACUUM TOV. . OIL FILL AND HEAT-UP
Proceourc : #01-001
Page
: 6 of 15
Issued : 11/23/92
Revised : 12/02/92
24. Line-up 650 product wash oil into the discharge of 13-G-18B turoine anc airec. the flow to F01068 as Tod P/A through 13-E-23 cooler and bacx to Vacuum Tower. Allow wash oil to overflow internal tower travs and cascaoe inrcugr. the tower.
25. When wash oil fills L01011 at Tray 7, drain all free water from Vacuum Mid P/A pumos.
26. When 13-G-19A/B pumps are water free, line-up and start flow througn Mic P/A circuit. If pump starts to cavitate, shut it down until Tray 7 level is re established.
CS* Continue draining free water from Vacuum heater pass control Ioods. pass outlets, and all tower flow circuits.
27. When wash oil appears at Tray 5 (L010131. line-up and start 13-G-21. Circulate flow through F01076 and back to Tray 5. Make certain that 4" block valve at Atmospheric Tower is closed downstream of L01013.
28. When an oil level is indicated by L01014/15 as Vacuum Tower bottoms and the drain lines from 13-G-22A/B are water free, (ine-up and begin circulating oil through the Vacuum Heater. (Stop the in-coming flow of 650 wash oil when bottoms circulation is satisfied.)
Open a small flow of atmospheric bottoms into the Vacuum Tower through the bottoms Quench line (F01079). This should heavy up the bottoms and heip stabilize temperature and flow through the heater.
29. Open 13-B-2 pass flow controllers (F01047 thru 58) separately in manual control. Make certain that each Pass shows a positive flow, and pressure at the loop.
30. Raise heater outlet temperature at 1Q0*F per hour. Stabilize in 250-30C-,F range for two hours to allow excess water to boil out. This period will also help establish good levels on upper tower trays for pumparound circulation.
31. Be careful not to flood the tower excessively during the wash oil fill. Once the bottoms show indication, pinch back or completely stop the in-coming flow. Maintain level indications whenever possible. IA 3* pumpout line off the common discharge of 13-G-22A/B is available to remove the excess bonoms level to CGO or slop).
32. Continue heat-up and total systems control of both Atmospheric and Vacuum Sections Color check Atmospheric product taps often and line-up storage rundowns with Oil Movements as soon as cuts are ready.
33. Marry the Atmospheric and Vacuum Sections when both towers are running within 50*F of each other at 500-550*F on bonoms temperature. Secure bot' tower levels within reliable control range. Target the Crude charge at a 110r. B/D prior to the mate.
ABDOO102835
Proceoure : eul-uu
Page
: 7 of 15
Issued : 11/23/92
Revised : 12/02/92
The bottom level controls for each tower. (L01007) 1-D-1, (L01015J 13-D-10, may act sluggish immediately following the valving change. Make certain that all instrument changes are inserted at the console to correspond with the new control scheme. Communication must be accurate and direct from unit personnel to th# control console at the time of the switch
34. Do not proceed to raise tower temperatures or unit rates further until the tower mating is complete and good level control is established. Line out the unit at 120m B/D.
35. When Unit is lined out with all operating parameters normal, prepare line-uD of Hot Resid for Coker feed and 550 Hvy Kero for Coker purge oil.
H. NORMAL OPERATING PARAMETERS
The following are approximate operating conditions which will serve as a guide in lining out the unit after the Atmospheric and Vacuum Towers have been married.
CRUDE. DESALTER. PREHEAT
Crude Flow (40-G-1I Desalter Psig |40*G-2A/C) Desalter Inlet Stnoped Sour H30 Stripped Sour H30 1-B-1A Charge Rate l-B-1 B Charge Rate Cooling HjO P$ig
F01001 P01001 T01012 F01002 F01039 F01003 F01004 P01018
30m B/D 155# PSIG 270*F 3.5m B/D 3m B/D 90m B/D 90m B/D 55-60# PSIG
ATMOSPHERIC ' .THON
Tower Top Psig Top Temperature Top Reflux Transfer Temperature 1-B-1A/B Pass Temperature Bottoms Level Top P/A Mid P/A Btm P/A Tower Boot Steam Condenser Outlet Accumulator Psig
P01009 TQ1057
F01031 T01055 T01018-40 JL01007
F01032 F01037 F01041 F01045 T010E1 P01011
20# PSIG 30C-F 20m B/D 680-F 675-680'F 50-557. 60m B/D 80m B/D 11 Om B/D 30m 165*F 10-12# PSIG
ABD00102836 VACUUM SECTION
Procedure : #01 -001
Page
: 8 of 15
Issued : 11/23/92
Revised : 12/02/92
Tower Too Psig
P01Q17
Top Relux Temoerature
T01166
Transfer Temperature
TO1144
13*8*2 Pass Temperature
T01118-135
Bottoms Level
L01015-
Top P/A
F01068
Mid P/A
F01072
Mid P/A Temp Return
T01170
Btm Grid Wash
F01071
Btm Tower Psig Btms Temperature
P01020
Ton 62
Resid to Storage
F01080
Hot Resid to Coker
` F06061
11 mm Hg 175*F 760BF 775-780F
50V. 18m B/D 110m B/D 340"F 20m B/D 20mm Hg 690-F 10-15m B/D 20-22m B/D
EMERGENCY CONDITIONS/SITUATIONS
1. Flange leaks.
2. Pump seals.
3. Instrument problemr.
__
4. Valve failure.
5. Refer to the following-Bmergency Procedures in the UEI&P Manual.
(a) Steam -failure.-f^irpr
lb) Electric failure.
(cl Instrument air-failure.'--"
Id)
(e)
(f) (gi TDC-3000 Difffftbutive Control Failure.'
ABDOO102837
J. CRITICAL OPERATING LIMITS Pressure, leveis. and temperatures.
Procedure : #01-001
Page
: 9 of 15
Issued : 11/23/92
Revised : 12/02/92
DEVIATIONS
High Desalter Pressure (P01001I
CONSEQUENCES 1. PSV's relieve to 1-D?1
STEPS TO CORRECT/AVOID
1. Reduce Crude Rate ana Temperature accordingly
High Desalter Temperature | (TO 1012)
High Heater Pass Outlet Temperature 1-B-1/13-B-2
High Tower Pressure 1 -0-1 (P01009)
High Bottoms levei 1-D-l (L01007I
Low Bottoms Level 1-D-l (L01007)
High Tower Pressure 13-D-10 (P01017I
Low Bottoms Level 13-D-10 (L01015/141
Low Fuel Pressure (Fuel gas) (Fuel oil)
Loss of Compressors) I1-G-1A/B)
1. Crude vaporization; suction loss to Booster Pumps
2. Overpressure. PSV's relieve
1. Reduce Crude inlet Temper ature to 1-D-6 below 270eF
1. Heater tube-coking
1. Stroke C/V manually 2. Increase Flow with Control
Valve Bypass 3. Bias Pass Flows 4. Reduce Heater Firing
1. PSV's relieve to atmosphere
1. Reduce Boot Steam 2. Reduce Heater Transfer
Temperature (T01055) 3. Reduce Crude Charge
1. Tower Flooding Closes Boot Steam C/V
2. Permits Lighter Feed into Vacuum Tower
1. Reduce Crude Charge 2. Control L01007 in Manual - 3. Switch to scare l-G-12 if
F01046 is oown or lost
1. l-G-12 cavitation; pump
damage 2. Low Flow to 13-B-2
Interlock Shutdown
1. Reduce Boot Steam Rate 2. Reduce Heater Transfer
Temperature (T01055) 3. Increase F01077 (Recycle!
1. Ejector steam 7s lost 2. PSV's relieve to atmosphere 3. Seal Drum gas to flare 4. Upper tray.levels diminish as ,,,,
Tower top overheats
1. Remove'Stripping Steam 2. Reduce Crude Charge
3. Reduce 13-B-2 Temperatures 4. Maintain cooling from reflux
circuits
1. 13-G-22 cavitation; pump damage
2. Loss of crude pre-heat ' 3. Hot Resid to Coker is lost
1. Remove Stripping Steam 2. Reduce 13-B-2 Temperatures 3. Increase tower Quench 4. Reduce Vacuum (Hg mm)
1. Fuel Gas Chopper closes: -- 1. Reduce crude rate to 90m
Interlock Shutdown
^2. Steam Purge Heater boxes
2. Fuel Oil Chopper closes: - -5 ": '3. Isolate gas burners. Reset
may overload .gas firing
- Chopper. Re-light
3. L01007 - High Level
4. Isolate oil burners. Reset
Chopoer, Re-light
1. P01011 opens to flare ` 2. PSV's relieve if P01011 does
not open (manual set dsd?) -
1. Reduce Unit Charge 2. Verify Interlock system.
*
R
f
I
r
t
i
E
Loss of Cruoe Flow
Loss of Coolant System (Equipment Leak)
Loss of Cooling Water
ABDOO102838
riui.euu(e . owi'uwi
Page
: 10o< 15
Issued : 11/23/92
Revised : 12/0292
1. Hign Heater Pass outlet temperatures
2. Possible coking of tubes @ 800F
3. Overheating crude exchangers 4. Eventual loss of reduced
crude to Vacuum Tower
1. Exchanger overheating 2. Exchanger plugging 3. External leakage to OWS will
upset the WWT svstem 4. Environmental Incident
1. Compressed gas and Condensing systems overheat
2. Compressors) shutdown; gas is flared
3. Possible Unit Shutdown
1. Check for Flame out: Manual set TRC valves and Reset
2. Inject steam in heater tuoes 3. Unmarry Atmospnenc and
Vacuum towers 4. Reduce 13*B-2 firing 5. Stop H;0 and all chemical
injection streams 6. Stop product draws: reduce
reflux circuit flows
1. Reduce unit rates. 2. Bypass exchangers to
prevent overheating and damage to tubes 3. Allow enough flow through exchangers to avoid oiuoging 4. Isolate equipment if external leakage is not preventable
1. Reduce Crude Charge 2. Reduce Heater Temperatures 3. Reduce 150# Ejector Steam
K. SAFETY SYSTEMS AND THEIR FUNCTIONS
1. Unit Pressure Safety Valves
PSV #
1-D-6 Desalter
PSV-01015
1-D-6 Desalter
01016
1-B-1A 150# Steam 01019
1-B-1B 150# Steam 01029
1-0*1 Tower
01030
1-D-1 Tower
01031
1-D-1 Tower 1-D-1 Tower 1-D-1 Tower
01032 01033. 01034
1-D-1 Tower
01035
1-D-1 Tower
01036
C D X
o
o
H
CO
Size 6' x 10" 8" x 10' 4" x 6' 4* x 6"
8* x 10" 8" x 10" 8" x 10"
8" x 10* 8" x 10"
Relief PSIC set @ 203# set @ 168.5# set @ 175# set @ 175# set @ 32.5# set @ 32.5# set @ 32.5# set @ 32.5# set @ 32.5# set @31#
set @ 31 *
ABDOO102839
Procedure Page Issued Revised
#01-001
11 of 15 11/23/92 12/02/92
1*D*1 Tower
01037
; 4* x 6*
set @ 32.5*
l-D-7 Accumulator 01044
4" x 6'
set @ 23*
1-D-7 Accumulator 01045
4* x 6"
set @23*
o1
X
GO
1-E-21 Outlet
01078
1-E-21 Outlet
01079
13-D-10 Tower
13056
13-D*10 Tower
13057
13-D-11 Seal Drum 13059
13-D-10 Seal Drum 13060
13-D-10 13-D-23 13-D-12
13080 13084 13064
8' x 10' 4* x 6' 4" x 6* 6* x 8* 6' x 8* 6' x 8IV X 2" 4" x 6"
set @ 25* set @ 25* set @ 26* set @ 25* set @ 25* set @ 26* set @ 26* set @ 15* set @ 85*
Unit HIC (depressuring) valves.
a. P01011
b. P13549
3. Interlock systems.
a. * Low Crude Flow to 1*B*1 A/B Heaters; TRC's - Minimum Fire
Low Feed Flow to 13-B-2 Heater; TRC's - Minimum Fire
b. Low Fuel Gas Pressure to 1-B-1 A/B; Interlock Shutdown
Low Fuel Gas Pressure to 13-B-2; Interlock Shutdown
C. Low Lube Oil Pressure to 1-G-1A/B: Comp_ressor_S_hutdown
Hi KO Drum Level (1-D-8); Compressor Shutdown
d. Low Discharge Pressure; Snare Pump Acceleration
0) 1-G-4B Reflux Turbine
12) 13-G-18A Top P/A Turbine
e. High Tower Btms Level; Closes Stripping Steam C/V
f. High Current on 1-D-6; Shuts down Transformer Power
ABDOO102840
Procedure : #01*001
Page
: 12 of 15
Issued *.11/23/92
Revised : 12/02/92
ENVIRONMENTAL. SAFETY AND HEALTH CONSIDERATIONS
1. Environmental Practices
The successful operation of the entire
Refinery will be deoendem joon
the environmental control practices in the refinery. It is vital that all employees
work as a team to achieve good environmental control within the refinery. Our
ability to comply with both air, noise, and water criteria and objectionable
odors will be reflected in large pan by the housekeeping practices of tne
refinery. It is important that all refinery employees be aware of bad
housekeeoing situations which will contribute to either air or water pollution.
a. Water
Listed on the following page are situations which may be bom a housekeeoing and an environmental problem for water treating effluent streams:
(11 Large unit area oil spills which are not promptly cleaned up in an efficient manner.
(a) Fuel oil from 1-B-1A/B Atmospheric Heaters.
.(b) Open vent or drain valve on hydrocarbon lines.
(c) Leaking flanges of hydrocarbon exchangers,
td) Hydrocarbon line ruptures.
(2) Haphazard draining of chemicals to oily water sewer system.
(a) Leaking seals or packing glands of chemical injection pumps.
(b) Cleaning chemical injection pumps and piping for repairs.
(3) Draining targe quantities of hydrocarbons to oily water sewers.
(a) -- Line cleanng and.draing for repairs, or for turnaround periods.
(b) Leaking mechanical seals on pumps.
(c) Gearing pumps for repairs, blind installation.
(4) Draining of sulfide contaminated water to oily water sewers.
(at Sour water from Accumulators 1-D-7, l-D*9, and 13-D-11. Normally ail potential oily water sewer contaminant vessels have blinds installed to the oily water sewer at drain points to eliminate the possibility of accidental draining.
ABDOO102841
Procedure : #01-001
Page
: 13 of 15
Issued : 11/23/92
Revised : 12/02/92
(51 Disposal of solids to oily water sewers.
(a) Sludge and scale deposits from vessels and lines ounng turnaround.
(6) A standard operating procedure will be to inform tne utilities section and water effluent treating section omcklv when anv of the previously listed contaminants are accidently spilleo to oilv water sewer system.
(7) Employees should be alert to their role in environmental control. For example, they should know of the conseouences wnen treating facilities are overloaded or large Quantities of contaminants are dumped into sewers. Biological systems adapr reasonably well to some variability in waste water characteristics. However, the bacteria and micro-organisms m our activated sludge process can be destroyed, or their efficiency reduced, by sudden, sharp changes in environmental conditions. Problems with microbial activity can be caused by:
(a) Sudden temperature rise. Optimum range is 65* F. min., 100* maximum.
(b) Sulfides in concentrations greater than 10 mg/I.
(cl Phenolics in concentrations greater than 50 mg/l.
(d) Low pH caused by acid contamination or high pH from caustic contamination. Optimum pH range for biological activity is 6.5-8.5.
b. Air Criteria and Monitoring
(1) During normal day to day operation of the Crude Unit, me possibility of exhausting sulfur dioxide (S03) from either Air Preheater, Heater I1-B-1A/B or 13-B-2) stacks is alwavs present.
(a) 1-B-1A/B will often be base loaded with fuel oil firing.
(bl Incomplete combustion of the fuels or poor efficiency of the heaters can cause stack emissions.
(c) Operation of heater soot blowers will cause some paniculate emissions.
td) Lighting off and removing fuel oil burners may result in some smoke emissions.
(2) ' Fuel gas is continually monitored to analyze for H3S. Any H,S level exceeding .015 vol% in the fuel gas must be reported per the New Source Performance Standards.
(3) To eliminate or lessen the possibilities of heater stack emissions without controls, analyzers have been provided at each heater to give notice of some abnormal condition.
ABDOO102842
Proceoure : #01-001
Page
: 14 of 15
Issued : 11/23/92
Revised : 12/02/92
(4) -During heater steam, air decoking operations, special care m-js: be taken to prevent excess air and noise pollution.
(a) A decoking drum and water quench system has oee..
provided
o
minimize these emissions.
Noise
Noise exposure limits have been set by the Walsh*Healy Ac: ano are presently under the jurisdiction of the U.S. Department of Labor. The limits are generally defined in decibels. The decibel is a unit usee to measure sound intensity. On the decibel scale, zero decibel is the threshold of hearing and 120 decibels is the threshold of pain. Instruments commonly used for sound measurement are sound level meters and octave band analyzers. A passenger car at 30 MPH emits a noise level of 60 to 78 decibels and rises to 72-90 decibels at 70 miles per hour. Our refinery site prior to construction ranged from 38*54 decibels with most of the noise emanating from traffic on 1-55. Refinery eauipment has been selected so that sound pressure levels will meet limits at worker exposure locations. Auxiliary noise reduction devices have been specified where needed. Periodic noise surveys will be made in all refinery areas.
(1) A normal source of noise in day to day operation will be from heaters burner air intake even though some muffling designs have been incorporated in the heater construction.
12) *The motors and fans rotating on the overhead cooler fans wn. -- produce a certain amount of noise because of their rotation and
` height.
(3) Each piece of equipment has been measured for noise emission and noted on conspicuously posted signs that will advise of tne noise emission levels. These signs also advise personnel of ear protection required in the work area.
<4).._/' All employe'esvvill_be issued ear covers or plug inseas
(1) There is presently no definitive regulation on odor. Neverthe
less, we must be diligent in minimizing release of objectionable
-..odors .to the atmosphere in the refinery. It is a form of
^poiludon.that is readily detectable and of considerable concern the-general public."*. -.7 --
. -^.'U iCOICTTUni--1
-.
' `^WF^^There should be no odor emission from any normal
operating equipment within the Crude Unit. Only
" **' - ' during an abnormal operation condition would there be - - -i--particular odor emission.
(b> During unit shutdowns, hydrocarbon freeing or * * steaming out of vessels and lines will be a possibilir an unusual odor or smelt.
ABDOO102843
Proceoure : #01*001
Page
: 15 of 15
Issued : 11/23/92
Revised : 12/02/92
tc) A strong odor present during normal operation, pay tc day. would be certain indication of machinery or equipment failures: leaking flanges, valve packing, mechanical seals of pumps or line ruptures.
2. Safety
a. Fire Equipment
The Crude Unit is equipped with dry chemical portable hana
extinguishers, along with (2) 350# wheeled units, tine hose reels ana
fixed stationary monitors are also provided. A fixed fire water spray
system is manifolded from the unit B/L Interconnecting pipewav to
provide water blanketing of all unit product and hot oil pumps. Safety
showers and fire blankets are also available in the unit, instructions for
care and use of this system is contained in the
Refinery
Emergency Response Manual. Every Technician should become familiar
with the location and use of this equipment.
b. Self-contained Breathing Apparatus
Self-contained breathing apparatus is available on or near the Unit. Refer to the . - c Refinery Emergency Response Manul for instructions for the use of this apparatus.
3. Health
Refer to the following facility inventory report to obtain MSDB TRN numbers and MSDBs through CD*MACSIN. In order to get safe handling and health information on chemicals used-in the Crude.
ABDOO102844
D-4 Operating Procedures - Crude Unit (Emergency Procedures) The following is an emergency operating procedure used for a crude unit, generally found in a petroleum refinery. The procedure outlines the necessary steps to be taken during emergency situations such as; power loss, steam outage, plant air failure, instrument air failure or heater tube rupture.
36
ABDOO102845
X. EMERGENCY PROCEDURES
An operator's best preparation For an emergency is a thorough knowledge of the equipment and normal shutdown procedures. The operator in charge is expected to use his own judgment in each situation. Thorough knowledge allows safe methods to be improvised to handle emergencies. Good practice is to follow normal shutdown procedures as soon as safely possible.
Every type emergency that could occur cannot be covered or anticipated. Some operating conditions which require emergency action are mentioned in this section.
A. Pov/cr Interruption: Loss An Automatic Re-acceleration Program has been designed to automatically restart selected electric motors when power is restored within five (5) seconds after o power failure. When power -failure is ionger than five (5) seconds all electric driven equipment on the reacceleration schedule must be manually restarted,
A list of motors restarted and the time (in seconds) that they are restarted following
a power loss of lees than five (5) seconcs fellows :
10 Seconds
Units Started
1-G2B 13-G 19 A & B
Crude Booster Pump Vacuum Mid. P/A and Product
25 Seconds
1 1
1-G5 1-G6A 1-G6B
Atmospheric Top P/A Atmospheric Mid. P/A Spare for 1-G5and T-G6A
1 1 1
1-G7
Atmospheric Bottom P/A
1
ABDOO102846
25 Seconds
Units Started
1-G13 A&B 13-G24A&B 13-E24 A,D/E,H 13--E 23B
Compressor Auction K.O. Drum Coolant Pumps (Methanol) Coolant Cooler Fans Vacuum Top P/A Cooler Fan
1 1 4 1
1-E 2I,A,E,1,M,Q, D, H,L,P,T
Atmospheric Overhead Condenser Fans
10
3.0 1-G4A
40 Seconds Straight Run Gasoline
1-G14 A&B
Light Gasoline
1-G8
450 E.P. Product
1-G9A
550 E.P. Product
1-G9B
Spare for 1-G8 and 1-G9A
1-015
Sour Water Fium 1-D7
1-G10A
650 E.P. Gas Oil Product
1-G11
Atmos. Heavy Gas Oil Product
1-G10B 13-G23 A&B
Spare for 1-G1QA and 1-G11 Ejector Condensate
13-G 20
Vacuum Bottom P/A
1-E 22B
650 E.P. Gas OH Cooler
Acceleration is completed generally 6 to 15 seconds after starting times
shown.
4.0 Auto Start
Motors that are started by a (Instrument Interlock) FSL, PSl, LSH, etc. will
automatically restart 10 seconds after power restoration when switch Is set in
* the automatic position.
ABI$P 102847 All electric driven equipment mult be checked when power is restored within five (5) seconds after a power failure to ascertain reacceleration is complere and to restart manually that equipment not on the automatic restart list. Unit conditions, temperatures, levels, flows, etc., must be checked closely and returned to normal operation.
Atmospheric and vacuum tower top temperature control is protected by stecm driven spare pumps. Atmospheric tower overhead Reflux Pump, 1-G3, is spared by o steam turbine driven pump 1-G4B, that will start on low discharge pressure of 1-G3. Vacuum tower top reflux pump 13-G18A Is spared by a steam turbine driven pump 13-G8B, that will start on low discharge pressure of 13-G18A.
Action will depend on the duration of the power failure, steps should be taken to *icu:i: through c!! hectare. Change cl' prrHurt lines to sloo, and bring in wash oil from off sites, to "wash out heavy oil systems and prepare for unit restart. Unit pressures must be monitored closely and vented as needed. Cooling water pumps Include one turbine drive so cooling water will be available at reduced rates.
5.0 Desalter Transformer The Crude Desalter transformers will fall out on voltage drop. They must be re-energized when power Is restored. If the desolter water pumps (18-G-9 & 13-G-23) were started some time ahead of the transformers, some water carryover in .crude could occur.
ABDOO102848 B. Steam Outage: Loss
There are three (3) separate steam systems in the Crude Unit area, a list of their pressures and normal usage is listed below: 1.0 600 PS1G System 1.1 Soot Blowers on atmospheric heaters, 1-B1 A&B 1.2 Soot Blowers on vacuum heater 13-B2
ABD00102849 -6-
2.0 150 PS1G System: 2.1 To atmospheric heaters 1-B1 A&B for superheating then for stripping
steam to towers: a. Atmospheric Tower 1-D1 b. 450 E.P. Stripper 1-D2 c. 550 E.P. Stripper 1-D3 d. 650 E.P. Stripper 1-D4 e. Atmospheric Heavy Gas Oil Stripper 1-D5 f. Vacuum Tower 13-D 10 g. Purge Steam to Desalter Relief Valves 2.2 Vacuum Tower Ejectors - 13-G 25 A&B. and 13-G 27 A&B. 2.3 Atomizing steam for Oil ourneia in Heaters 1~51 A&B and 13-^? 2.4 Steam out connections to Heaters 1-Bl A&B and 13-B2 2.5 Snuffing steam to firebox and header box of Heaters 1-5 l A&B and 13-B2. 2.6 Snuffing stecm to all Relief Valves from Atmospheric Tower 1-D1 and
Vacuum Tower 13-D 10. 2.7 Supply Steam to:
a. S.R. Gasoline and Atmosphere Top Reflux Turbine Driven Spare Pump 1-G 4B.
b. Vacuum Tower Top Reflux and Product Turbine Driven Spore Pump 13-G 18B.
2.8 For steam air decoking all Heaters.
3.0 40 PS1G System: 3,1 To fuel gos plate heaters.
ABDOO102850
3.2 For atomizing steam to waste gas burner? in Heaters 1-B1 A&B. 3. 3 For heating coll of Vacuum Tower Top Pump Around Cooler 13-- 23. 3.4 For vaporizer in ammonia system at Storage Drum 1-D 13. 3.5 . To heating coils in Caustic Tank 1~F5, and other enclosures. 3.6 To all Utility Stations. 3 J As Quench Steam to Resid Pumps 13-G 22 A&B.
4.0 Steam Shortage In the event of a steam shortage it will become necessary to conserve all possible steam at each pressure level. Steps to be takenshould include:
4.1 No Soot Blowing of Heaters. 4.2 Ascertain thot Steam Turbine Driven Pumps are shut down and electric
drives are in &etvlc&. 4. 3 Reduce stripping steam to all Towers to the very minimum. This can be
determined by checking that product streams continue to meet specifications. 4.4 Check that all snuffing steam lines are blocked off. 4. 5 Shut down all fuel oil burners in heaters that the Fuel Gas System
pressure will allow. 4.6 Check that all Utility Stations are blocked in.
If steam shortage is for an extended time, or further conservation is necessary, crude charge rate should be reduced. This will permit a further reduction in all stripping steam and steam to vacuum ejectors, may be reduced a^vacuum tower temperatures and pressures will permit.
ABgUDO 102851
5.0 Complete Steam Loss If a complete steam loss occurs In the 600 PS1G System, there is no immediate action required on the crude unit, except no soot blowing. If a complete steam loss occurs in the 150 PSIG System the Crude Unit will need to be circulated down.
5.0.1 Reduce Crude Charge Rates, as required. 5.0.2 Change all product lines to the Recirculation Line. 5.0.3 Reduce all heater fires to torches. 5.0.4 Shut off all oil burners. 5.0.5 Shut down reflux and product pumps as levels are pumped out. 5.0.6 Circulate atmospheric and vacuum heaters to start up lines, to cool down. 5.0.7 Charge wash oii to the unit and wu!i out a!! heavy c:! circuits n prAooration
for restart.
5.0.8 Close all stripping steam steam valves. 5.1 If a complete steam loss occurs in the 40 PSIG system. 5.1.1 Shut down all waste gas burners and divert waste gas to the flare. 5.1.2 Shut down the ammonia system. 5.1.3 Check fuel gas burners for any possible liquid.
No further immediate action is required at this time.
Plont Air Failure Under normal crude unit operation, a complete plant air failure will require only a check, to ascertain that all oir outlets on utility stations are closed. If air failure should occur during a heater decoking operation, then air valves must be closed end steam flow adjusted to hold prescribed tube-pressure.
ABDOO102852
D. Instrument Air Failure 1.0 Crude Heater and Preheat Section 1.1 'Crude charge control valves and crude heater pass control valves fail open. 1.2 Water to and from the desalter regulators fail closed. 1.3 Fuel chopper valves to the curoe heater fuel regulators foil closed. 1.4 Initial action should include the following steps: a. Cut crude charge rate using handvalves upstream of exchangers 1-El A&B - leave enough to cool heaters. Adjust heater passes by hanavaives to assure flow through each pass. b. Steam hearer to the crude tower. These heaters have a single stecm line to men leswcuiivc charge iir.es. c. Vent superheater steam coils of heaters l-BI A&B to the atmosphere with hand valves located on each superheater coil outlet. Crude heaters ore not equipped with blowdown systems, but relieve and are steamed out to the tower. 2.0 Atmcsoheric Tower 2.1 All stripper draw regulators fail closed. 2.2 All steam to strippers and ATM tower fail closed. 2.3 All product to storage regulators fail closed. 2.4 AH pump around reflux and overhead reflux regulators fall open. 2.5 Accumulator off-gas through PRC on compressor discharge falls open. PIC - 11 to the flore header fails closed. 2.6 Reduced crude heater passes fail open.
>
E. Fuel Loss, Gcs - Oil
ABD00102853
1.0 Generol
The Crude Unit Atmospheric Heaters 1-B1 A & B and Vacuum Heater 13-62 are
fired by a combination type fuel system. These two systems one .(1) oil and one
(1) gas, moy be fired separately or in combination. A board mounted hand switch,
(HIC) is provided to change heater outlet temperature control to fuel gas or fuel
oil firing, and provide the following operations:
1.1 Heater outlet temperature control by TRC and Gas Fuel only.
1.2 Heater outlet temperature control by TRC-FIC cascade on OH Fuel only.
1.3 Heater outlet temperature control by TRC and Gas firing, base loaded with oil on
hand control set from F1C.
1.4 Heoter outlet temperature control by TRC-FIC cascode oil firing, with gas on
hand control to each yus firing valve.
2.0 Complete Fuel Oil Failure In the event of a complete fuel oil failure, actions required for above opercting conditions are:
2.1 No action required, main fuel oil supply valves will close on low pressure. 2.2 Change board mounted hand switch to gas firing position, -- heoter outlet
temperature control by TRC. Light additional gas burners as required, close oil firing control valves manually from FIC's, close fuel oil valve to each individual burner, steam through each burner until clear of oil and close steam valves. 2.3 Close oil firing control volves manually from FIC's,. close fuel oil valve to eoch individual burner, steam through each burner until clear of oil, close steam #valve, and light additional gas burners as needed.
ABDOO102854 2.4 Change board mounted hand switch to gos firing position, -- heater outlet
temperature control by TRC, light gas burners as needed,, close oil firing control valves manually from PIC's, close fuel oil valve to each individual burner, steam through each burner until clear of oil, and close steam vclve.
3.0 Complete Fuel Gos Failure In the event of o complete fuel gcs failure, actions required for the above operating conditions are:
3.1 Change board mounted hand switch to oil firing position, heater outlet temperature control by TRC-FIC cascade. Light oil burners as required, close fuel gas valve to each individual burner.
3.2 No action required, main fuel gcs supply valves will close cn low pressure. 3.2 Change bocrd mounted hand switch to oil firing position. Hecter outlet
temperature control by TRC-FIC cascade. Light additional oil burners as recuired, and close fuel gas valve to each individual burner. 3.4 Light additional oil burners as needed, and close fuei gas valve to each individual burner. The center section (Fire Box ^2) of the vacuum heater 13-B2 is not provided with fuei oil burners. In the event of o complete fuel gcs failure, with 100% fuel oil firing. Individual pass outlet temperatures must be checked closeiy, and flows adjusted to prevent overhearing in individual coils.
F. Heoter Tube Rupture
ABDOO102855
"
1.0 General
In the event of a heater tube rupture, action taken will depend on the
size and location of the failure and the heater involved. As there ore no
block valves or check valves between'the heaters and the towers, this
influences handling of emergencies.
The general procedure is to put snuffing steom In the fire box, block out
the heater feed, steam through the tubes to the tower and block out all
fuel systems.
These heaters hove a single steam line to their respective charge lines and
each pass must be steamed separately.
2.0 Crude Heaters 1-81 A & B
Follow General procedure given above and then continue with normu!
shut down procedure. Leave steam to the tower and strippers to prevent
vapors from flowing bock to the heater. Bypass pump out.
3.0 Reduced Crude Heater 13-S2 Follow General procedure given above and then bypass reduced crude to
resid, crude exchangers 13-E10A, B, C & D. Reduce vacuum by shutting
down one ejector in each set of jets (3).
Increase steam to the tower os needed to breok the vacuum. Vacuum is
reduced to prevent pulling air into the tower. All ejectors should be
shut down and steam left in the tower when steam is cut out of heater
tubes. Pump out the entire vacuum side and gas oil wash the vacuum side as soon as possible.
ABDOO102856
-14-
G. Loss of Coaling Water A failure of the cooling water system will cause the following equipment to heat to excessive temperatures* 1* Overhead Accumulator Vapor Condensors 1-E 13 A & B. 2. Compressor Discharge Cooler? 1-E 14 A&B. 3. Compressor Circulating Coolont Cooler 1-E 26 4. Compressor Luo. Oil Coolers 1-E 25 A&B 5. Ejector 1st stage (ntercondensers 13-E 18 A & B 6. Ejector 2nd stage Intercondensers 13-E 19 A & B 7. Ejector 3rd stage Aftercondensers 13-E 20 A & B
If a cooling water failure occurs proceed as follows: 1. Reduce crude charge rate for unit shut down. 2. Shut down all heater fires. 3. Shut down overhead gas compressors, allow excess pressure to flcre 4. Change run down lines to circulating line. . Shut down all ejectors. 6. Stop waste gas flow to atmospheric heaters, vent to the flare. 7. Proceed with unit shut down.
.8 When cooling water flow returns to normal, restart unit.
ABDOO102857
H. Loss of Compressor? Single or Both Under normal conditions the Overhead Gas Compressor's, 1-G1 A & B, handle the Crude Unit Overhead Gas production. Uncondensed off-gas from the Atmospheric Overhead Accumulator 1-D7 flows to the Compressor Knock Out Drum 1-D8 through Condensers 1-E 13 A & B. PRC-9 in the Compressor
i
t
i
Discharge Line, controls the Crude Tower pressure and maintains the pressure at approximately 10 PSIG in the Accumulator. In the event of a compressor shut down, gas make above that which can be handled
i t
by a single Compressor will be diverted to the flare by PIC-11 on the Accumulator. Unit feed rates will have to be adjusted to match the gas hondling capacity of one compressor. If a shut down of both compressors occurs, unit feed
t
I
rates must be reduced to the flare system gas handling copacity. Norma! cas flow to the compressors is 3398 MSCFD for the sweet block. Compressor i-Gl A & B design capacity is 2C40M5CFD/Unit (Sweet Block).
I. Loss of Feed If a total .crude unit feed loss occurs action must be taken to prevent excessive
i
i
r
v
temperature build up in equipment. 1. Notify the Oil Movements Control Room technician. 2. Stop all water, acid, etc., injection streams to the crude and desalter.
p
i
3. Cut out all heater fires, open stack and air dampers.
p
4. Place all heater's on circulation for 'tooling. 5. Stop all product draws and circulating reflux circuits to prevent over
p
heating crude exchangers.
p
6.* Change all product run down lines to the slop header.
p7. Take all necessary action to prevent excessive pressures, temperatures an !eve?
When feed is available restart the unit.
p
ABDOO102858 -16-
Exchanger Leaks Exchanger leaks will fall into two categories, external or internal. Operation of exchangers at pressure, temperatures or flow rotes not in accord with design conditions may cause leaks in tubes and internal or external gaskets. 1.0 External Gasket leaks can be detected by a visual inspection of the
following points: 1.1 Channel Section Gasket. 1.2 Channel Cover Plate Gasket 1.3 Shell Side Inlet and Outlet Nozzle Gaskets. 1.4 Bell Head Gasket 1.5 Tube Side Inlet and Outlet Nozzle Gaskets In the event of a minor leak at any of the above locations, the first action taken should be to have all bolts checked for proper tightness, at operating temperatures. If leak ccnnot be stepped by this operation, then exchanger must be bypassed and removed from service for repair.
2.0 When a leak develops in an exchanger tube or internal gasket contamination will occur. The higher pressure stream will flow into the lower pressure stream in proportion to the pressure difference of the two streams and the size of the leak. When a leak of this nature is detected the exchanger must be removed from service and repaired.
ABDOO102859
Desolter Out of Service If it becomes necessary to remove the Desalter from service under normal Crude Unit operations, bypass lines are provided. Steps to be taken Include: 1. PIC-01 Desalter pressure control to crude charge system must be on
manual control, 2. All chemical, water, etc., injection to crude feed and Desalter must
be stopped. 3. Shut down Desalter electrical system. 4. Bypcss Desalter charge to Heater charge pumps 1-G2 A, B, & C, and
block in Desalter. 5. Block out Desalter inlet and outlet lines. 6. Check and adjust preheat train temperatures and pressures, for normal
operations. 7. Pump out the Desalter via the pumpout line provided to the suction of
Crude Booster Pump 1-G2C.
Loss of Methanol Coolont System A circulated Coolant System is used for cooling Combined Gas Oil Coolers 13-E 17 A thru D and Vacuum Mid. Pumparound Cooler 13-E 16. The heat absorbing liquid in this coolant system is wafer plus methanol. The coolant is circulated tram the Coolant Surge Drum 13-D )2, through air coolers 13-E25 for heat removal, before returning to product coolers 13-E17 and 13-E16 . The system is circulated-with pumps 13-G 24A and spare is 13-G 24B. The surge drum liquid level Is maintained by the addition of boiler feed water and methanol as required.
ABDOO102860
-18-
A failure of the circulating coolant system will cause the following equipment to heat to excessive temperatures: 1. Combined gas oil Coolers 13-E 17 A, B, C and D, 2. Vacuum Mid, Pumparound Cooler 13-E 16. In the event of a complete loss of the circulating cooling system the hot stream side (shell side) of coolers 13-E 17 A thru D and 13-E 16, must be bypassed to prevent overheating of the tube side. Allow enough flow through the coolers to prevent plugging, without overheating.
The combined Gas Oil Stream will be too high in tempeature (about 350F) for FCC feed storage, and must be combined with resid to storage stream at battery limits.
The ability to pump the combined gcs oil and resid streams to storage may be a limiting factor, so that crude charge rates will need to be reduced to meet conditions.
ABDOO102861
M. TO REMOVE A HEAVY OIL PUMP FROM SERVICE Pumps in Heovy Oil Service are provided with a Wash Oil Line to flush the pump, suction and discharge lines, when the pump is removed from service. The Wash Oil is 550 E.P. product, from down stream of exchangers 1-E2, to down stream of each Indi vidual pump suction valve.
To remove pumps from service and flush with Wash Oil the following steps should be taken.
1.0 Atmospheric Tower Bottom Pumps 1-G 12 A&B 1.1 Slowly close the discharge valve and stop the pump to be removed from service.
Ascertain that the spore pump is in service and at normal operating conditions.
1.2 Close the Suction Valve of the pump removed from >civl.c.
1.3 Check that block valve in wash oil line downstream of exchangers 1-E2 is open. Slowly open block valve in wash oil line to downstream of pump suction valve.
1.4 Restart the pump and slowly open the dischaicc valve enough to establish a flew as indicated by pump discharge pressure.
1.5 Only run pump long enough to displace Heavy Oil from the pump, suction and discharge lines. This is to be determined by a visual check of pump vent or drain line.
1.6 When pump and lines ar& clear, close discharge valve, stop the pump, close
block valve in wash oil line, open pump drains and vents.
ABPOO102862
1.7 Check that block valves are open on the hot flow bypass line, if one is provided.
2.0 Vacuum Tower Recycle Pump 13-G21
This pump hos no spare so operating conditions must be checked and adjusted when it is removed from service.
2.1 Slowly close F1C-13076 and the associated block valves. 2.2 Slowly close pump discharge valve, then stop the pump.
2.3 Close pump suction valve, check that block valves ore closed on the hot flow bypass line.
2.4 Check that block valve is open in the wash oil line downstream of exchangers 1-E2. Slowiy open block valve in wos'n oil line downstream cf pump suction '"ah'*-
2.5 Restart the pump and slowly open the discharge valve enough to estaolish a flow as indicated by the pump discharge pressure.
2.6 Run the pump long enough to displace the heavy oil from pump, suction and
discharge lines. This is to be determined by a visual check of the pump drain line. 2.7 When pump and lines are flushed clear, close discharge valve, stop the pump, close block valve in wash oil line, open pump drain line.
2.8 Close L1CV-13013 and associated block valves.
ABDOO102863
3.0 Vacuum Tower Bottom Fumes 13-G 22 A&S When these pumps and lines are flushed, 550 E.P. product must not be allowed to enter the resid run down line, due to resid storage tank temperatures of ^ 4C0
3.1 Slowly close the pump discharge valve and stop the pump to be removed from service. Ascertain that the spare pump is in service and at normal operating conditions.
3.2 Close the pump suction valve. 3.3 Check that block valve in Wash CT1 Line downstream of exchangers 1-E2 is open. 3.4 . Close block valve in seal oil line upstream of PCV. 3.5 Close block vdve in 40 psig steem quench line. 3.6 Open block valve in wash oil line downsrreem of pump suction valve. 2.7 Open block valve in vent line from pump casing to theVacuum Tower 13-D10. 3.3 When pump, suction and discharge lines have been displaced with550 E.P.
product into the Vacuum Tower, close block valves in the vent line end wash oil line. Cpen pump drain.
ABDOO102864
D-5 Operating Procedures - Chemical Transfer Process The following is an example of an operating procedure for a chemical transfer process. It outlines the steps required to safely unload a tank truck containing methyl chloride, including the review of the appropriate MSDS and the proper personal protective equipment to be worn.
37
ABDOO102865
STANDARD OPERATING PROCEDURE UNLOADING A TANK TRUCK OF METHYL CHLORIDE
SOP #92-101 REVISION C: 12/27/93
PROCEDURAL SUMMARY - UNLOADING A TANK TRUCK OF METHYL CHLORIDE 1. READ MSDS FOR METHYL CHLORIDE 2. WEAR PROPER PERSONAL PROTECTIVE EQUIPMENT 3. CHECK METHYL CHLORIDE LEVEL IN ST-9 4. CALCULATE FINAL LEVEL IN ST-9 5. PLACE TRAILER AND CHOCK WHEELS, ATTACH GROUNDING CABLE 6. CONNECT METHYL CHLORIDE UNLOADING LINE TO TRAILER HOSES 7. DURING UNLOADING, WATCH FOR LEAKS AND MONITOR ST-9 LEVEL B. WHEN UNLOADING IS COMPLETE. PERFORM POST-UNLOADING TASKS
n n m *
i
1
i
36
ABDOO102866
STANDARD OPERATING PROCEDURE UNLOADING A TANK TRUCK OF METHYL CHLORIDE
SOP #92-101 REVISION C: 12/27/93
PROCEDURE AUTHORIZATIONS
PLANT MANAGER
DATE
OPERATIONS MANAGER'
DATE
SAFETY AND HEALTH SUPERVISOR
DATE
39
ABDOO102867
STANDARD OPERATING PROCEDURE UNLOADING A TANK TRUCK OF METHYL CHLORIDE
SOP #92-101 REVISION C: 12/27/93
PROCEDURE
ACTION
NOTES
40
ABDOO102868
STANDARD OPERATING PROCEDURE UNLOADING A TANK TRUCK OF METHYL CHLORIDE
SOP #92-101 REVISION C: 12/27/93
UNLOADING A TANK TRUCK OF METHYL CHLORIDE
1.
READ THE MSDS FOR METHYL CHLORIDE LOCATED IN THE HAZARDOUS MATERIALS NOTEBOOK
1.1
YOU MUST UNDERSTAND THE NATURE AND HAZARDS OF METHYL CHLORIDE BEFORE STARTING TO HANDLE THIS FLAMMABLE GAS
1.2 CAUTION: METHYL CHLORIDE IS SHIPPED AS A LIQUIFIED COMPRESSED GAS AND IS HIGHLY FLAMMABLE. KEEP SPARKS AND HOT EQUIPMENT AWAY FROM THE AREA WHILE UNLOADING METHYL CHLORIDE
2. WEAR HARD HAT, RUBBER GLOVES, AND FACE SHIELD WHILE UNLOADING METHYL CHLORIDE
2.1 CONTACT WITH METHYL CHLORIDE WILL CAUSE FREEZING BURNS
3.
CHECK THE METHYL CHLORIDE 3.1
HAVE MAINTENANCE INSPECT
LEVEL IN STORAGE TANK ST-9
THE LEVEL GAUGE IF IT IS NOT
USING THE LEVEL GAUGE
ACTING NORMALLY. DO NOT
LOCATED ADJACENT TO THE
RISK OVERFILLING THE
STORAGE TANK
STORAGE TANK
4. REVIEW THE PAPERWORK FOR 4.1 ADD THE METHYL CHLORIDE
THE METHYL CHLORIDE
WEIGHT IN THE TRAILER TO THE
SHIPMENT AND CONSULT WITH
WEIGHT IN ST-9; THE TOTAL
THE PRODUCTION
MUST BE LESS THAN THE FULL
SUPERVISOR TO CALCULATE
READING FOR ST-9
THE FINAL LEVEL IN STORAGE
TANK ST-9
41
ABDOO102869
STANDARD OPERATING PROCEDURE UNLOADING A TANK TRUCK OF METHYL CHLORIDE
SOP #92-101 REVISION C: 12/27/93
UNLOADING A TANK TRUCK OF METHYL CHLORIDE (CONTINUED)
5.
6.
7. 8.
FILL OUT THE PAPERWORK WHILE PERFORMING THE STEPS IN THE TANK TRUCK UNLOADING PROCEDURE
5.1
LOCATE THE TRAILER IN THE DIKED AREA, CHOCK THE WHEELS, AND ATTACH THE GROUNDING CABLE TO EXPOSED METAL ON THE TRAILER
UNLOCK THE METHYL CHLORIDE UNLOADING LINE AND REMOVE THE CAP
6.1
CHANGE ANY WORN GASKETS BEFORE CONNECTING HOSES
7.1
ASSIST THE DRIVER IN CONNECTING TRAILER HOSES TO THE METHYL CHLORIDE UNLOADING LINE
THE PROCEDURE GIVES RULES FOR NORMAL TANK TRUCK UNLOADING AND DETAILS THE PAPERWORK NECESSARY FOR TRAILER UNLOADING
BE SURE THAT THE CORRECT LOCK IS REMOVED TO MINIMIZE THE CHANCES OF MATERIAL CROSS CONTAMINATION GASKETS WILL LEAK WHEN OVERLY WORN
42
ADDOO102870
STANDARD OPERATING PROCEDURE UNLOADING A TANK TRUCK OF METHYL CHLORIDE
SOP #92*101 REVISION C: 12/27/93
PROCEDURE
UNLOADING A TANK TRUCK OF METHYL CHLORIDE (CONTINUED)
ACTION
9. OPEN THE VALVE AT THE METHYL CHLORIDE LINE CONNECTION GOING TO STORAGE TANK ST-9
10. DIRECT THE DRIVER TO OPEN THE VALVES ON THE TRAILER TO THE METHYL CHLORIDE TRANSFER LINE
NOTES
9.1 THIS IS THE ONLY VALVE IN THE TRANSFER LINE INTO THE TOP OF STORAGE TANK ST-9
43
Tmmrnmr
STANDARD OPERATING PROCEDURE UNLOADING A TANK TRUCK OF METHYL CHLORIDE
SOP #92-101 REVISION C: 12/27/93
PROCEDURE
ACTION
NOTES
11. WHILE THE DRIVER STARTS
11.1 SINCE MOST LEAKS ARE
THE TRANSFER PUMP, WATCH
OBSERVED ON START-UP, THE
FOR LEAKS AND DIRECT THE
OPERATOR MUST BE IN
DRIVER TO STOP THE
ATTENDANCE AS THE TRANSFER
TRANSFER IF ANY LEAKS ARE
BEGINS
OBSERVED
11.2 THE DRIVER SHOULD BE IN A
POSITION TO QUICKLY STOP THE
* TRANSFER IF A LEAK DEVELOPS
12.. WHEN THE TRANSFER HAS BEGUN SATISFACTORILY, PERIODICALLY CHECK THE LEVEL IN ST-9 USING THE LEVEL GAUGE TO ENSURE THAT THE LEVEL IS INCREASING
12.1 IF THE LEVEL IS NOT INCREASING, STOP THE TRANSFER AND DIRECT MAINTENANCE TO INSPECT THE LEVEL GAUGE
12.2 THE GAUGE SHOULD RISE AS SOON AS MATERIAL IS PUT INTO THE TANK
t
fe.
t
f
11 k.~
l l
1 fi-l*
mmm
pi
* i i
i i44
ABDOO102872
STANDARD OPERATING PROCEDURE UNLOADING A TANK TRUCK OF METHYL CHLORIDE
SOP #92-101 REVISION C: 12/27/93
PROCEDURE
UNLOADING A TANK TRUCK OF METHYL CHLORIDE (CONTINUED)
ACTION
NOTES
13. WHEN THE TRAILER IS EMPTY, 13.1 COOPERATE WITH THE DRIVER
CLOSE THE TRANSFER VALVE
TO COMPLETE POST-UNLOADING
TASKS
14. DISCONNECT THE METHYL CHLORIDE UNLOADING LINE FROM THE TRAILER, CAREFULLY VENTING THE LINE IN ORDER TO RELIEVE ANY EXCESS PRESSURE
45
ABDOO102873
STANDARD OPERATING PROCEDURE UNLOADING A TANK TRUCK OF METHYL CHLORIDE
S0P #92-101 REVISION C: 12/27/93
PROCEDURE
ACTION
NOTES
15. INSTALL THE CAP ON THE
15.1 THIS WILL PREVENT AN
UNLOADING LINE AND LOCK rT
UNAUTHORIZED MATERIAL
CLOSED
TRANSFER INTO STORAGE TANK
ST-9
16. READ AND RECORD THE FINAL 16.1 COMPARE THE FINAL LEVEL TO
LEVEL IN STORAGE TANK ST-9
THE CALCULATED LEVEL IF THE
VALUES ARE SIGNIFICANTLY
DIFFERENT, CHECK THAT THE
TRAILER IS ACTUALLY EMPTY OR
WHETHER THE LEVEL GAUGE IS
OPERATING CORRECTLY
17. FILL OUT THE POST UNLOADING REPORT AND THE DRIVER'S PAPERWORK
18. REMOVE THE CHOCKS FROM THE TRAILER WHEELS AND REMOVE THE GROUNDING CLAMP
r
i i
i i
i
R
S
r
K
i
46