2.

1 Startup Procedures

2.1.1 Precommissioning Procedures

This section contains some instructions pertaining to preliminary

startup procedures. The information is not intended to cover all
aspects of this work. Vendor instructions must be obtained and
completely understood prior to initial operations. Warranties are
usually voided if these instructions are not followed. Vendor
representative assistance on startup is often required for special
equipment and must be scheduled with the vendor as soon as
practical.

2.1.1.1 Mechanical Completion and Punch Listing

When construction is nearing completion,

Commissioning and Startup personnel carefully
check out the units in detail against a set of P&IDs,
equipment data sheets and vendor drawings. A
detailed list (punch list) of missing, incomplete
and/or incorrect items is prepared and submitted to
the Construction Department for correction. There must
be no doubt that the plant is constructed according to plans
and specifications. Necessary changes to the original
design that become apparent during these checks will be
handled in accordance with the Job Instructions.

The following list represents the major items to be

checked:

a. General

1. Check with the laboratory supervisor to

confirm that the necessary equipment
has been installed and tested; procedures
for testing are available, and reagents,
standard solutions, chemicals, reference
gases, calibration gases etc., are ready
when needed. Procedures should
include a sampling schedule, sample
procedures, laboratory procedures,
calculation procedures, etc. Sampling
devices must be available before startup.

2. Conduct a personal inventory of

chemicals, packing, desiccants, filter aid,
internals, trays, instrumentation, etc. that
must be installed or used in the course of
commissioning and startup.
 3. Confirm that Operating manuals and Job
Manuals containing all the necessary
vendor data are available.

4. Confirm availability of utilities and

completion of prerequisites for startup
listed for each unit.

b. Safety and Safety Equipment

1. Review the plant for unsafe piping

arrangements and accessibility of critical
valves, which would have to be used
during plant upsets, and emergencies.

2. Check location, availability and

operability of firewater monitors,
eyewashes, safety showers, fire
extinguishers, stretchers, first aid kits,
H2S monitors, gas masks, air packs, etc.

CAUTION
Check location, availability and operability of firewater monitors, eyewashes, safety showers, fire
extinguishers, stretchers, first aid kits, H2S monitors, gas masks, air packs, etc.
CAUTION

3. Check for completeness of ladders,

platforms, handrails and safety cages.

4. Check area lighting to determine if safe

operation at night is possible.

5. Check rotating equipment for

installation of guards.

6. Inspect for proper placement of thermal

insulation for personnel protection.

7. The area should be free of construction

equipment, debris, etc.

8. Check for proper warning signs, safety

equipment location signs, etc.

c. Piping and Instrument Diagrams (P&IDs)

1. Conduct a check of every line in the unit

to see that all the items shown in the
P&IDs are present and installed
properly. Prepare a Punch List
 following the procedures described
below:

 Use the latest revisions for the field

check. Normally the Process and
Control System Engineers make
separate P&ID check.

 “Yellow-Off” lines and equipment

checked.

 Use red mark to identify item to be

corrected. Give tag number to each
correction to be made.

 Prepare a separate punch list for each

unit subdivided by P&ID numbers.

 Similar correction, e.g. missing plug,

can be grouped as one item in the
punch list, and be given the same item
number at the various locations on the
P&ID.

 Retain the “Yellowed-Off” P&ID as

the master copy. Release a copy and
the Punch List to the Startup
Manager.

2. Check location and accessibility of

instruments. If a local indicator is used
in conjunction with manually operated
valves, the indicator should be visible
from the operating point.

3. Check for valves at critical vent and

drain locations. The valves should be
plugged or blinded.

4. Check for proper installation, location

and accessibility of sample points.

5. Check control valves, check valves, and

globe valves to see that they are installed
properly with respect to flow.

6. Review piping for dead spots, water

traps, check valve location, adequate
block valve and blinding facilities to
isolate the system as required for
preparing for startup.
 7. Check for proper pressure ratings of in-
line items. Particular attention should be
given to “speck breaks”.

8. Check for free movement of pipe shoes.

Be sure that the tie-points are properly
located and that the pipe is free to
expand in the directions intended.

9. Check for proper installation and

presetting of pipe hangers.

10. Review piping and instrument

connections for steam tracing,

11. Check for reconnection and installation

of items removed before hydrotesting of
lines.

12. Confirm that hydrotesting of all lines

was done. A line should be retested if
welding is required to complete the
punch list items after hydrotesting has
been completed.

13. Confirm that all control valves have

been pulled and stroked.

14. Confirm that all relief valves, have been

pulled, bench tested, properly tagged and
reinstalled.

15. Check for proper installation and

completeness of insulation.

16. Check for removal of temporary

construction blinds and proper position
of permanent blinds.

17. Check for proper placement and

installation of differential pressure
transmitters.

d. Vessels, Tanks and Towers

Welding on vessels in the field should be

avoided if at all possible. A thorough
inspection of vessels and towers will at least
help analyze and diagnose problems that may
occur during the startup operation.
1. Check the vessel tag plates to see that
the design conditions, test conditions,
and codes meet the requirements of the
specifications.

2. Inspect every nozzle for orientation,

placement, size and rating.

3. Open and inspect every tower for proper

installation of trays, free movement of
tray valves, proper downcomer clearance
and tray seal, cleanliness, location of
thermowells and other instruments, type
and location of cladding, tray spacing,
tray levelness, tray tightness, existence
of weep holes for free draining,
installation of demisters, distributors,
vortex breakers, tray supports, seal
welds, gaskets, packing, packing
supports, linings, weir adjustments, etc.
The tower should be thoroughly checked
against the P&IDs as well as the vendor
drawings.

4. Open and inspect every vessel and tank

for cleanliness, stingers, vortex breakers,
supports linings, cladding coatings,
proper installation of elements,
demisters, distributors.

5. Confirm that all internal flanges on gas /

liquid distributors are tightened.

6. Confirm that all pressure vessels were

properly hydrotested.

7. Check ladders and platforms for

accessibility of manways, instruments,
etc.

8. Check for completeness of hot insulation

and proper placement of insulation for
personnel protection.

9. Check for proper gaskets. Temporary

gaskets are often used during
hydrotesting and vessel checkout.

10. Confirm that all quality control checks,

field test records, field installation
checklists, and vessel closing
 authorization have been completed to the
satisfaction of the commissioning team.

e. Shell and Tube Exchangers

1. Check the tag plate to see that the design

conditions, test conditions, and code
meet the requirements of the
specifications.

2. Confirm that the design configuration,

stacking, and installation meet the
process requirements.

3. Inspect every nozzle for orientation,

placement, size and rating.

4. Check for proper insulation.

5. Check for installation of vents, drains,

thermowells, plugs, etc.

6. Confirm that all exchangers were

hydrotested. Be cautious of limitations
of tube sheet differentials.

7. Check for removal of shipping braces

and tack welds on slide plates. Slide
plate should be lubricated.

8. Check for installation of proper gaskets.

9. Confirm quality control test, field test

records, field installation checklist, and
inspection has been completed to the
satisfaction of the commissioning team.

10. Check the expansion slot, the bolt have

to be center, in order to avoid any
restriction of the move of the exchanger
(hot service)

f. Air Coolers

1. Check the tag plate to see that the design

conditions, test conditions, and code
meet the requirements of the
specifications.

2. Confirm that the design configuration,

stacking, and installation meet the
process requirements.
 3. Inspect every nozzle for orientation,
placement, size and rating and gasket
installation according with the service.

4. Check for high point vents and missing

plugs and gasket installation according
with the service.

5. Compare motor nameplate information

to the air cooler specifications.

6. Checks for proper installation of drive

belts.

7. Check and test fan pitch adjuster,

louvers and temperature control
mechanisms.

8. Confirm quality control test, field test

records, field installation check list, and
inspection has been completed to the
satisfaction of the commissioning team

9. Confirm leak test for this equipment

g. Pump and Drivers

1. A line-by-line, item-by-item check

should be made of vendor supplied lube
oil systems and seal oil systems for large
pumps. Special attention should be
given to vendor/buyer interface items.

2. Check the cooling water piping, seal

flush piping, etc., against the vendor
drawings.

3. Vent and drain piping and valves should

conform to the standard sketches
published for this project.

4. Check the nameplate data on motors,

gears, and pumps against the
specifications.

5. Check on availability of specified lube

oil, other lubricants and spare parts.

6. Ensure that suction strainers, screens and

blinds have been properly installed.
 7. Check suction and discharge piping for
proper support and expansion.

8. Ensure that couplings are made up and

that guards are installed.

9. Check for free and proper rotation of

pumps and drivers.

10. Consult with Electrical Engineer for

confirmation of the checkout of the
electrical system, motor dryout, motor
run-in, etc. Each pump should be
cleared by the Electrical Engineer just
prior to startup.

11. Each pump should be cleared by

Mechanical Engineer just prior to
startup. Confirm that field installation
check lists have been completed to the
satisfaction of the Commissioning Team

h. Compressor and Drivers

1. A line-by-line, item-by-item check

should be made of vendor supplied lube
oil systems and seal oil systems for large
pumps. Special attention should be
given to vendor/buyer interface items.

2. Check the nameplate data on motors,

turbines, vessels, relief valves and
auxiliaries supplied by the vendor.

3. Check for removal of shipping braces,

plugs, etc.

4. Ensure that suction screens and blinds

have been properly installed.

5. Check suction and discharge piping for

proper support and expansion.

6. Check for free and proper rotation of

compressor and driver.

7. Confirm that lube and seal oil system

has been hydrotested.

8. Ensure that couplings are made and that

guards are installed.
 9. Consult with Electrical Engineer for
confirmation of the checkout of the
electrical system, motor dryout, motor
run-in, etc. Each compressor should be
cleared by the Electrical Engineer just
prior to startup.

10. Each compressor should be cleared by

Mechanical Engineer just prior to
startup. Confirm that field installation
check lists have been completed to the
satisfaction of the Commissioning Team

i. Fired Heaters

1. Check the overall assembly of firebox,

convection section, economizers, stack,
etc., against the specifications and
vendor drawings.

2. Check all feed piping, flow control

stations and other process monitoring
instruments.

3. Check all fuel gas and pilot gas piping

and control stations for completeness.

4. Check snuffing steam piping and access

to the steam valves. Ensure there is no
low-point for condensate to accumulate.

5. Ensure location and access to the

emergency isolation valve.

6. Check and test the heater shutdown

logic.

7. Check for proper installation of burners

and pilots.

8. Ensure smooth operation of air registers

and exhaust damper.

9. Carry out visual check of refractory and

firebrick installation

10. Check for proper operation of

combustion air fan, if any.
j. Hydrostatic Testing

All the vessels are generally hydrotested in the

shop prior to shipment to the site. Many fired
heaters and all heat exchangers are hydrotested
in the field.

Systematic and thorough pre-operation testing

attempts as far as possible to test for
satisfactory tightness wider anticipated
operating conditions. The suggestions outlined
here are intended to supplement the provisions
of engineering piping specification "Field
Pressure Testing of Piping, Sewers, Fired
Heater Tube Assemblies and Exchangers, The
procedures detailed in this specification are
followed in all pressure testing.

1. Preparation for the Test

(a) Check that the weight of towers

and vessels, when filled with
water, will not exceed foundation
or structural design strength, or
that pipes, when filled with water,
will not exceed the strength of pipe
racks or supports.

(b) Two test gauges should be used on

each test system, and they should
be calibrated as specified. The test
pump should not be left unattended
when connected to the system.

(c) Occasionally it is desirable to add

a phosphorescent dye to the
hydrostatic test water. After a
period of time under pressure, the
outer surfaces can be inspected
with ultraviolet light to readily
detect minute leaks.

(d) A test schedule is prepared

defining the extent of each test and
specifying the test pressure. The
test system should be as large as
practical in order to minimize the
number of untested joints.

(e) The schedule should be

independently rechecked to be sure
 that the test, pressure does not
exceed that permitted on each line
and piece of equipment.

(f) Pumps and compressors are not

field pressure tested. Do not allow
water to get into compressors or
other such equipment.

(g) Remove all equipment internals,

which are not to be subjected to
test pressures such as check valves,
gates, level floats, etc.

(h) Checklists should includes

tabulation of all equipment
removed, vents and/or drains
installed, temporary restraints
installed, and blinds placed in
service. Use care that no
equipment removed is misplaced.
After tightness testing, this
checklist may be used to ensure
that all equipment is replaced and
blinds removed.

2. Testing

Inspection of the system is made during

the time the test pressure is being applied
and leaks repaired as required. When the
test pressure is reached and maintained
for the time indicated below the final
inspection is made of the entire test
system by the interested parties.

3. Duration of Test

The pressure shall be maintained long

enough to enable the inspector to make
certain there are no leaks. For flanged
joints fifteen minutes is considered ample
time, but for welded joints one-half hour
is usually sufficient. For piping, vessels
and equipment with one-half inch or less
of wall thickness, one-half hour test
period is desirable, and for wall thickness
over one-half inch, one hour is
recommended.
 CAUTION
Before draining a vessel, a top vent must be opened to avoid pulling a vacuum.
CAUTION

k. Records

Records shall be made of each test system,

witnessed and signed by both Contractor and
client personnel. These records should include
date of test, identification of test, test fluid, test
pressure, and approvals.

2.1.1.2 Flushing

Flushing is required to remove construction debris

and other trash that may damage equipment or
restrict flow lines during operation. Failure to
properly flush new piping systems clean is the most
frequent cause of operating difficulties at startup. A
thorough job of flushing will usually prevent a great
deal of stuffing box and seal trouble, control valve
trouble, and excessive machinery wear during initial
operations.

a. Steam Piping

In general, certain principles are to be followed

during the flushing operation.

 Flushing lines with steam are noisy and

potentially dangerous. The area should be
cleared and barricaded by “Off-Limit” tape
for safety.

 Start routing the steam from boilers to

distribution main. Before blowing a steam
line for cleaning, provide an open end for a
free passage of steam and debris. This is
done by breaking the end-flange or cutting
off the end-cap. Then flush lateral headers,
one at a time, in the same manner.

 Introduce steam slowly to heat up the line

gradually. Condensate should not be
allowed to accumulate in order to avoid
water hammer. Thus, steam flow rate is
limited by the rate of condensate drainage.
 As the line heat up, observe its expansion
and determine that there is no binding or
distortion.

 When the line is hot, increase the steam rate

to provide a hard blow.

 Flush downward or horizontally and at low

points. The low point openings should be
near line size if possible. Make the opening
by breaking flanges and disconnecting
equipment.

 Place a target place at the exhaust. Replace

the target plate occasionally with new one.
When there is no more debris hitting the
plate, the line is considered clean.
Commonly these target place are installed
in system that are going to move turbine
associated to pump or compressor

 If the open-end is a temporary provision, be

certain the end is tied down securely to
prevent possible whipping caused by high
velocity steam vent.

 Close the valves to steam traps. Keep them

out of service until the line cleaning is
completed. Open drains to keep the line
free of water.

 When the line is clean, place the steam traps

in service.

 Remove control valves, flow meters and

restriction orifices.

 All connections to instruments should be

closed off or disconnected at the instrument.
Instrument air lines must be blown with
instrument air with special thoroughness.

 Avoid flushing line debris into equipment.

 All connections at compressors and pumps

must be disconnected. Always cover the
open connections on the equipment to
prevent entry of flushing medium.

 Disconnect the heater burner piping

  After blowing, permit the line to cool and
contract, then repeat the proceeding
blowing. The expansion and contraction of
the piping loosens much of the mill scale,
which is blown free during the succeeding
steam blow. The cleaning procedures
should be repeated three times.

The basic utility systems steam, water, and air

should be put in normal working order after
they have been cleaned, so that supplies will be
available for further operations

b. Process Lines

Process and any hydrocarbon systems are

mainly washed with water. Any lines not
accessible to water, or lines that would trap
water in such a way that it could not be
drained, may be blown out with air. Most of
the process and auxiliary lines may be flushed
through established circuits from vessels, the
vessels being filled with water for the purpose.

In general, certain principles are to be followed

during the flushing operation.

 A single filling of a vessel may not provide

sufficient water to flush all lines. In such a
case a continuous or intermittent flow of
water into the vessel should be maintained.
Water may be admitted to most vessels via
temporary connection to a nozzle on the
bottom outlet line.

 If washing of the vessel itself is also a

primary object, introduce water into the top
of the vessel, by hose connection to a top
reflux line or other entrance. When
washing exit lines of a vessel always be
certain the vessel is adequately vented to
prevent a vacuum condition. Inadequate
venting of vessels not designed for vacuum
service could collapse them.

 To the greatest extent possible, flush

downward, or horizontally, and out at low
points. The low point discharge opening
will usually be temporary openings made by
disconnecting flanges or fittings; normal
drains may be used for flushing outlets,
 provided they are equal to line size or
nearly so.

 The higher the velocity of flushing, the

more thoroughly a line will be scoured.
However, if it is necessary to throttle the
flushing flow, do so at the supply end.

 Flush through all vents, drains and other

side connections. Flush bypasses
alternately with their main channels.

 Do not flush line debris into equipment

where it may become lodged or trapped.
This applies to such things as exchangers
(both sides), distributor piping with small
holes, and other points of discharge into
vessel internals.

 Remove pipe spool before the control valve

or control valve itself, if small, to dump
debris. Continue to wash downstream
through bypass. Finally, replace the plate or
valve and flush through the valve in normal
alignment.

 Flow meter and restriction orifices should

not be installed until lines are clean. Any
orifices installed before cleaning should be
removed.

 All connections at pumps must be closed

off or disconnected. The flushing outlet
point should be as near the pump as
possible. This can be done by swinging the
valve out of way or removing spacer/blind.
Where this is done on the pump side of the
block valve, cover the open pump
connection if necessary to prevent entry of
the flushing flow. In the discharge lines
containing a check valve immediately
adjacent to the pump (generally the case
with centrifugal pumps), a flush outlet may
be made by removing the check valve cover
plate, provided the flapper or disc remains
in place to seal off the pump itself. Where it
is desirable to flush through a check valve,
the flapper must be removed and the cover
replaced.
  All connections to instruments should be
closed off during flushing, or disconnected
at the instrument and flushed. Instrument
air lines must be blown with special
thoroughness.

 Have furnace burners disconnected until the

fuel gas line thereto is clean and then
reconnect and blow through the burner and
pilot.

At the conclusion of flushing any system,

check carefully to see that normal alignments
are restored, temporary connections broken,
temporary breaks reconnected, check valve
flappers and/or cover plates replaced, orifices
installed, etc. In the case of lines that will
receive further cleaning during the subsequent
breaking-in of pumps, this instruction may be
qualified in part.

When flushing of process lines is finished,

drain water from the system as completely as
possible. Provide ample top venting during the
draining operation, or whenever the level is
being lowered in a vessel, to avoid pulling a
vacuum on the equipment. Blow lines with air
to effect further water removal.

At the conclusion of draining and blowout,

temporary strainers may be removed if no
longer needed, instrument leads connected,
orifice plates installed, etc.

CAUTION
Remove temporary strainers at the end of flushing if no longer needed (compressor suction strainers).
CAUTION

2.1.1.3 Instrument Preparation

a. Control Loops

Control loops must be checked to demonstrate

the proper action and direction. Valves and
auxiliary power circuits should be properly
lined tip and readied for normal operation.
Continuity and functional checks should be
witnessed.
b. Alarm Settings and Interlocks

Alarm settings and interlock sections shall be

checked for correct operation and set for
anticipated operating conditions. Test all
alarms and safety and operational interlocks.

c. Flow Meters and Flow Recorders

During pump run-in procedures, flow meters

and transmitters can be activated and all
control valves run over their full valve travel to
check for full stroke on full instrument output
pressure.

d. Level Instruments

Whenever possible, level instruments on

towers and vessels should be activated and
placed on automatic control and checked for
operation.

e. Orifices and Flow Meters

All flow meters should be independently

double-checked as to bore and location before
installing. Since the plant guarantees are
determined by such primary elements there
should be no question that the proper orifice is
correctly installed at the proper location.

f. Instrument Calibration and Checks

Transmitters are zeroed. An instrument list

should be utilized to check off each instrument
serviced prior to initial operation. All tests
should be witnessed.

g. Safety and Relief Valves

It is recommended that the factory settings of

all relief valves be rechecked before
installation. Installation must be carefully
checked against valve lists to insure that each
valve is installed in the correct location.

h. Control Valves

Check that the valve action is correct and that

on air failure is correct. Control valve packing
should be properly adjusted after the valve is
 placed into operation. Do not tighten packing
for the tightness tests.

i. Thermowells

Thermowells must be checked for proper

position and immersion in the fluid and for
proper insulation to stop heat leaks around
thermocouple or thermometer bulbs.

j. Emergency Isolation Valves

Activate all emergency isolation valves operate

according to specified time via local and/or
remote switches. Check valve closure time.

k. Gas Detectors

Combustible gas detectors and H2S detection

systems must be checked and calibrated

l. Analyzers

Calibrate each analyzer with standard samples.

2.1.2 Commissioning and Initial Start-Up Procedures

2.1.2.1 Mechanical Equipment Run-In

In starting all moving equipment, watch for excessive

vibration, overheating of bearings, excessive heating
of the driving motor, and listen for unusual noises. If
excessive vibration is detected the unit must be
stopped immediately to determine the cause.
Attempt to turn the machine over by hand first, if
possible, and then operate with a no-load condition.
Next check performance with a light load operation
before the final full load checkout.

Particular attention should be given to lubrication,

balancing and alignment.

All bed-rings should be flushed clean arid the correct

lubricant in the proper quantity must be provided.
Cards should be affixed to the driver and driven
equipment showing the date of flushing, type of
lubricant used, and the signature of the lubricator
actually doing the job.

Alignment should first be done cold and then

rechecked after the equipment has had the
 opportunity to thoroughly heat up. A heat up period
of six hours is not unusual for heavy equipment.

2.1.2.2 Pumps

The most critical period in the life of a pump is

during the initial start and several minutes
immediately following. Before pumps are put in
operation for the first time, they should be checked as
follows:

 Proper lubricants are provided and lubricators

filled.

 Cooling water is started through bearing

housings, stuffing box jackets, smothering glands
and pump pedestal, if required, and flushed clear.

 Temporary strainers are provided for the suction

of each pump to be installed on the pump side of
the suction block valves. These strainers will be
installed after the suction lines are flushed and
can be removed when the lines are free of foreign
matter. Best practice is to keep the strainers in
service for the first week under full load.
Temporary strainers should be checked viewing
the suction pressure indicator and frequently by
alternating pumps where possible.

 Pumps are not field hydrostatically tested.

 Check for the correct installation of the API plan

for each pump

 During the initial circulating period, all pumps

should be put into operation in order to determine
whether they are in good mechanical condition
and to break them in. The length of time for
breaking in may vary for different pumps, but a
period of four hours is usually satisfactory. A
minimum of eight hours trouble-free run-in time
is desirable on boiler feedwater pumps.

 If water is used for breaking in the pump, care

must be taken not to overload the motors on
motor driven pump. The amperage on motor
driven centrifugal pumps should be checked. If
the current drawn is too high, the discharge valve
should be partially closed until the amperage
drawn by the motor is normal.
 During the breaking in period, all push buttons
shall be checked on motor driven pumps to
determine that they are in proper working order.
The emergency trips should be checked on
turbine driven pumps. Steam inlets to the
turbines should be drained of any condensate, and
turbines warmed up slowly, and traps on live and
exhaust steam lines should be checked to see that
they function properly.

 Before starting the pumps, the unit (pump and

driver) is rotated by hand through at least one
complete revolution to make sure all moving
parts are free. All pumps must be completely
filled and vented because rotating parts within the
pump depend upon the liquid for lubrication
and/or cooling, and they may seize if the pump is
operated dry. When the pump is located below
the level of the liquid to be pumped, it will prime
itself when the vent (or vents) on the top of the
pump case is opened to release entrapped air or
vapor. Pumps with vertical suction and discharge
nozzles are self-venting.

 The pump is rechecked for correct rotation before

operating. After the pump is first started, the
driver and pump bearings are checked frequently
for excessive heating or vibration. If stuffing
boxes overheat, the pump is stopped and the
stuffing boxes allowed cooling off.

a. Centrifugal Pumps

Centrifugal pumps should be started fully

primed, with the discharge pinched (not closed
off, however) and with the suction wide open.
Under no circumstances should the pump
discharge the closed off so that the pump
deadheads. Check the pump head and power
consumption before opening discharge valve
wide open.

With pumps equipped with mechanical seals,

be sure that the seal faces are clean and there is
an adequate flow of seal or lubricating liquid.

b. Reciprocating Pumps

Reciprocating pumps may be checked for

operability on water. Both inlet and discharge
valves must be wide open. Water may be
 supplied by means of a hose connected to the
suction line header and may be discharged
through the discharge drain to the sewer.

While the pump is being checked out, the

packing gland must be fairly loose and the
piston rod frequently lubricated with heavy oil
to prevent scoring of the piston rod. A period
of two hours should be sufficient for checking
these pumps. Disconnect the water hose and
connect an air hose to the suction line header
and free the pump of water through the
discharge drain.

c. Special Pumps

The preparation for operation and the initial

run-in of any special pumps must be carried
out in strict conformance with the instructions
furnished by the manufacturer. In some cases
it may be desirable to have a manufacturer's
representative supervise the run-in.

2.1.2.3 Compressors

Compressors and drivers of all types must be

properly installed and operated for "run-in" similarly
to the pumps so as to assure satisfactory service. The
detailed instructions issued by the manufacturer for
the installation and operation of the machine must be
closely followed. The following check-list should be
observed:

 Except for very simple machines, vendor field

service engineers should be present.

 Check lube and seal oil system on compressor

and driver. Circulate "run-in" oil in lube and seal
oil system to clean all lines. Heat oil as
necessary. "Run-in" oil should be changed. See
manufacturer's instructions.

 On turbine driven machine, check overspeed trip

and governor with turbine disconnected.

 Check gearbox lubrication.

 Check out suction and discharge piping vent and

drain connections, block valves, bypasses and
relief valves.
  On gas engine driven compressors, check out fuel
system and starting air system. On turbine-driven
equipment, check out all the turbine and
condensing equipment.

 Check operation of valve unloaders and clearance

pockets on reciprocating machines.

 Check out intercooler and interstage knock-out

drums.

 Be sure there is no liquid in suction piping and

bottles on reciprocating machines before starting
compressor.

 Check out control system and emergency

shutdown devices.

 Centrifugal compressors may be run in on gas

different from that specified for the design of the
machine. However, if there is an appreciable
difference in gas properties, the manufacturer
should be consulted.

 Cooling water to oil coolers, intercoolers, and

aftercoolers must be made available.

 If permanent strainers are not installed, temporary

strainers at each suction flange must be installed
and removed after run-in.

If the compressor has carbon parts, the run-in period

is used to polish and seat the carbon parts before
pressure is applied to them.

2.1.2.4 Heater Dry-Out

a. Purpose

Furnace dry-out procedures are utilized as a

means of curing furnace refractory before
initial process operation. At the same time, the
dry-out period is also used as a means of
checking the operation of certain heater
components such as burners and control
devices that may be used during the dry-out
period.
b. Duration

A three (3) day dry-out cycle is specified

during which furnace temperatures are
gradually increased to the point that the
refractory is completely dry. During the dry-
out cycle, moisture in the heater refractory
close to the flame is evaporated within a very
short time. Over a three (3) day cycle,
however, moisture inside the refractory is
gradually heated and evaporated. Therefore,
heater casing temperature may gradually
increase to the point that it reaches
approximately 2120F. This is an indication that
moisture next to the shell is now being
evaporated. After this point, a drop off in shell
temperature will be noted to normal levels.

c. Tube Protection

During the dry-out cycle, it is necessary to

circulate steam through all process tubes in
order to prevent overheating. Use the skin
thermocouples or an infrared pyrometer for
detecting tube metal temperature. The
maximum tube metal temperature for radiant
section is 10000F and 8000F for the convection
section. To avoid condensation, steam flow
through the tubes should be started when flue
gas temperature is approximately 5000F. all the
design temperature have to be review with the
design of the heater

d. Dry-out Procedure

1. Open stack dampers, burner duct damper

and burner registers to a full open
position for a “natural draft” mode of
operation. Inject steam into all furnace
snuffing steam connections to purge the
furnace of any combustible gases. Allow
a steam purge of at least 15 minutes
before lighting the first burner. If the
heater draft is a forced, induced or
balanced , all the duct have to be in mind
in order to dry out all the internals
refractories
 CAUTION
Allow a steam purge of at least 15 minutes before lighting the first burner.
CAUTION

2. Remove blinds in the fuel lines to the

unit. Have valving at the burners set up
on manual control during the dry-out
cycle.

3. After the refractories have air cured for

at least 24 hours, dry-out can be
initiated. A gradual heat-up will be
required to remove the residual moisture
in an orderly manner. Too rapid heat-up
can cause bond disruption, spalling and
excessive cracking.

The following heat-up schedule, based on

the radiant arch flue gas temperature, is
recommended:

(a) Raise temperature from ambient to

2500F at 500F per hour.

(b) Hold 2500F for 12 hours.

(c) Raise temperature from 2500F to

5000F at 500F per hour.

(d) Hold 5000F for 12 hours.

(e) At 5000F sufficient steam flow is

to be injected into all coils to
prevent the tube metal temperature
from exceeding 10000F in the
radiant section and 8000F in the
convection section.

(f) Raise temperature from 5000F to

10000F at 500F per hour.

(g) Hold 10000F for 12 hours.

(h) Reduce temperature from 10000F

to 5000F at 500F per hour.
 (i) At 5000F, shut off all burners and
steam flow to coils and allow
furnace to air cool.

4. As a general rule, no more than 1/4 of

the total number of burners in the heater
will be lighted at any one time during
the dry-out cycle. It is advisable,
however, to rotate the burners in use so
that during the dry-out all burners have
been fired and checked for ignition
stability and ease of operation.

5. If the heater is to be shut down for an

extended period after the dry-out cycle,
it is recommended that it be closed up
tightly by closing all burner registers,
peepholes, and all pressure relief doors.
Close the stack damper. In areas where
freezing or excessive humidity can
occur, circulation of low pressure steam
is also recommended.

6. Burners should be ignited with the

burner dampers in the near closed
position. Once lit, adjust dampers. No
attention has to be given to proper
operating levels of excess air during the
dry-out period. Burners should be
operated at high excess air during this
phase of operation. Process technician
should visually check that flames are
stable during all changes in burner load
or combustion air requirements.

2.1.2.5 Steam Generation Equipment Boilout

Typically the steam generation system consists of the

HCGO Pumparound /MP Steam Generator and the
HCGO /Product MP Steam Generator and associated
instrumentation and piping. On initial start-up, a
special boilout should be performed to ensure a clean
metal surface on all parts of the steam generation
system in contact with steam and water. The boilout
removes rust, oil accumulation from the rolling, mill
scale, welding flux, and all other foreign material left
from fabrication.

Chemicals normally used in boiling out are soda ash

and caustic soda. Other chemicals should consult
their boiler chemical supplier for recommendations
regarding boilout procedures for this system.

The following is intended to provide some guidelines

for boilout:

a. Fill the system with BFW.

b. One pound of caustic soda and one pound of

soda ash should be added for each 300 pounds
of water in the system. The two chemicals
should be thoroughly dissolved in water prior
to their addition to the boiler water and each
should be mixed separately. Observe the rules
for handling these chemicals safely. Handle
the chemicals only while wearing rubber
gloves and always add the chemicals in small
amounts to large volumes of water. Add
chemicals just prior to heating (as described
below), because the chemicals will encrust on
the boiler surfaces if allowed to set in cold
boiler water for any length of time.

c. When boiling out, the system should be

completely blocked in with all drain valves
and makeup valves closed except where noted
later in the procedure. Level instruments
should be lined up to receive boilout liquid
and monitor level. Plan to replace the level
gauge glasses used during boilout since the
boilout chemicals will attack the glass.

d. Isolate the tube sides of the HCGO

Pumparound MP/Steam Generator and HCGO
Product /MP Steam Generator and prepare for
heating with steam. Make temporary low
pressure steam connections and if desired,
attach steam traps. Heat the system at a rate
not exceeding 100F per hour in boiler water.
Review the design pressure of these
equipments

e. After 8 hours, blowdown valves should be

operated at approximately ½ hour intervals
while replacing the blowdown with fresh
feedwater. Continue blowing down until the
blowdown water appears clear.

f. Discontinue steam addition and cool the

system down. At this point, drain and again
 fill the system with fresh boiler feedwater.
Drain again. This will remove any remaining
caustic on the internal surfaces. Check pH
while draining (should be about 7 on pH
paper).

g. Open up the system. Leave all drains open and

wash all tubes and the shell with water.
Carefully wash the gauge glass and level
control connections and drains. Open and
clean piping anywhere that water and
chemicals may have lain stagnant during the
boilout. Upon completion of the washing,
inspect the surfaces to determine that the
boiler is in satisfactory condition for initial
start-up.

h. All system gaskets should be replaced after

completion of boilout.

2.1.2.6 Purging

Before introducing hydrocarbons in the plant, the

plant must be essentially free of air to eliminate
possibility of fire and explosion. Creating this safe
environment is accomplished either by steam-out or
purging with inert gas.

a. Steam-Out

Virtually all equipment in hydrocarbon service

in the that unit is designed for special steam-
out conditions. Some exceptions are applied to
facilities where possible full vacuum may exist
during the course of startup, shutdown and
normal operation.

Steam-out connections are provided on most of

vessels, towers, heat exchangers, pumps, etc.,
to deliver LP steam. If there is no permanent
steam-out connection is available, then
establish a temporary hose connection from the
nearest utility station. To steam out equipment
follow the steps described below:

 Remove spectacle blind on the steam line.

Remove blinds on vessel and line vents and
drains.

 Open the vent and drain.

  Open the steam valve.

As steam enters the cold equipment and lines,

it condenses. Condensates must be drained to
sewer so as not to flood the equipment. When
healthy flow of steam is observed from the
drain and vent, air is being purged out of the
system. In half an hour, air will be essentially
purged out. Close the vent and stop the steam.
As steam condenses, introduce refinery fuel
gas or nitrogen. Always ensure that no vessel
is inadvertently put under a vacuum. To
prevent this, always maintain a minimum
pressure of about 10 psig.

CAUTION
Ensure that a top vent to the atmosphere is open during steamout to avoid pulling a vacuum. do not
open vent to flare as an explosive mixture of hydrocarbons and air may be formed if hydrocarbons
are admitted back from the flare.
CAUTION

b. Gas Purging

Nitrogen is used to purge a process system

with the combination of flow and pressuring-
venting technique.

1. Flow Purge

Purging of the plant can be accomplished

by establishing a nitrogen flow through
the piping and equipment of various
sections. A check should be made to
ensure that all vents, drains, and PSV
bypass valves are closed. Open control
valves, block valves in each system in the
plant as they are lined up for purging.
Systematically, one by one, open vents
and drains to purge the air trapped in dead
spaces. Each system should be marked
up on the mechanical flow diagrams as it
is purged. Keep a log to record pressure
profiles, oxygen content of the piping and
equipment. Once a system has been
purged, keep a positive pressure and flow
through it where possible. Do not allow
flow from a system that has not been
purged into one that has.
 2. Pressure Purge

By repeating pressuring-and-venting,
oxygen can be reduced progressively.
Dead air spaces in vessels, equipment,
and piping can be purged by pressuring to
about 50 psig and depressurizing to 2~3
psig. Normally, three (3) times is
sufficient. Oxygen content should be
checked after the second depressuring,
and each one after until oxygen content is
1 mol. % or less.

To purge air out of large reactor vessels

packed with fine catalyst, the system is
often evacuated by an eductor provided
specifically for this purpose.

2.1.3 Checklist before Going Onstream

After successful completion of pre-commissioning and

commissioning activities, the unit is ready for start-up.

CAUTION
Note that preparation for gas plant start-up (if the Delayed coker unit DCU have a gas plant) should
be underway at the same time DCU is starting up. Full coordination among operating teams is
necessary to assure continuity and to avoid unnecessary delays.
CAUTION

2.1.3.1 Check to make sure all relief valves have been

installed and that block valves on both sides (where
applicable) are locked open. Spares should be
blocked and locked closed.

2.1.3.2 Check to make sure all blinds have been pulled in

accordance with the blind list

2.1.3.3 Notify all associated units that a DCU start-up is

imminent

2.1.3.4 Check to make sure that block valves on cooling

water supply and cooling water return lines are
open.

2.1.3.5 Check to make sure that all utilities are available

and ready for use

2.1.3.6 Ensure that all utility stations are ready for use.
 2.1.3.7 Check to make sure that the flare system is
commissioned and ready for operation.

2.1.3.8 Check to make sure that all pumps minimum flow

bypass lines are commissioned and ready for
operation.

2.1.3.9 Ensure that all control loops are functioning

properly.

2.1.3.10 Ensure that all auto modes and cascade controls are
properly activated and functioning at start-up.

2.1.3.11 Ensure that all alarm and trip settings are correct and
all alarms are active and will function properly.

2.1.3.12 Ensure that start-up naphtha, diesel and purchased

gas oil are available for filling and circulating
through the designated circuits.

2.1.3.13 Block in pressure transmitters and differential

pressure transmitters.

2.1.3.14 Crack vessel drains, pump case drains and other low
point drains in preparation for draining steam
condensate.

2.1.3.15 Open high point vents on lines and equipment.

2.1.3.16 Check the following specific connections to and

from the unit . for proper routing (valves and control
elements are at the right mode, position etc) and
adequacy of operation. Ensure that Site Acceptance
Tests (SAT) are completed and control loops and
instrumentation are checked for adequate process
control during start-up and normal operation.

2.1.4 Normal Startup Procedure

Normal start-up DCU take place when the upstream Crude Unit
is already onstream and Vacuum Residue is available to feed the
DCU. The following downstream processing units should also
be onstream to receive and process the DCU products, typically:

 Utilities & power service

 Gas Plant
 Hydrotreater
 Hydrocracker
 Amine Regeneration
 Sour Water Stripper
 Sulfur Recovery
 Tail Gas

The DCU start-up must be coordinated with all other units

interfaced to avoid production disruption and assure continuity
of operation.

Generally; Naphtha, LCGO and HCGO may also be routed to

storage to build up inventory for the hydrotreater and the
hydrocracker as necessary.

The start-up procedure for DCU includes the following major

steps:

 Steam-out and Gas Blanketing

 Establishing Naphtha Inventory

 Flushing by Naphtha Circulation

 Establishing Diesel Inventory

 Flushing by Diesel Circulation

 Filling and Commissioning Blowdown System

 Heating up the Plant

 Introducing Purchased Gas Oil via the Flushing Oil System

 Introducing Vacuum Residue

 Starting the Coking Cycle

 Stabilizing Operation

Circulation will initially start cold through the Delayed Coker

Unit and the Gas Plant, then warm-up circulation will follow,
and finally heating the plant to start-up the coke drums when the
vacuum residue is introduced and proper operating temperature
level is reached.

2.1.4.1 Steamout and Gas Blanketing

a. Steam out all towers, vessels, exchangers, and

lines.
 b. Steam pressure test lines with 10 psi under the
lowest pressure relief valve setting in the unit.
Repair any leaks found and if necessary purge
and retest lines once more.

c. Drain Water from all low points and water

boots.

d. Break vacuum by using nitrogen and fuel gas

as needed.

e. Nitrogen-purge the Coker Gas Compressor

and its associated piping to sweep away air
prior to fuel gas introduction.

CAUTION
Close all control valves and bypasses, replace any blind flanges or remove plugs. Battery Limit
valves are to be closed.
CAUTION

f. Blanket equipment with fuel gas introduced

from the Start-up/Vacuum Protection Fuel Gas
Line connected to the Coker Fractionator
overhead line .

g. Coke drums not to be fuel gas blanketed since

they will be steam purged and pressure tested
prior to warm-up.

h. Activate purge steam and blocking steam in

the coke drums area at the switch valves and
all the SP valves.

i. Start fans on all air coolers, and start cooling

water to all water coolers in the unit.

j. Use fuel gas to pressure the unit up to 10 psig

by activating the control valve at the top of the
Coker Fractionator

k. Put the Coker Gas Compressor on-line and

test operation with fuel/natural gas supplied
from start-up line e. above. Fuel gas will flow
backwards through the anti-surge line and
isolation valves to the Coker Gas Compressor
suction-line and Compressor Suction Drum
and will fill the Coker Gas Compressor circuit
and gradually pressurize the system.
 l. Follow compressor vendor’s instructions
regarding Coker Gas Compressor and
auxiliary systems (dry and wet seals,
lubrication etc), commission the
performance/anti-surge controller and place
Coker Gas Compressor on 100% recycle.

CAUTION
Pay attention to the low molecular weight of the natural gas during compressor start-up. Inspect for
instability in compressor.
CAUTION

Pay attention to the low molecular weight of

natural gas during compressor start-up. While
the machine should be able to run in a stable
mode with low molecular weight start-up gas,
proper tuning of the performance/anti-surge
controller is essential to ensure a stable
operation of the Coker Gas Compressor. If
the machine becomes unstable shut back down
and restart when refinery fuel gas becomes
richer (higher molecular weight) or when
coker wet gas becomes available.

m. Be prepared to introduce wet gas to Coker Gas

Compressor when Fractionator Overhead
Drum pressure reaches 2 psig and vapors
reach Compressor Suction Drum and also
when Crude Unit Offgas, and Blowdown Vent
Gas from Blowdown Settling Drum reach the
suction drum.

2.1.4.2 Establishing Naphtha Inventory

CAUTION
All this procedure have to be taken as example because can change according with unit
design.

Naphtha Startup Circulation Loop (fractionator

overhead drum-absorber/stripper-depropanizer-
debutanizer-fractionator overhead drum)

a. Fill the Fractionator Overhead Drum with

naphtha from diluent storage , via Fractionator
Overhead Condenser and Fractionator
Overhead Trim Cooler.
 b. Drain water from the low point in the naphtha
loop

c. A good best practice is to fill all that lines that

are going to handled sour water with plant
water, in order to avoid that all these lines fill
with naphtha

2.1.4.3 Flushing by Naphtha Circulation

a. Flush the overhead system via the reflux line

using Fractionator Overhead Pump

b. Also send naphtha from Fractionator

Overhead Pump to Compressor Interstage
Drum via Compressor Interstage Condenser

c. Allow naphtha to flow down the Coker

Fractionator to and remove debris and water.
Drain water at all low points.

d. Allow the Coker Fractionator bottom to fill to

1/3 level as read on level transmitter

e. Establish naphtha flow through the Gas Plant.

Start Unstabilized Naphtha Pump to send
stream from Compressor Interstage Drum to
the Gas Plant through High Pressure Cooler
to High Pressure Separator . Start Rich Oil
Column Feed Pump to send stream to Rich Oil
Column Feed/Bottoms Exchanger tubeside,
then to Rich Oil Column feed line.

f. When about (NLL) of liquid are accumulated

at the bottom of the Rich Oil Column, start
Rich Oil Column Bottoms Pump.

g. Pump the fluid through the shellside of Rich

Oil Column Feed/Bottoms Exchanger. Close
block and bypass valves around control valve
on Lean Oil Line feeding Primary Absorber,
to direct flow back to Fractionator Overhead
Condenser, to flush water back to the Coker
Fractionator. Bring in additional start-up
naphtha as necessary to maintain levels.

2.1.4.4 Establishing Diesel Inventory

Diesel Startup Circulation Loop.

 a. Bring in start-up diesel to the Coker
Fractionator bottom and raise the level to
about 80-90%.

b. Empty the Coker Fractionator bottoms to slop

through the tower pump-out at the
Recirculation Pump discharge The inventory
will then be stored in the Coker Blowdown
Drum for final disposal to the heavy slop
header via line at the Blowdown Circulating
Oil Pump discharge.

c. Refill the Coker Fractionator bottom again

with diesel, then empty to slop. Refill again.
Monitor levels

d. During the filling cycles, flush the Vacuum

Residue Coker Feed with start-up diesel. Also
fill with Start-up Diesel from storage via the
Flush Oil System as it is flushed and dried
out.

2.1.4.5 Flushing by Diesel Circulation

a. At a level of approximately 80-90% of start-

up diesel in the Coker Fractionator bottom,
open the suction and discharge valve on the
heater pump, open the control valve flow to
the heater and fill for gravity. Increase again
the level of the fractionator. Start Heater
Charge Pump and establish circulation
through the Heater Charge Pump discharge
back to the Coker Fractionator via switch
valve at the coke drum . Personnel have to be
in the diesel star up valve , do not forget the
level are going to low

b. After circulation have been established,

open/Close the bypass valve and establish
circulation to the Coker Heater and the Switch
Valve, bypassing the coke drums, then back to
the Coker Fractionator via the Coke Drum
overhead line. Confirm by monitoring the
flow meter( the heater passes flow
controllers).

c. Start Recirculation Pump, and establish

circulation through the Recirculation Strainer
and monitor flow indicator at the pump
discharge line back to the Coker Fractionator.
d. Fill the HCGO/LCGO Stripper with diesel via
the start-up fill connection to the Coker
Fractionator rich sponge oil return on top of
column . Diesel will flow to the stripper via
the gravity draw line from the Coker
Fractionator. Fill the HCGO (pumparound and
product circuit with diesel via suction
pumparound pump

e. As the level builds up in the stripper to about

80% , start LCGO Product Pump to circulate
diesel to the Gas Plant. Coordinate with the
Gas Plant to direct flow to LCGO/Rich
Sponge Oil Exchanger tubeside, then to
Sponge Oil Cooler ,and Sponge Oil Trim
Cooler to Sponge Oil Absorber and activate
the control level at absorber bottom.

f. Bring in LP Natural Gas or refinery gas to the

Amine Absorber Overhead Line in the Gas
Plant to pressurize the column. Close bypass
and block valves around pressure control
valve at the overhead line, and make sure that
a liquid level (seal) is built at the absorber
bottom to prevent gas “pass through” to
Amine Regeneration Unit or block flow
through the bottom “Rich Amine Line” by
closing the bypass and block valves around
flow control valve.

g. Block flow through all lines connected to the

Amine Absorber, except vapor from Sponge
Absorber Line where LP Natural Gas or
refinery gas shall pass through to the Sponge
Absorber in the reverse flow direction. The
gas (up to 70-psig pressure) will push the
diesel back via shellside to DCU Coker
Fractionator Rich Sponge Oil Return Line on
top of the column. This step will flush the
circuit and send all accumulated water back to
the Coker Fractionator.

h. Once the levels in the Coker Fractionator

HCGO section have been established as
indicated on level control valve, by overflow
from the LCGO section, establish circulation
through the HCGO Pumparound Circuit using
HCGO Pump

i. The HCGO Pump draws diesel from Coker

Fractionator bottom tray (P-1). Route the
 flow through HCGO Product, and
Pumparound Circuit consisting of HCGO/MP
Steam Generators (and Gas Plant Rich Oil
Column Reboiler back to Coker Fractionator
through Control flow of pumparound to
reboilers by temperature /flow cascade control

j. Pump diesel to circulate through the HCGO/

product circuit to HCGO Product , then
through HCGO Product/MP Steam Generator
(12-E-003), to HCGO/BFW Exchanger, to
HCGO Product Cooler. Send the stream back
to the Coker Fractionator through the
connection to the start-up diesel line to
storage.

k. Coordinate with the Hydrocracker to flush

HCGO product line to the unit by opening
bypass of flow control valve located at HCGO
Product.

l. During start-up circulation, verify proper

functioning of control loops split range and
cascade from level controllers/flow controllers
to maintain adequate flow and circulation
through both units( DCU and Hydrocracker).

m. Continue to circulate diesel through all

circuits in order to flush water back to the
Coker Fractionator. Bring in additional diesel
as necessary to maintain levels.

n. Flush the LCGO product line to the Light Oil

Hydrotreating Unit. This is accomplished by
pumping diesel from LCGO stripper bottom
through LCGO Product Pump to gas plant
Unit -LCGO / Rich Sponge Oil Exchanger
tubeside, then to hydrotreating Unit.

o. Dispose of any excess circulating diesel via

this route or directly to slop oil

p. Fill the HCGO Product/MP Steam Generator

and Pumparound Steam, and HCGO/BFW
Exchanger with boiler feed water.

2.1.4.6 Filling and Commissioning Blowdown System

a. Fill Water Seal Drum with utility water to

NLL and open overhead line to flare.
b. Introduce diesel to Blowdown system through
LCGO make-up connection from discharge to
Coker Blowdown Drum

c. When level reaches about 80% as read by

level instrument , start Blowdown Circulating
Pump, taking suction from blowdowm tower
through Blowdown Circulating Oil Strainer.
Then the stream is pumped to :

1. Blowdown Circulating Oil Cooler back

to Coker Blowdown Drum on top tower,
and

2. To Blowdown Drum Heater back to the

tower

d. Control oil flow rate to Blowdown Drum

Heater by flow control valve (depend of the
design: internal or external heater ).

e. Start heating steam flow to Blowdown Drum

Heater and control the temperature at
blowdown tower bottom .

f. Control liquid level at the bottom by

level/flow cascade downstream of Blowdown
Circulating Oil Cooler, to Slop Header and to
Heavy Slops through Interconnecting Piping
to Slop Oil System .

g. Introduce Heavy Slop Oil from Tankage to the

circuit via line to shellside feed line of
Blowdown Drum Heater as needed. Control
flow by flow control.

h. Commission all Blowdown lines to SOL and

SOH to flush out water and have the system
ready for start-up and normal operation.

i. Vapors separated at the top of Coker

Blowdown Drum are condensed in Blowdown
Condensers and collected in Blowdown
Settling Drum

j. Introduce Fuel gas to Blowdown Settling

Drum via the Fuel Gas Vacuum Breaker to
maintain 2 psig pressure and monitor liquid
levels in Oil and Sour Water compartments.
 CAUTION
Line up the fuel gas vacuum breaker before bringing the blowdown system on-line. Failure to do so
will draw vacuum at the vapor blowdown system.
CAUTION

k. When liquid level reaches (NLL) on the

waterside, start Blowdown Sour Water Pump
The pump is provided with minimum flow
bypass and the flow will be adjusted by
level/flow cascade, Level Controller and Flow
Controller to sour water stripper.

l. As oil level builds up and reaches (HLL) on

the oilside, Blowdown Slop Oil Pump shall
auto start. Direct flow back to its normal
route to Coker Blowdown Drum, also to SOH
to complete circulation, flushing, and system
commissioning.

2.1.4.7 Heating Up the Plant

(Procedure written for Coker Heater)

a. Purge the Coker Heater with steam and light

pilots.

b. Light selected burners, as suggested by heater

vendor start-up guidelines, at minimum firing
conditions.

c. Start steam tracing to all lines and make sure

that all traps are functioning.

d. Heat Coker Fractionator to 212°F as read on

(Coke drum overhead vapor to Coker
Fractionator” zone) by circulating through the
heater and back to the Coker Fractionator

e. Do not exceed a heat up rate of 50°F an hour

when raising each heater outlet temperature.

f. Heat up cautiously to 250°F, and hold

whenever water appears in the overhead drum

g. Drain water from the overhead drum boot.

h. Heat up cautiously to 300°F, and hold again

whenever water appears at overhead drum
 i. Monitor overhead drum water boots for water
production as read on level instrument and
keep draining.

j. When no more water appears, heat up at 50°F

per hour

2.1.4.8 Introducing Purchased Gas Oil via the Flushing

Oil System

CAUTION
This step may precede step 2.1.4.7 to prevent pump cavitation as the sysytem is being heated up.
CAUTION

a. Bring in gas oil via the Flush Oil connection

to diesel start-up fill line to hold the level at
the Coker Fractionator bottom.

b. Start reflux to Coker Fractionator via

Fractionator Overhead Pump and keep the
overhead temperature at 270F (normal
operating temperature). Control temperature
by temperature control cascade control loop.

c. Hold the Coker Fractionator temperature

about 600°F until vacuum residue is available

d. When the heater flue gas temperature reaches

500°F, start MP steam to the steam
superheater coils. Vent the steam to
atmosphere via the Exhaust Silencer until the
steam exiting the coils does not contain
condensate

e. Start stripping steam to the LCGO/HCGO

Stripper. Drain condensate from low points in
the striping steam piping.

2.1.4.9 Introducing Vacuum Residue

a. When Vacuum Residue becomes available,

raise the heater outlet temperature to 650°F -
700°F at a rate of 50°F an hour.

CAUTION
Do not raise the heater outlet temperature above 700oF.
CAUTION
 Do not raise the heater outlet temperature
above 700°F. Temperatures to be controlled
TIC on the heater passes.

b. Bring in a small amount of vacuum residue to

hold Coker Fractionator bottoms level if
necessary.

Starting the Coking Cycle

c. When the heater outlet temperature reaches

625°F, start HS steam injection to the process
coils at the heater front end-convection
section- and control the rates through 1,550
lbs. /hr for each pass. Injection at the radiant
section points will depend on the coil’s
pressure drop.

d. Prepare the designated drum for warm-up

using the following steps

1. Steam purge and pressure test the coke

drum at 90% of PSV set pressure)

2. Open SP-7A and drain liquid condensate

through Drain Line DR-12-5020-J1001-
14”-Is to settling maze. Close drain
valves.

3. Close blocking steam between SP-1A

and SP-2A valves located on Coke
Drum Overhead Vapor Line and drain
condensate.

4. Open SP-1A and SP-2A valves and

throttle SP-3A valve located on Coke
Drum Overhead Vapor Line to Coker
Fractionator to force the vapors back to
the drum for heating up.

CAUTION
Assure proper warm-up of the coke drums during start-up to minimize thermal fatigue that may lead
to potential bulging/cracking of shell/shell welds, leak and fire.
CAUTION

e. When the coke drum midpoint temperature

reaches 600°F, prepare to switch into the drum
using the following steps
 1. Make sure the Switch Valve is free. If
the valve is jammed, lower the heater
outlet temperature 5°F - 10°F to free up
the valve before proceeding.

2. Block in the start-up diesel at the Coker

Fractionator

3. Close SP-7A and the downstream block

valve to the Coker Blowdown Drum

4. Fully open SP-3A valve to direct coke

drum overhead vapor to Coker
Fractionator

5. Close blocking steam between Switch

Valve and SP-6A valve and drain the
condensate

6. Open SP-6A on Heater Effluent to Coke

Drum

7. Increase and direct the vacuum residue

feed rate from Crude Unit to 70 or 80%
capacity

8. When the heater outlet temperature

reaches 800°F and is rising, switch into
the designated coke drum by turning the
switch valve from the drum bypass
mode into the drum.

9. Continue raising the heater outlet

temperature to the designated coking
temperature of 925 F

10. Steam-out the coke drum bypass line to

the Coker Fractionator and close the SP-
5A valve.

f. Start HCGO quench oil to the coke drum

overhead vapor line. Flow is controlled by
temperature control. However at start-up,
open bypass to start quenching. TIC will
control/increase the flow when the
temperature exceeds the set point of 840 F.

2.1.4.10 Stabilizing Operation

a. Route HCGO product to tankage by directing

the flow to storage rather than back to Coker
Fractionator (depend of the design)
b. Route LCGO from LCGO stripper through
LCGO Product Pump to storage via Gas Plant
LCGO/Rich Sponge Oil Exchanger and
Sponge Oil Cooler to storage.

c. As Coker Fractionator overhead vapor flow

stabilizes and reaches minimum flow rate for
Coker Gas Compressor to be put on-line and
export gas to gas plant, restart the Coker Gas
Compressor, if it was shut down after its test
run.

d. Start-up of Gas Plant must be underway. .

e. Activate level/flow cascade control loop on

Coker Fractionator overhead liquid from
Fractionator Overhead Drum to direct flow to
Compressor Interstage Condenser as the liquid
level builds up.

f. Monitor liquid level in Compressor Suction

Drum and activate the control loop to assure
proper and safe Coker Gas Compressor
(operation. Start Coker Gas Compressor
Suction Liquid Pump and send fluid to
Compressor Interstage Condenser

g. Bring ammonium polysulfide from

Polysulfide Storage Drum via Polysulfide
Metering Pump, and bring Condensate from
Booster Pump to Interstage Condenser Spray
Nozzle

h. Adjust stream flows and temperatures to

balance with Crude Unit production and to
meet product specs.

i. Close the Start-up Naphtha circulation-line

from the Gas Plant back to Fractionator
Overhead Condenser.

j. Route the LCGO to the Light Oil

Hydrotreating Unit via Gas Plant LCGO/Rich
Sponge Oil Exchanger. Control flow to the
Sponge Absorber downstream of Sponge Oil
Cooler and Sponge Oil Trim Cooler . Excess
will be sent to storage and the flow will be set
by level signal at LCGO Stripper bottom.
Also
k. Route HCGO from Coker Fractionator to
Hydrocracker through HCGO Pump, and to
HCGO Product MP Steam Generator, then to
HCGO/BFW Exchanger to Gas Oil
Hydrotreater when it is ready for cracked feed
and the stream is on spec.

l. Start the coke drum switching cycles and

increase throughput as conditions allow.