refinery complex t from concept to commissioning

REFINERY COMPLEX – FROM CONCEPT TO

COMMISSIONING

BY

SUJIT RAY, M.Tech. (1968)

ON

DEC 06, 2020

REFINERY COMPLEX – FROM CONCEPT TO COMMISSIONING

The subject will be presented in three sections:

Section-1: Design of a Refinery Complex from concept to Basic Engineering.

Section-2: Detail Engineering from the kick-off (after project approval) to mechanical completion.

Section-3: Pre-commissioning, Commissioning and Start-up with special reference to start-up of the Crude Distillation Unit, the first unit to be commissioned in a refinery complex.

The discussion will be focused primarily on process engineering aspects covering process design, process control and operation. Aspects of project execution like matching the various project activities in the frame of project timeline which are primarily in the scope of project engineering will not be discussed.

INTRODUCTION (CONTD.)

Section-1

What is a refinery complex?

A refinery complex consists of a number of processing units along with supporting infrastructure facilities.

The first unit is the Crude Distillation Unit which produces straight-run cuts.

Depending upon the type of crude oil and the associated impurities, the straight-run cuts are further processed to produce value-added finished products. In general there are three categories of refineries:

INTRODUCTION (CONTD.)

1. Fuel-based refinery: producing fuel gas, LPG, gasoline, kero /ATF, diesel, furnace oil, asphalt and coke.

2. Lube-based refinery: producing primarily lube oil base-stocks in addition to fuel-based products.

3. Petrochemicals-based refinery: producing primarily petrochemical feedstocks (namely ethylene, propylene, butylene and aromatics) in addition to fuel-based products.

Complexity of a refinery complex is expressed by a number called Nelson Complexity Index which relates to the number of high-value conversion units and their capacity with respect to the crude unit.

The refinery complex of Reliance Industries in Jamnagar, Gujarat is one of the most complex refinery in the world (Nelson Complexity Index = 14.3)

FIRST SECTION: REFINERY COMPLEX

- FROM CONCEPT TO BASIC ENGINEERING

Various Phases of Project Development

PROJECT DEVELOPMENT PHASES

• Idea or Concept

• Opportunity Study

• Front-end Level 1 (FEL-1): Feasibility Study • Front-end Level 2 (FEL-2): Process Definition -> Design Basis Memorandum (DBM)

• Front-end Level 3 (FEL-3): Basic Engineering -> Engineering Design Specification (EDS) or FEED (Front End Engineering Design) • Detail Engineering: Detailed Design – Engineering, Procurement and

Construction (EPC)

CONCEPTUAL DESIGN AND BASIC

ENGINEERING

Conceptual Design and Basic Engineering • Idea or concept

Initial idea or concept can come from the owner or client company, government organization or stake holder or a consultant. After review, the concept is firmed up. • Opportunity Study

Study is made and an opportunity identified based on the concept. Range of possible configurations analyzed and reviewed - for example, nature of crude, type of processing, throughput, products etc. Methodology - order of magnitude, capacity factored. Cost Class (AACEI) – Class 5, Estimate Accuracy: -30% to +50%.


ENGINEERING

Conceptual Design and Basic Engineering • Preliminary Feasibility Study: FEL-1

Various configurations analyzed, for example type of refinery, process technology etc. A few probable cases identified in FEL-1. Methodology - capacity / equipment factored. Cost Class (AACEI) – Class 4/5, Estimate Accuracy: -30% to +50%. • Feasibility Study: FEL-2 Best one or two options analyzed. Comparative study made. Throughput determined and project economics evaluated. Process defined in FEL-2 (Design Basis Memorandum or DBM). PFD, equipment list, data sheets prepared. Methodology - equipment factored. Cost Class (AACEI) – Class 4, Estimate Accuracy: -15% to +30%.


ENGINEERING

Conceptual Design and Basic Engineering

• Basic Engineering: FEL-3

Detailed process description of the selected process and process design basis made.

Engineering Design Specification (EDS)

or FEED (Front End Engineering Design)

P&ID, equipment list, data sheets prepared.

Methodology - Semi-detailed unit cost

with assembly level line items

Cost Class (AACEI) – Class 2/3, Estimate Accuracy:

-10% to +25%.

DETAILED ENGINEERING

Detailed Engineering

• Verification / Validation of Basic Engineering Package (FEL-3 or FEED) by Detailed Engineering Contractor / Process Licensor.

• Detailed Design: Engineering, Procurement and Construction (EPC) by the Detailed Engineering Contractor based on validated Basic Engineering Package.

• Completed final engineering design (EPC Package).

Methodology - Detailed unit cost with detailed material take-off

Cost Class (AACEI) – Class 1, Estimate Accuracy:

-5% to +15%

… see Section-2 for Detailed Engineering

Section-2

DETAILED ENGINEERING AND CONSTRUCTION OF A REFINERY COMPLEX

REFINERY COMPLEX

TYPICAL REFINERY UNITS (Fuel Block)

• Process Plants Crude Distillation Unit

Vacuum Distillation Unit

Gas Treating & LPG Unit

Naphtha Hydrotreater

Catalytic Reformer

Kero Hydrotreater

Diesel Hydrotreater

Delayed Coker Unit

Asphalt Unit

Etc.

REFINERY COMPLEX

• Utilities & Offsites

Steam Generation Unit (Boiler / Captive Power Plant)

Air Compressor (Plant Air & Dry Air) Unit

Raw Water, Fire Water and Cooling Water System

Fuel Gas / Fuel Oil Supply System

Crude Oil Storage and Pumping

Intermediate & Finished Product Storage and Pumping

Product Dispatch – Pipeline, Tank Wagon / Truck Loading Gantry

Refinery Flare System

Offsites Piping Network

DETAILED ENGINEERING

Detailed Engineering

• Verification / Validation of Basic Engineering Package (FEL-3 or FEED) by Detailed Engineering Contractor / Process Licensor.

In fact all basic process engineering activities done in FEL-3 or

FEED will be re-done in Detailed Engineering.

• Detailed Design: Engineering, Procurement and Construction (EPC) by the Detailed Engineering Contractor based on verified / validated Basic Engineering Package.

• Completed final engineering design (EPC Package).

Methodology - Detailed unit cost with detailed material take-off

Cost Class (AACEI) – Class 1, Estimate Accuracy:

-5% to +15%

REFINERY COMPLEX DETAILED ENGINEERING AND CONSTRUCTION

• DETAILED ENGINEERING CONTRACTOR SELECTED BY THE CLIENT OR OWNER.

• CLIENT OR OWNER SETS UP ITS OWN PROJECT TEAM AND OPENS ITS LOCAL OFFICE.

• PROJECT SITE OPENED AND CONSTRUCTION WORK MOBILIZED.

• CONSTRUCTION SITE OFFICE OPENED BY THE ENGINEERING COMPANY.

• DETAILED ENGINEERING KICK-OFF MEETING WITH ENGINEERING CONTRACTOR / PROCESS LICENSOR, CLIENT OR

OWNER / STAKE HOLDERS FOLLOWING OFFICIAL APPROVAL OF THE PROJECT.

• START OF CIVIL, CONSTRUCTION AND ENGINEERING WORK AT SITE.

• PRIORITIES SET UP FOR CONSTRUCTION AND PROCUREMENT ACTIVITIES BY PROJECT / PROJECT CONTROL

GROUP OF THE ENGINEERING COMPANY IN CO-ORDINATION WITH THE CLIENT.

• PROCESS DEPARTMENT OF THE ENGINEERING COMPANY PREPARES THE LIST OF DELIVERABLES CO-ORDINATING

WITH PROJECT PLANNING & SCHEDULING GROUPS.


• FIRST PROCESS UNIT TO BE COMMISSIONED IN THE REFINERY COMPLEX IS THE CRUDE DISTILLATION

UNIT ALONG WITH THE REQUIRED UTILITIES AND OFFSITES FACILITIES. PRIORITIES OF

CONSTRUCTION SET UP ACCORDINGLY.

• REFINERY OVER-ALL PLOT PLAN PREPARED. ALL UNIT AREAS – ISBL (Inside Battery Limit) & OSBL

(Outside Battery Limit) IDENTIFIED.

• PREPARE PROCESS DESCRIPTION AND PROCESS DESIGN BASIS GIVING THE PROCESS PARAMETERS.

• PREPARE BLOCK FLOW DIAGRAM AND UNIT TENTATIVE ISBL PLOT PLAN.

• PREPARE PROCESS FLOW DIAGRAM AND UTILITY FLOW DIAGRAM.

REFINERY COMPLEX DETAILED ENGINEERING

• PERFORM PROCESS SIMULATION USING THE SOFTWARE SELECTED FOR THE PROJECT AT THE NORMAL DESIGN THROUGHPUT OF THE CRUDE UNIT.

• PREPARE HEAT AND MATERIAL BALANCE FOR THE CRUDE UNIT AT THE DESIGN THROUGHPUT PROVIDING THE FLOW RATE, COMPOSITION, PRESSURE AND TEMPERATURE OF EACH STREAM AT EACH EQUIPMENT IN THE PFD.

• PREPARE UTILITY FLOW RATES AND POWER REQUIREMENTS TABLE.

• PREPARE EFFLUENT SUMMARY TABLE.

• PREPARE CHEMICAL CONSUMPTION RATES AND DESIGN CHEMICAL INJECTION FACILITIES.


• PREPARE EQUIPMENT LIST AND FINALIZE EQUIPMENT LOCATIONS ON PLOT PLAN.

• PROCESS DATA TO BE PROVIDED TO ELECTRICAL FOR HAZARDOUS AREA CLASSIFICATION.

• ELECTRICAL PREPARES SINGLE LINE DIAGRAM (By Electrical, Process to review.)

• DETERMINE OPTIMUM PIPE SIZE FOR EACH STREAM IN PFD AND ESTIMATE LINE LOSS.

• ESTIMATE INLET AND OUTLET PRESSURE AT EACH EQUIPMENT.

• PREPARE DESIGN PRESSURE – DESIGN TEMPERATURE (DP-DT) DIAGRAM FOR EACH EQUIPMENT.

• ALL ENGINEERING SPECIFICATIONS, DESIGN STANDARDS AND PROCEDURES ARE IN PLACE FOR THE PROJECT.


• PREPARE MATERIAL SELECTION DIAGRAM FOR ALL EQUIPMENT AND PIPING WITH INPUT FROM STREAM PROPERTIES AND IMPURITIES CONSIDERING DESIGN PRESSURE AND TEMPERATURE CONDITIONS (TO BE CHECKED AND REVIEWED BY METALLURGIST).

• SELECT PIPE CLASS FOR THE TYPE OF SERVICE AND DETERMINE EQUIPMENT DESIGN CLASS (DESIGN P AND T).

• PERFORM SIZING OF EQUIPMENT – PUMP, COMPRESSOR, VESSEL, COLUMN, HEAT EXCHANGER ETC. FOLLOWING THE PROCEDURE APPROVED BY THE PROCESS DEPARTMENT.

• PREPARE PROCESS DATA SHEET OF EACH EQUIPMENT AND DELIVER TO THE EQUIPMENT DESIGN GROUP - FOR EXAMPLE, MECHANICAL. DESIGN GROUP WILL ISSUE THE DATA SHEET FOR FABRICATION. BASED ON THIS EQUIPMENT WILL BE PURCHASED FOLLOWING THE PROCUREMENT PROCEDURE.


• PREPARE INSTRUMENT DATA SHEETS AND SAFETY VALVE DATA SHEETS WITH PRELIMINARY SIZING.

• PREPARE PIPING AND INSTRUMENTATION DIAGRAM (P&ID) FOR THE CRUDE DISTILLATION UNIT. FOLLOW P&ID DRAFTING PROCEDURE.

• PREPARE CONTROL LOGIC NARRATIVE FOR THE UNIT.

• PREPARE SHUTDOWN LOGIC AND SAFETY INTERLOCKS.

• PREPARE CAUSE & EFFECT DIAGRAM FOR THE UNIT.

• REVIEW PLOT PLAN AND LOCATION OF EQUIPMENT, EQUIPMENT ELEVATION (FOR PUMP SUCTION REQUIREMENT OR PIPING CONSIDERATIONS).

• PREPARE LINE DESIGNATION TABLE IDENTIFYING BY LINE NO., FROM/TO, SIZE, CLASS, INSULATION, PAINT ETC.

• PREPARE BATTERY LIMIT TABLE WHICH WILL INDICATE THE PRESSURE AND TEMPERATURE OF ALL STREAMS AT THE UNIT BATTERY LIMIT.


• PROVIDE P&ID, PLOT PLAN / EQUIPMENT LAYOUT, EQUIPMENT DATA SHEET, LINE LIST TO DRAFTING / EQUIPMENT LAYOUT GROUP TO PREPARE THE MODEL BY AUTOCAD.

• FINALIZE THE PIPE ROUTING AND MODEL BY PERFORMING STRESS ANALYSIS BASED ON DESIGN CONDITIONS BY PIPING STRESS GROUP.

• PERFORM 3-D MODEL REVIEW OF THE UNIT DIVIDED INTO CONSTRUCTION MODULES. FINALIZE PIPING CONSTRUCTION DRAWING AND ISSUE TO SITE.

• ALL CONSTRUCTION WORK IN OTHER AREAS – CIVIL, MECHANICAL, ELECTRICAL AND INSTRUMENTATION WORK WILL CONTINUE ALONG WITH THE PIPING WORK AS ABOVE FOLLOWING THE CONSTRUCTION SCHEDULE OF THE PROJECT.

• UTILITIES AND OFFSITES AREA INCLUDING WASTE WATER TREATMENT PLANT WILL BE MADE READY FOR THE REQUIREMENT OF CRUDE DISTILLATION UNIT PROVIDING POSITIVE ISOLATION TO OTHER UNITS NOT YET READY FOR COMMISSIONING (FOLLOW CONSTRUCTION SCHEDULE).

• DESIGN WORK WILL CONTINUE IN PHASES - ISSUE FOR REVIEW, AND ISSUE FOR HAZOP (HAZARDS & OPERABILITY STUDIES), ISSUE FOR DESIGN.

• PERFORM MODEL REVIEW WITH MECHANICAL EQUIPMENT, PIPING AND LAYOUT GROUP AT 30% AND 60% COMPLETION OF PIPING AND STRUCTURAL WORK AT SITE. INCORPORATE MODEL REVIEW COMMENTS.

• PERFORM HAZOPS WITH PARTICIPATION OF OWNER’S OPERATION, MAINTENANCE AND INSTRUMENT GROUP, ENGINEERING CONTRACTOR / LICENSOR’S PROCESS GROUP / EQUIPMENT DESIGN GROUP. ALL HAZOP RECOMMENDATIONS TO BE INCORPORATED IN DESIGN.


• ALL VENDOR DRAWINGS OF EQUIPMENT, CONTROL VALVES AND SAFETY VALVES WILL BE CHECKED FOR NOZZLE / FLANGE SIZES AND MATCH WITH P&IDs.

• ISSUE P&ID FOR DESIGN (90%) INCORPORATING ALL COMMENTS TO BE CONSISTENT WITH ALL EQUIPMENT DATA SHEETS, INSTRUMENT DATA SHEETS AND LINE LISTS ETC. FOR THE PROJECT.

• ALL EQUIPMENT WILL BE INSPECTED AT THE VENDOR’S SHOP BEFORE SHIPPING TO SITE FOLLOWING THE QUALITY PROCEDURE OF THE ENGINEERING CONTRACTOR.

• COMPLETE CHECKING AND REVIEW OF VENDOR DATA ON SAFETY VALVES FOR RELIEF LOADS.

• RECHECK SIZING OF PSV OUTLET LINES, RELIEF HEADER AND FLARE LINE (USE FLARENET MODEL). MAKE ANY CORRECTION IN PSV OUTLET LINES / FLARE HEADER IF REQUIRED.

• INCORPORATE ALL AUXILIARY VENDOR DRAWINGS IN P&ID.

• ISSUE P&ID FOR CONSTRUCTION IFC (100%) FOR THE PROJECT TO BE CONSISTENT WITH FINAL IFC DATASHEETS OF EQUIPMENT, PIPING AND INSTRUMENTS.

• INSTALLATION OF EQUIPMENT AND HYDRO-TEST (FOLLOWED BY DRYING) WILL BE COMPLETED BY CONSTRUCTION AND THE FACILITIES FOR COMMISSIONING OF THE CRUDE DISTILLATION UNIT WILL BE DECLARED MECHANICALLY COMPLETE.

• PRE-COMMISSIONING ACTIVITIES WILL FORMALLY START AT THIS POINT.

REFINERY COMPLEX

DETAILED ENGINEERING AND CONSTRUCTION

• DETAILED ENGINEERING DESIGN COMPLETED.

As an example, detailed engineering of the first unit of the refinery complex (Crude Distillation Unit - CDU)

with associated Utilities & Offsites was considered. Detailed engineering of other units of the refinery complex

will proceed simultaneously following the priorities as per Overall Project Schedule.

• ENGINEERING CONTRACTOR PREPARES THE COMPLETE EPC PACKAGE AS PER CONTRACT REQUIRED BY CLIENT.

• EPC PACKAGE CONSISTS OF:

PROCESS DESIGN BOOK FOR ALL UNITS

REFINERY LAY-OUT / CIVIL ENGINEERING / STRUCTURAL DESIGN BOOK

EFFLUENT TREATMENT FACILITIES DESIGN BOOK

UTILITY SECTIONS DESIGN BOOK

OFFSITES FACILITIES INCLUDING REFINERY FLARE SYSTEM DESIGN BOOK

ELECTRICAL SYSTEMS DESIGN BOOK

INSTRUMENTATION AND CONTROLS DESIGN BOOK

ALL ENGINEERING DESIGN, CALCULATIONS AND DRAWINGS FOR EQUIPMENT AND PIPING

• ALL MATERIAL TAKE-OFFS COMPILED AND PURCHASE & PROCURE DEPT. HANDED OVER TO CLIENT.

• MECHANICAL COMPLETION OF THE PROJECT FOR THE FIRST UNIT CDU AND ASSOCIATED UTILITIES AND OFFSITES.

• PRECOMMISSIONING, COMMISSIONING AND START-UP

• PLANT HANDED OVER TO CLIENT SATISFYING ALL CONTRCTUAL OBLIGATION.

See Section-3 for Pre-commissioning, Commissioning and Start-up.

Process Units (ISBL): Drawings / Tables

1. Refinery Complex Overall Process Scheme

2. Plot Plan of Individual Process Unit: Crude Distillation Unit (Typical)

3. Process Flow Diagram (PFD): Crude Distillation Unit (Typical)

4. Utility Flow Diagram (UFD)

5. Equipment List

6. Heat & Material Balance Table

7. Utility Summary Table

8. Effluent Summary Table

9. Chemical Consumption Table

10. Service Water and Cooling Water Systems

11. Potable Water & Safety Shower System

12. Boiler Feed Water System

13. Steam and Condensate Systems

14. Plant Air and Instrument Water Systems

15. Design Pressure – Design Temperature Diagram

16. Material Selection Diagram (MSD)

17. Process Flow & Instrumentation Diagram (P&ID): Process & Utilities

Process Units (ISBL): Drawings / Tables (contd.)

18. Line Designation Table (LDT) / Line List

19. Battery Limit Table

20. Electrical Area Classification Drawing

21. Electrical Single Line Diagram

22. Emergency Power Supply System

23. Control Logic Narrative

24. Cause & Effect Diagram

25. Safety Shutdown & Interlock Diagram

Utilities & Offsites (OSBL): Drawings / Facilities

1. Refinery Utilities & Offsites Over-all Plot Plan

2. Utilities UFD and P&ID – Raw Water / Service Water, Fire Water, Cooling Water Systems

3. Water Treatment Plant, Boiler Feed Water System UFD and P&ID

4. Steam System UFD and P&ID

5. Plant Air & Instrument Air System UFD and P&ID

6. Fuel Gas & Fuel Oil Supply & Distribution System UFD & P&ID

7. Refinery Flare System

8. Product Storage & Pumping

9. Product Dispatch & Distribution

10. Effluent Treatment Plant

11. Laboratory

12. Fire Station & First Aid

13. Workshop & Maintenance

14. Warehouse & Stores

Process Data Sheets of Equipment

• Pumps

• Compressors

• Coolers

• Heat Exchangers

• Fired Heaters

• Vessels

• Columns

• Filters

• Storage Tanks

Mechanical Data Sheets of Equipment

• Pumps

• Compressors

• Coolers

• Heat Exchangers

• Fired Heaters

• Vessels

• Columns

• Filters

• Specialty Equipment

• Storage Tanks

NOTE: Mechanical data sheets will be complete with General Arrangement Drawings, Isometrics, Vessel / Column internals etc. for installation.

DETAILED ENGINEERING OF A REFINERY COMPLEX

Important Notes to Process Engineers

Important Process Responsibility

• Process is responsible for the Process Design document with input from client on

owner on Site Conditions and project specific information.

• Process prepares PFD, Heat & Material Balance with stream properties including

the impurities.

• Process Department prepares the Datasheets of all equipment in project specific

templates providing all process parameters, normal and design flow rates,

temperature and pressure, line class, metallurgy, corrosion allowance and any

other process specification.

• Process hands over these data sheets to the respective Mechanical Department.

Mechanical in turn prepares the Mechanical Data Sheet for equipment fabrication.

There are many stages of checks / revisions with inputs from various other

disciplines. Mechanical issues the fabrication datasheet after final approval from

Process Department.


• Piping / Equipment Layout group prepares the unit plot plan with Process input based on safety and operability issues. Equipment elevation based on Pump NPSH requirement.

• Process provides all information in P&ID, namely equipment data, line No., line size, line class, insulation type/ thickness, fire-proofing details, paint class, spec. break, equipment nozzle size with any notes related to pipe layout required by construction at site. In fact P&ID IFC (Issue For Construction) is the basic document for construction and must contain all final design information to be consistent across the board.


• Process prepares the Line Designation Table for all process and utility

lines giving all the design parameters like line size, line class, flow rate,

pressure, temperature, insulation thickness/ class, paint class, flushing

(steam-out) requirement, pipe support etc. It is the responsibility of

Process Department to provide the above information to Piping / Lay-

out group for construction.


• Process provides input for hazardous area classification to the

Electrical.

• Process prepares electrical load of the unit.

• Process indicates the spare pumps for each service.

• Process provides input to Electrical to prepare the Single Line

Diagram.


• Process prepares data sheets of all process instruments

including all control valves, shut-off valves, safety valves and

all measuring devices and delivers to Instrument Department

giving process parameters and instrument range.

SECTION -3

PRE-COMMISSIONING, COMMISSIONING AND START-UP OF A

REFINERY COMPLEX

REFINERY COMPLEX

TYPICAL REFINERY UNITS (Fuel Block) • Process Plants

Crude Distillation Unit Vacuum Distillation Unit

Gas Treating & LPG Unit

Naphtha Hydrotreater Catalytic Reformer

Kero Hydrotreater Diesel Hydrotreater

Delayed Coker Unit

Asphalt Unit

Etc.

REFINERY COMPLEX

• Utilities & Offsites

Steam Generation Unit (Boiler / Captive Power Plant)

Air Compressor (Plant Air & Dry Air) Unit

Raw Water, Fire Water and Cooling Water System

Fuel Gas / Fuel Oil Supply System

Crude Oil Storage and Pumping

Intermediate & Finished Product Storage and Pumping

Product Dispatch – Pipeline, Tank Wagon / Truck Loading Gantry

Refinery Flare System

Offsites Piping Network

REFINERY COMPLEX

PRE-COMMISSIONING

PRE-COMMISSIONING INCLUDES:

• TESTING AND CALIBRATION OF INSTRUMENTS

• TESETING OF SAFETY VALVES AND SAFETY DEVICES ETC. • HYDROSTATIC TEST OF PIPING

• EQUIPMENT / PIPING FLUSHING, CLEANING AND DRYING

• ENSURING CORRECT INSTALLATION OF INTERNALS SUCH AS DEMISTERS, GRIDS, DISTRIBUTORS AND TRAYS

• CORRECT INSTALLATION OF CHECK VALVES, SHUT-OFF VALVES AND CONTROL VALVES, STRAINERS AND OTHER FITTINGS

• ROTATING MACHINE ALIGNMENT • PUMP / COMPRESSOR RUNNING IN WITH INERT FLUID (WATER / NITROGEN OR AIR).

• CHECKING FOR CORRECT FUNCTIONING OF ALARMS AND SHUTDOWN INTERLOCKS

• LOADING CATALYSTS IN REACTORS • HEATER REFRACTORY DRYING

• ENSURE FOR FREE THERMAL EXPANSION OF SUPPORTS OF HEAT EXECHANGERS AND HOT PIPING

REFINERY COMPLEX

PRE-COMMISSIONING

• FIRST PROCESS UNIT TO BE COMMISSIONED IN THE REFINERY COMPLEX IS THE CRUDE DISTILLATION UNIT ALONG WITH THE REQUIRED UTILITIES AND OFFSITES

FACILITIES. PRIORITIES SET UP ACCORDINGLY.

• THE DETAILED ENGINEERING CONTRACTOR’S COMMISSIONING GROUP WILL BE RESPONSIBLE TO PREPARE, UPDATE AND FINALIZE THE COMPLETE OPERATING GUIDELINES FOR EACH UNIT OR FACILITY. OWNER’S OPERATIONS WILL PREPARE THE DETAILED OPERATING PROCEDURES TO BE FOLLOWED BY THE OPERATORS.

• THE FOLLOWING IS A BRIEF DESCRIPTION OF THE PRE-COMMISSIONING / COMMISSIONING / START-UP ACTIVITIES THAT SHOULD BE CONSIDERED AS A GUIDELINE ONLY.

• PRE-COMMISSIONING IS THE PERIOD WHEN CONFORMITY VERIFICATIONS

ACCORDING TO SPECIFICATIONS AND DRAWINGS AND NON-OPERATING CHECKS ARE CARRIED OUT.

REFINERY COMPLEX

COMMISSIONING

COMMISSIONING:

• COMMISSIONING IS THE PERIOD WHEN THE DYNAMIC VERIFICATION OF

THE FUNCTIONING EQUIPMENT, THE SIMULATION OF CONTROL LOOPS

AND SAFETY SYSTEMS, AND THE OPERATIONAL TESTS ARE CARRIED OUT.

• COMMISSIONING INCLUDES ALSO A VARIETY OF ACTIVITIES SUCH AS DRYING-OUT OF EQUIPMENT AND PIPING SYSTEMS, BOXING UP AND

TIGHTNESS TESTS AND PURGING OUT WITH NITROGEN.

• ALL COMMISSIONING ACTIVITIES ARE CONDUCTED BEFORE FEED

INTRODUCTION INTO THE PLANT AND END UP AT A POINT IN TIME CALLED

READY FOR START-UP OF THE UNIT.

.

REFINERY COMPLEX

COMMISSIONING

THE FOLLOWING ARE THE SYSTEMS TO BE PUT ‘IN SERVICE’ OR MADE ‘READY TO USE’ IN COMMISSIONING. (Follow commissioning procedure for individual utility station.) • INSTRUMENT AIR .. IN SERVICE

• UTILITY AIR .. IN SERVICE

• COOLING WATER SYSTEM .. IN SERVICE, (Individual user isolated, drain open)

• NITROGEN SYSTEM .. IN SERVICE, (checked for proper O2 content)

• STEAM .. IN SERVICE, (Drains and traps checked; follow procedure for steam line commissioning.)

• FIRE WATER .. IN SERVICE

• FLARE SYSTEM .. READY TO USE

• OILY WATER SEWER .. READY TO USE

• ELECTRICAL SYSTEM .. READY TO USE, (all wiring, junction boxes, breakers, switches have been checked for correctness and compliance with specifications. Electric motors have been run in for 4 hours and disconnected from the driven machine).

REFINERY COMPLEX INITIAL START-UP

• REFER TO PROCESS DESIGN BOOK THAT PROVIDES PROCESS DESCRIPTION, PFD, P&ID AND DATA-SHEETS.

• REFER TO OPERATING GUIDELINE FOR THE UNIT PREPARED BY THE COMMISSIONING

GROUP.

• THE ENTIRE UNIT – EQUIPMENT, STRUCTURE, CIVIL, PIPING, ELECTRICAL AND INSTRUMENTATION INSPECTED BY THE COMMISSIONING TEAM OF THE CONSTRUCTION

CONTRACTOR / DETAIL ENGINEERING CONTRACTOR, BASIC ENGINEERING CONTRACTOR / PROCESS LICENSOR AND THE OWNER AS A FINAL CHECK. STOP ALL

CONSTRUCTION ACTIVITIES

• ENSURE AND CERTIFY THAT THE PLANT IS BUILT AS PER THE PROCESS DESIGN PACKAGE IN CONFORMANCE WITH THE ENGINEERING SPECIFICATIONS AND THE LATEST ISSUE FOR

CONSTRUCTION P&ID (IFC) INCLUDING COMPLETION OF ALL ACTION ITEMS ARISING OUT OF HAZOPS / AND LATEST CHECK LIST ITEMS.


THE FOLLOWING PRE-REQUISITES SHOULD BE FULFILLED BEFORE START-UP:

• ALL TESTS OF EQUIPMENT (AS REQUIRED BY DESIGN SPEC./CONTRACT) HAVE BEEN

CARRIED OUT.

• PLANT OPERATORS AND MAINTENANCE PERSONNEL ARE FAMILIAR WITH THE PLANT.

• FIRE, SAFETY AND ENVIRONMENTAL REQUIREMENTS ARE SATISFIED.

• STEADY POWER SUPPLY WILL BE AVAILABLE.

• ALL UTILITIES ARE AVAILABLE.

• FEED SUPPLY FROM STORAGE AND PRODUCT DISPOSAL TO TANKS ARE ENSURED.

• REFINERY FLARE IN OPERATION (WITH PILOTS) FOR ANY CONTINGENCY.

• OILY-WATER SEWER SYSTEM UPTO EFLUENT TREATMENT PLANT IN OPERATION.

• CLOSED BLOWDOWN TANK IS READY TO RECEIVE ANY EMERGENCY DRAIN.

• UNIT BATTERY LIMIT VALVES (AT ISBL / OSBL ITERFACE) ARE IN PROPER POSITION.

• LAB IS AVAILABLE TO TEST ALL SAMPLES.

• ALL COMMUNICATION SYSTEMS WITHIN UNIT AND OUTSIDE IN ORDER.

• UNIT IS READY FOR START-UP.


• REFER TO THE START-UP MANUAL OF THE CRUDE UNIT AND THE UTILITIES & OFFSITES FACILITIES. FOLLOW START-UP PROCEDURE OF INDIVIDUAL EQUIPMENT.

• FEED CUT IN FOR COLD CIRCULATION - ENSURE THAT THE CRUDE FEED IS READY FROM STORAGE AND LINED UP TO BATTERY LIMIT VALVE. (FEED TANK IS PREPARED BY PROPER DRAINING OF WATER).

• ALL HYDROCARBON LINES ARE TO BE MADE FREE FROM AIR BY NITROGEN PURGING AS A GENERAL RULE (FOLLOW STANDARD PROCEDURE).

• EQUIPMENT IN CRUDE OIL CIRCUIT LIKE COLUMN, VESSEL, HEATER AND HEAT EXCHANGER ETC. WILL BE PURGED WITH STEAM TO REMOVE AIR. CRUDE FEED MAY BE CUT IN WHILE MAINTAINING A POSITIVE PRESSURE OF STEAM (0.5 KG/CM2G).

• LINE UP CRUDE CIRCUIT THROUGH HEAT EXCHANGERS, HEATER AND TO THE MAIN FRACTIONATING COLUMN, FROM COLUMN BTM TO PUMP AND RETURN TO CRUDE PUMP FOR CIRCULATION VIA START-UP LINE (TO BE SHOWN IN P&ID.)

• LINE UP ALL OTHER PRODUCT CUTS FROM VESSEL / COLUMNS TO THE RESPECTIVE PUMPS WITH THE OPTION TO ROUTE OFF-SPEC PRODUCTS THROUGH A MANIFOLD AT THE BATTERY LIMIT TO SLOP TANK.


• START HEATER FIRING AT 20 DEG C/ HR AND MAINTAIN HEATER OUTLET AT 60 DEG C FOR 2-4 HOURS.

(Follow Heater firing procedure.) • MAINTAIN LEVEL AT CRUDE COLUMN BOTTOM AT 50% BY PUMPING IN

CRUDE. STOP STEAM PURGE CONNECTION. ALLOW WATER TO SETTLE AT LOW POINTS AND DRAIN. MAINTAIN COLUMN TOP AT 0.5 KG/CM2G.

• INCREASE HEATER FIRING AND RAISE TEMPERATURE TO 80 DEG C AND PUMP IN MORE CRUDE.

• INCREASE COOLING WATER TO OVERHEAD CONDENSER IF REQUIRED.

• MAINTAIN HEATER OUTLET AT 80 DEG FOR 2-4 HOURS AND COLUMN LEVEL AT 50% . ALLOW WATER TO SETTLE AT LOW POINTS AND DRAIN. COLUMN PRESSURE TO BE MAINTAINED AT 0.5 – 1.0 KG/CM2G. EXCESS PRESSURE TO BE RELEASED TO FLARE.

(Refinery flare commissioned and lit as per procedure.)

• AT THIS POINT, CHECK THE CRUDE LINE-UP THROUGH THE DESALTER. START WATER INJECTION AT DESALTER INLET AND COMMISSION THE DESALTER AS PER VENDOR OPERATING PROCEDURE. MAINTAIN REQUIRED TEMPERATURE. CHECK FOR EMULSION BREAK FOR SETTLING OF WATER. DRAIN WATER FROM DESALTER.


• INCREASE HEATER FIRING GRADUALLY TO 120 DEG C HEATER OUTLET PUMPING IN MORE CRUDE AND VAPORISING LIGHT ENDS.

• CONTINUE HOT CIRCULATION AT 120 DEG C.

• HOLD FOR 2 HOURS AND CHECK FOR ANY WATER AT LOW POINTS AND DRAIN.

• CHECK THE WHOLE CIRCUIT COMMISSIONED AND FIX ANY LEAKS THROUGH FLANGES.

• WATCH FOR LIQUID LEVEL IN TOP REFLUX DRUM AND THE TOP SIDE-STRIPPER.

• CONTINUE RAISING HEATER OUTLET TEMPERATURE GRADUALLY AT 20 C/HR UPTO 200 C INCREASING CRUDE FEED RATE TO 50% OF NORMAL.

• CHECK ALL FLANGES IN HOT LINE AND DO HOT BOLTING. • CHECK SUPPORTS OF HOT EXCHANGERS AND HOT PIPELIES FOR FREE THERMAL

EXPANSION.

• CHECK THE FUNCTIONING OF ALL INSTRUMENTS FOR FLOW, PRESSURE, TEMPERATURE AND LIQUID LEVELS. CHECK ALL INSTRUMENT ALARMS IN THE SYSTEM AS IT IS COMMISSIONED.

• INITIALLY INSTRUMENTS TO BE KEPT ON MANUAL AND WHEN STEADY CHANGED TO AUTO.


• FOLLOW UNIT OPERAING PROCEDURE. RAISE HEATER TEMPERATURE FURTHER FROM 200 C TO THE REQUIRED NORMAL HEATER OUTLET TEMPERATURE MAINTAINING THE FEED RATE AT 50% OF NORMAL.

• START TOP REFLUX PUMP AND CONTROL TOP TEMPERATURE AND PRESSURE AT THE NORMAL VALUES.

• INTRODUCE STRIPPING STEAM TO THE MAIN COLUMN AT 50% OF NORMAL RATE; ALSO STRIPPING STEAM TO THE SIDE STIPPERS AS MAY BE REQUIRED.

• ESTABLISH PUMP-AROUND REFLUX WITH INCREASE IN TEMPERATURE AS PER PROCEDURE CHECKING THE COLUMN TEMPERATURE PROFILE.

• MAINTAIN NORMAL PRESSURE AND TEMPERATURE PROFILE AT 50% OF NORMAL THROUGHPUT.


• START PUMPS AS LIQUID LEVEL BUILDS UP IN THE SIDE-STRIPPERS. • INITIALLY COMBINE THE TOP PRODUCT, SIDE CUTS AND MAIN COLUMN BOTTOM TO

THE SLOP MANIFOLD AT THE BATTERY LIMIT AND ROUTE TO SLOP TANK. • TOP VAPOUR FROM THE COLUMN OVERHEAD MAY BE ROUTED TO FUEL GAS

SYSTEM . • STABILIZE THE UNIT OPERATION AT 50% THROUGHPUT BY ADJUSTING HEATER OUTLET

TEMPERATURE, TO THE NORMAL OPERATING VALUE AND SETTING THE DRAW-OFF RATE OF SIDE STRIPPERS TO THE OPERATING VALUES AT 50%

• CHECK PRODUCT SAMPLES FOR IMPORTANT PARAMETERS LIKE FLASH POINT, DISTILLATION, DENSITY, VISCOSITY ETC.

• MAKE ADJUSTMENT TO CONDITIONS TO GET THE DESIRED SPEC OF THE STRAIGHT RUN PRODUCTS FROM LAB.


• ONCE ALL PRODUCTS MEET SPEC., ROUTE TO RESPECTIVE STORAGE TANK FROM THE BATTERY LIMIT.

• INCREASE THROUGHPUT GRADUALLY FROM 50% TO 100% IN STEPS OF 10% MAINTIANING THE TEMPERATURE, PRESSURE AND FLOW RATES OF STREAMS TO MATCH WITH PFD HEAT & MATERIAL BALANCE TABLE. GET SAMPLES ANALYZED BY LAB. ENSURE PRODUCT SPEC AS PER DESIGN.

• CONTINUE TO RUN THE UNIT FOR 72 HRS (AS AGREED UPON IN CONTRACT FOR GUARANTEE TEST RUN) AT 100% THROUGHPUT. NOTE DOWN ALL PARAMETERS OF EQUIPMENT AND PRODUCT SPEC. AT REGULAR INTERVALS.

• UNIT ON-SPEC. AT 100% THROUGHPUT.

• ANY UPSETS OR INTERRUPTION IN OPERATION SHOULD BE RECORDED WITH PROBABLE CAUSE TO BE ANALYZED LATER.

• ANY DISCREPANCY IN OPERATING PARAMETERS FROM DESIGN SHOULD BE JOINTLY RECORDED BY THE COMMISSIONING TEAM / LICENSOR / OWNER AND RESOLVED BY THE ENGINEERING CONTRACTOR / LICENSOR(AS PER CONTRACT).

• START-UP IS COMPLETE.

• UNIT IS HANDED OVER TO OWNER’S OPERATIONS.


COMMISSIONING

APPENDIX

1. PFD Example *

2. P&ID Example *

3. Time Schedule: Refinery Project

4. Time Schedule: Engineering-Construction Interface

* Note: Only typical examples of PFD and P&ID of any process is shown. For details

of a Refinery Overall Flow Diagram and PFD / P&IDs of the processing units, refer to

text books on Petroleum Processing or Hydrocarbon Processing magazines. Actual

PFD / P&ID of a refinery complex are proprietary items of the company.

$ PRG.PR.GEN.0002

Rev. 1 Data May 1995

Sheet 1 (2)

Form code: MDT.GG.QUA.0516 Sht. 01/Rev. 1.94 File code: CRIDESBI.DOT Data file: PRG_PR_GEN_0002_R01_E.doc CONFIDENTIAL document. Sole property of Snamprogetti. Not to be shown to Third parties or used for purposes other than those for which it has been sent.

ANNEX I

PROCESS FLOW DIAGRAM (PFD) EXAMPLE

$ PRG.PR.GEN.0002


Sheet 2 (2)


ANNEX I

PROCESS FLOW DIAGRAM (PFD) EXAMPLE

$ PRG.PR.GEN.0002


Sheet 1 (1)


ANNEX II

MATERIAL AND HEAT BALANCE EXAMPLE

NOTES TO PFD EXAMPLE

1. The PFD EXAMPLE shows a section of a typical PFD.

2. Standard PFD symbology may be referred to understand the PFD sketch.

3. All equipment are identified and connection of process streams shown.

4. Stream properties shown in Material Balance like flow rate, pressure, temperature etc. are typical for the of normal operating conditions of the process.

5. Heat Balance is shown in terms of enthalpy of each stream.

6. All process controls are identified in the PFD.

NOTES TO P&ID EXAMPLE

1. The P&ID EXAMPLE shows a section of a typical P&ID.

2. Standard symbology of a P&ID may be referred to understand the P&ID drawing.

3. All lines are identified by No., size, class, insulation, paint etc. matching with the Line Designation Table prepared by Process.

4. All equipment details to be provided as per the Equipment Data Sheets (matching with process data).

5. All equipment nozzle sizes and equipment elevation from grade should be shown.

6. All control loops and shutdown schemes should be shown as per P&ID symbology in co-ordination with Instrumentation.

7. Any note for Piping / Construction and operation should be listed in the P&ID under Notes.

Notes to TIME SCH-1

APPROXIMATE TIME SPAN FOR EACH ACTIVITY IN PROJECT EXECUTION OF A REFINERY COMPLEX (48 m)

Basis: 0 month taken as Feed (Crude Oil) Cut-in time; other activities estimated backward.

1. Process Engineering Package FEL-3 or FEED: 52 m

2. Project Approval: 48 m

3. Site Enabling: 48 – 36 m

4. Detailed Engineering: 48 – 14 m

5. Civil / Structural Engineering: 40 – 16 m

6. Engineering / Piping Erection: 32 – 6 m

7. Testing: 8 – 2 m

8. Pre-commissioning: 2 – 0 m

9. Commissioning and Start-up (Feed Cut-in): 0 m

Notes to TIME SCH-2

ENGINEERING INTERFACE WITH CONSTRUCTION IN PROJECT EXECUTION

OF A REFINERY COMPLEX (36 m)

Basis: 0 month taken as Feed (Crude Oil) Cut-in time; other activities estimated

backward.

1. Civil and Structural: Engg. 36 -13 m / Constn. 31 – 9 m

2. Piping: Engg. 32 - 11 m / Constn. 26 – 4 m

3. Electrical: Engg. 33 - 13 m / Constn. 19 – 4 m

4. Instrumentation: Engg. 32 - 12 m / Constn. 15 – 3 m

5. Overall: Engg. 36 - 11 m / Constn. 31 – 2 m

6. Ordering Interface with Engg. Place Order: 30 – 20 m

7. As Built Issue Manual: Engg. 2 – (-) 1 m / Constn. 5 – (-) 1 m


COMMISSIONING

QUESTIONS ??

(For any question, email to [email protected]

stating the subject “REFINERY COMPLEX – QUESTIONS”)

mailto:[email protected]

refinery complex t from concept to commissioning

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