4288-6111-OM 01 0

PDIL PROJECTS & DEVELOPMENT INDIA LTD DOCUMENT NO. REV

SHEET 1 OF 117

OPERATING MANUAL
FOR

GAS SWEETENING UNIT

(CAPACITY EXPANSION TO 14.0 MMSCMD)

GAIL (INDIA) LIMITED

UP PETROCHEMICAL COMPLEX, PATA

JUNE 2006

P 26.06.06 26.06.06 ISSUED FOR COMMENTS AKT RKS RSS

REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD
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PREFACE

This manual gives the operating guidelines for the Gas Sweetening Unit at UP
Petrochemicals Complex at Pata (Auraiya) of GAIL(India) Limited. The manual
includes process description. operating procedures, PFDs and P&IDs for these
facilities.

The instructions have been prepared so as to facilitate stat-up and subsequent

operation. The operating procedures and conditions given are only indicative and
modifications may be necessary in actual operation as a result of experience
gained during operating these facilities. Detailed operating and maintenance
instructions of equipment are not included in this manual. These can be found in
vendor's manual.

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TABLE OF CONTENTS

Section Description Page No.

1 General
2 Process Description
3 Preparation for Start-up
4 Plant Operating Procedures
5 Equipment Operating Procedures
6 Safety Procedures

ANNEXURES

Annexure Description Page No.

1 Material Balance
2 Process Flow Diagrams
3 Piping & Instruments Diagrams
4 Emergency Logic & Safe Charts

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DETAILED TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 GENERAL 1

1.1 INTRODUCTION 1
1.2 UNIT CAPACITY 1
1.3 STREAM HOURS AND TURNDOWN RATIO 1
1.4 FEED STOCK CHARACTERISTICS 1
1.5 PRODUCT CHARACTERISTICS 2
1.6 ESTIMATED UTlLITIES AND
CHEMICALCONSUMPTION
1.7 BATTERY LIMIT CONDITIONS 3
1.71 FEED 3
1.72 PRODUCTS 3

1.7.3 UTILITIES 4

1. EQUIPMENT LIST WITH BROAD 5

SPECIFICATIONS

2.0 PROCESS DESCRIPTI0N 10

2.1 PROCESS SUMMARY 10

2.2 DETAILED DESCRIPTION 12

2.2.1 ABSORPTION SECTION 12

2.2.2 TREATED GAS WATER WASH

AND COOLING 14
2.2.3 RICH AMINE CIRCUIT 15
2.2.4 REGENERATOR SECTION 17
2.2.5 LEAN AMINE CIRCUIT 19

2.2.6 AMINE STORAGE AND RECIRCULATION 19

2.2.7 FILTRATlON PACKAGE 21

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2.2.8 ANTI FOAM PACKAGE 22

2.3 FLARE AND CLOSE BLOW DOWN 22

2.3.1 FLARE 22
2.3.2 CLOSE BLOW DOWN 22

2.4 ISBL UTILITY SYSTEMS 23

2.5 INTERLOCK DESCRIPTION 26

3.0 PREPARATION FOR START-UP 32

3.1 INTRODUCTION 32

3.2 INSPECTION OF EQUIPMENT 32

3.3 PREPARATION OF THE UNIT 34

3.4 COMMISSIONING OF ISBL

UTILITY SYSTEMS 34
3.4.1 INSTRUMENT AIR AND
PLANT AIR SYSTEM 34
3.4.2 SERVICE WATER. COOLING WATER AND
PROCESS WATER SYSTEM 35

3.4.3 LP STEAM AND LP CONDENSATE SYSTEM 36

3.4.4 FUEL GAS AND INERT GAS SYSTEM 36

3.4.5 SEWER AND DRAIN SYSTEM 36

3.5 PIPE FLUSHING AND CLEANING 36

3.6 FUNCTIONAL TEST OF

ROTATING EQUIPMENT 40

3.7 INSTRUMENTS 41

3.8 TIGHTNESS TEST/ VACUUM TEST 43

3.9 DRYING, PURGING AND INERTISING 43

3.10 CHEMICAL CLEANING OF DEA SYSTEM 45

3.11 LOADING OF CH AND FILTER MEDIA 49

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4.0 PLANT OPERATING PROCEDURES 52

4.1 GENERAL 52

4.2 INITIAL START-UP 52

4.2.1 START-UP PREPARATION 52

4.2.2 OVERALL START-UP SCHEME 54

4.2.3 DETAILED ST ART UP PROCEDURE 56

4.3 NORMAL OPERATION 70

4.3.1 NORMAL START-UP PROCEDURE 70

4.3.2 NORMAL OPERATING PARAMETERS 72

4.3.3 ALARMS AND TRIPS SETIINGS 78

4.3.4 RELIEF VALVE SETTINGS 83

4.3.5 CONTROL POINTS DURING

NORMAL OPERATION 85

4.4 NORMAL SHUTDOWN 86

4.5 EMERGENCY SHUTDOWN 90

4.6 SAMPLING PROCEDURES 94

5.0 EQUIPMENT OPERATING PROCEDURES 96

5.1 INTRODUCTION 96

5.2 CENTRIFUGAL PUMPS 96

5.2.1 GENERAL 96

5.2.2 START-UP 96

5.2.3 SHUTDOWN 97

5.2.4 TROUBLESHOOTING 99

5.3 POSITIVE DISPLACEMENT PUMPS 100

5.3.1 GENERAL 100

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5.3.2 START-UP 101

5.3.3 SHUTDOWN 101

5.3.4 PREPARATION FOR MAINTENANCE 101

5.3.5 TROUBLESHOOTING 102

5.4 HEATEXCHANGER 103

5.5 FILTRATION PACKAGE 104

6.0 SAFETY PROCEDURES 105

6.1 INTRODUCTION 105

6.2 GENERAL HAZARD IN UNIT 105

6.2.1 HAZARDSOF PETROLIUM PRODUCTS 105

6.2.2 ELECTRICAL APPARATUS 105

6.2.3 STRAY ELECTRIC CURRENTS 106

6.2.4 STATIC ELECTRICITY 106

6.2.5 LIGHTENING 106

6.2.6 NON-ELECTRICAL SOURCES OF IGNITION 107

6.2.7 AUTO IGNITION 107

6.3 SAFETY GUIDELINES 110

6.3.1 GENERAL 110

6.3.2 SAFETY RULES FOR PARTICULAR
OPERATION 113
6.3.3 PREPARATION OF EQUIPMENT FOR
MAINTENANCE 114
6.3.4 FIRE FIGHTING GUIDELINES 116
6.4 HAZARDOUS PROPERTIES OF CHEMICALS
HANDLED 118

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SECTION-1

GENERAL

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1.1 INTRODUCTION

The Gas sweetening unit is a part of Petrochemical Complex at Pata

(Auraiya), owned by GAIL (India) Limited. The other units inside this
complex are C2 / C3 Recovery, Gas Cracker and Cracker downstream
processing units.
(The HBJ pipeline gas coming from Vijaypur (M.P.) forms the feed stock for
the GSU. CO2 present in the feed gas is removed in the gas sweetening unit
by amine absorption process.
The unit is designed to operate for three cases of operation as discussed
in section 1.4.

1.2 UNIT CAPACITY

The unit is designed to handle 14.0 MMSCMD of sour feed gas from the
HBJ pipeline. After amine absorption the unit produces 13.3MMSCMD of
sweetened gas, which is sent for further processing.

1.3 STREAM HOURS AND TURNDOWN RATIO

The unit is designed to operate for 8000 stream hours per annum. The unit
has been designed for a turndown of 50 % at the design flow.

1.4 FEED STOCK CHARACTERISTICS

The unit is designed to operate for three different cases of operation.

Depending upon the case of operation three different compositions of the
feed gas is possible. The feed gas compositions for different cases are
given in Table 1.1 at the end of this section.

1.5 PRODUCT CHARACTERISTICS

The unit is designed such that H2S concentration in the treated gas does
not exceed 4 ppm (v/v) and CO 2 concentration in the treated gas does not
exceed 50 ppm (v/v). The hydrocarbon concentration in the acid gas will be
minimized (< 1 %).

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1.6 ESTIMATED UTILITIES AND CHEMICAL CONSUMPTION

Utilities

Utility Normal Consumption Maximum Requirement

LP Steam (TPH) 100.0 100.5
Cooling Water (M3/Hr) 3860
Instrument Air (NM3/Hr) 80
Plant Air (NM3/Hr) Plant Air (NM3/Hr)
Inert Gas (NM3) 868* & 1900 **
Process Water (M3) 400. **.

* Intermittent Consumption

** For Start-up

Chemicals

Chemicals Consumption per annum First loads

Pure DEA (tons) 130 230
Antifoam Silicone Oil RP-
12.0
426( tons)
Cellulose (kg) 3275 3300
Charcoal (kg) 3209 2400
(activated carbon)

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1.7 BAITERY LIMIT CONDITIONS

1.7.1 FEED

Pressure Temp.
Kg/cm2a 0
C Source

Sour Gas 52.0 10-30 HBJ pipeline

1 .7.2 Products

Pressure Temp.
Kg/cm2a 0
C Destination

Treated Gas 50.0 45 (C 2-C3) Unit

Fuel 6.0 - Fuel gas

system
1.7.3 Utilities

Pressure Temp. Other

Kg/cm2a C
0
Specifications

LP Steam 4.5 165

Instrument Air 7.5 Amb (Dew point -40°C at atm )

Plant Air 7.5 Amb

Cooling Water 5.5 33°C

Inert Gas 7.5 Amb (Oil Free)

Process Water 9.5 45 (Note-I)

BFW 3.0 110 (Note-2)

Condensate 5.5 100

(return)

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Notes:
1. Process water condition during normal operation.

2. BFW from the(C 2-C3) Recovery Unit with the battery limit conditions
mentioned above shall be used during unit start-up.

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1.8 EQUIPMENT LIST WITH BRO(\D SPECIFICATIONS

SR NO.ITEM NO. DESCRIPTION DIAMETER (M)

HEIGHT/ TYPE MOC
LENGTH (M)
A VESSELS
1 O6-VV-101 Fuel Gas K.O.Drum 2.9 6.0 H CS
Rich Amine Flash
2 O6-VV-I02 3.0 9.6 H SS 304
Drum
Regenerator Reflux
3 06- VV -103 2.4 3.6 V CS
Drum

4 06-VV-I04 Condensate Drum 2.2 5.1 H CS

5 06- VV -105 Amine Sump Drum 2.4 6.0 V CS

6 06-VV-J06 Filtration Precoat Drum

2.1 2.1 V CS

Charcoal Filter
7 06- VV -107 1.4 4.0 V CS
Separator

8 06- VV -108 Antifoam Surge Drum 1.2 1.5 V CS

B COLUMNS

SHELL CS
1 06-CC-101 A/B
HP Absorber 3.4 24.3 TRAY
TRA Y SS
SHELL CS
2 06-CC-102 Regenerator 4.5 23.4 TRAY
TRA Y SS
SHELL CS
3 06-CC-103 Sweet Gas Water Wash
3.4 10.1 PACKED2" SS PALL
RINGS

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HEATDUTY
SR NO.
ITEM NO. DESCRIPTION (MKCAL/HR)PER MATERIAL OF CONSTRUCTION
UNIT

HEAT TUBE/PLATE
C SHELL/FRAME
EXCHANGERS

06.EE.101 Rich Lean Amine SS

1 13.655 CS resin cured
A/B/C/D/E Exchangers

06.EE.102 Regenerator CS
2 10.76 CS
A/B/C/D Reboilers

Regenerator
3 06-EE-103 Overhead 12.8 CS SS
Condenser

06-EE-104 CS TITANIUM
4 Lean Amine cooler12.71
A/B/C/D resin cured

5 06-EE-105 Sweet Gas Cooler1.24 CS SS

LP Condensate
6 06-EE-105 0.323
Cooler

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SR. NO.
ITEM NO. DESCRIPTION TYPE NOR CAP
DlFF HEAD
MATERIAL OF
(M3/HR) (KG/CM2) CONSTRUCTION
D PUMPS CASING IMP/PIST

SS-316L
06-PA-IOI Amine Charge
I Cent. 362 60.9 SS-316L
A/B/C Pumps

Regenerator Reflux SS-316L

2 06-PA-102 A/B Cent. 19.7 5.13 CS
Pumps
Sweet Gas Water SS 11-13% Cr
3 06-PA-103 A/B Cent. 28.0 3.0 CS
wash pump
4 06-PA.I04 A/B
Condensate PumpCent. 91.3 6.42 CS SS 11-13% Cr
5 06-PA-105 Amine Sump PumpSubmer.25 max 4.0 CS SS-316L
Water Wash Booster SS 11-13% Cr
6 06-PA-I06 Metering2.0 49.0 SS
Pump
Amine Filtration SS 11-13% Cr
7 06-PA-I07 Cent. 72.0 6.2 CS
Pump
Cent.. SS-316
8 06.PA-108 Filter Slush Pump 18.0 6.0 SS-316
Submer
Antifoam Injection SS-316
9 06-PA-I09 Pump Metering0.1 2.52 SS-316
(Continuous)
Antifoam Injection SS-316
10 06-PA-IIO Pump Metering1.0 max 2.52 SS-316
(Intermittent)

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SR NO.ITEM NO. DESCRIPTION DIAMETER (M)

HEIGHT/ LENGTH
TYPE MOC
(M)
E STORAGE TANK
1 06-TT-101 Amine Storage tank 9.1 11.5 Cone roof
Shell CS
Inter SS
F MISCELLANEOUS
1 06-JX-102 Amine Filter Note-1 Note-1 Horiz. Shell CS
Preco-atInter SS
2 06-JX-103 Cartridge Filter Note-1 Note-1 Cart.
3 06-VV-113 A/BCartridge Filter Note-1 Note-1 Cart.
4 06-VV-117 A/BCharcoal Filter Note-1 Note-1
LENGTH WIDTH DEPTH MOC
(M) (M) (M)

5 06-JX-104 9.0 2.0 2.0

slant
6 06-JX-105 Amine Preparation Unit 2.5 2.2 1.4 RCC
7 06-JX-101 Upstream Desuper heater RCC

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TABLE 1.1

FEED GAS COMPOSITIONS

Component Case I Case II Case III LPG CASE

N2 0.01 0.01 0.01 0.1
H2S 4 ppm 4 ppm 4 ppm 4 ppm
CO2 5.52 5.52 5.04 6.24
C1 84.06 83.12 82.07 77.12
C2 9.38 8.87 7.47 11.37
C3 0.99 1.90 3.70 3.64
iC4 0.02 0.22 0.62 0.59
nC4 0.02 0.25 0.75 0.70
iC5 0.0 0.05 0.15 0.12
nC5 0.0 0.04 0.13 0.1
C6 0.0 0.02 0.06 0.02
100.00 100.00 100.00 100.00

Case-I: Corresponds to feed gas composition received at Auraiya after LPG

extraction and without a bypass at Vijaypur.
Case-ll : Corresponds to feed gas composition. ex-LPG lean gas plus the required
bypass at Vijaipur.
Case-III: Corresponds to a case where one of the LPG Units at Vijaipur is shutdown
and the required amount of gas is bypassed at Vijaipur.
LPG case: Corresponds to a case when LPG cum C2-c3 Recovery option at Auraiya
is in operation. (This case is not yet studied).

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SECTION-2

PROCESS DESCRIPTION

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2.1 PROCESS SUMMARY

(Refer PFD No. 4288-6111-0050 / 0051 / 0052

The Gas Sweetening Unit uses SNEA(P)'s DEA (Dow Speciality Amine CS Plus)
absorption process to remove acid components from the raw HBJ pipeline gas. The
acid components present in the gas include mainly CO2 and traces of H2S (<4ppm).

The acid components are removed from the raw gas by counter current absorption
process carried out in the High Pressure Absorber Columns (CC-lO1 A/B) operating in
parallel.

The sweetened gas at the top outlet of the two absorbers is combined together and
taken into a Water Wash Column (CC-103) to remove any DEA solution carried over
with the gas, by contacting with water. The sweet gas is then cooled down in the Sweet
Gas Cooler (EE-105) to 40°C and sent to C 2 / C3 recovery unit for further processing.

The liquid (DEA solution) collected at the bottom of the Water Wash Column (CC103) is
routed to the Rich Amine Flash Vessel (VV-102). The rich amine solution at the bottom
of the HP Absorber Columns is also routed to the Rich Amine Flash Vessel which
operates at 6.5 Kg/cm2a.

Most of the hydrocarbons co-absorbed in the rich amine solution are desorbed in
vessel. The flash gas which consists of light hydrocarbons, CO 2 and traces of H2S is
routed to the plant fuel gas system.

The rich amine solution in the Flash Vessel is routed to the Regenerator Column (CC
102) after exchanging heat with hot lean amine solution in the Lean/Rich Amine
Exchanger (EE-101 A/B/C). In the Regenerator. CO2 is stripped from the rich amine
solution. The column overhead vapours are condensed in Regenerator Overhead
Condenser (EE-I03) and taken into the Regenerator Reflux Drum (VV-I03). The gases
which are not condensed in the condenser are routed to atmosphere at a safe location

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through a pressure control valve. Condensed liquid is pumped back as reflux to the
column with the help of Regenerator Reflux pumps (PA-I02 A/B). Heat duty for
regeneration is provided in the Regenerator Reboilers (EE-102 A/B/C/D) using LP
steam

The lean Amine solution leaving the Regenerator bottom is cooled down first by
exchanging heat with the rich solution in Lean/Rich Amine Exchanger and then in the
Lean Amine Cooler (EE-l04 A/B/C). After cooling down to about 45°C, lean solution is
sent to Amine Storage Tank (TT-101). From the storage tank, lean amine solutions
pumped back to HP Absorber columns with the help of Amine Charge Pumps (PA-101
A/B/C). A stream of stored amine solution is continuously sent to the filtration package
by Amine Filtration Pump (PA-107). The filtration package consists of Precoat Filters,
Activated Charcoal Filters and Cartridge Filters. From the operational point of view, the
gas sweetening unit is divided into following sections.

i) Absorption Section
ii) Treated gas water wash and cooling
iii) Rich amine circuit
iv) Regeneration section
v) Lean Amine circuit
vi) Amine storage and recirculation
vii) Filtration package
viii) Antifoam package

2.2 DETAILED DESCRIPTION

2.2.1 Absorption Section

(Refer P&ID NO. 4288-6111-0020 / 0021)

Raw gas from the HBJ pipeline after pressure reduction enters the GSU battery limit at
52 kg/cm2a and 30.C. The gas is taken into Raw Gas KO Drum (VV-101) for separation
of any liquid droplets present in the gas. Upstream of the KO Drum flow indicator (FI-
0101). Temperature indicator (TI-O104) and a sample point are provided on the gas
line. A differential temperature indicator (TDI-O104) along with low differential
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temperature alarm is also provided on the raw gas inlet line to indicate temperature
difference between lean amine solution and the inlet gas. Lean amine temperature is to
be kept 10-15° higher than the feed gas temperature so as to prevent heavier
components in the feed gas from condensing, which may lead to foaming in the
Absorber Columns. Raw Gas KO Drum is a horizontal vessel of CS construction having
a diameter 2.9m and length 6.0m. Raw gas enters the vessel from top and liquid
droplets are separated from the gas. The liquid is routed to the flare header manually
with the help of a globe valve. To indicate liquid level, a level indicator (LI- 0102) is
provided on the vessel. Software high and low level alarms are also available on DCS.

The gas from KO Drum is passed through a Feed Gas Filter Coalscer GN-001). The
Feed Gas Filter Coalscer separates any residual liquid droplets present in the gas. The
gas flow is then divided into two streams and taken into the HP Absorber Columns (CC-
101A/B).

There are two HP Absorber Columns operating in parallel. Raw gas from the KO Drum
flows into the bottom of each Absorber through a shut down valve. Each HP Absorber is
a tray column fitted with 30 valve trays. The top tray is a dry tray which minimizes
solvent carry over in the treated gas. Lean amine solution(40 %,) is fed into the column
top on tray no.2 at 51.4 kg/cm2a and 45 °C. The gas is counter-currently contacted with
the absorbent DEA solution so that CO2 present in the gas gets absorbed into the
solution. A flow indicator controller (FIC-OI03/FIC-0203) along with high flow alarm
(FAH) and low flow alarm (FAL) is provided on the solution inlet line of each Absorber. A
very low flow trip alarm (FALL) is also provided on the solution inlet line which on
actuation gives a signal for auto start after standby pump (PA-101 A/B/C ). In case, the
standby pump does not start and FSLL still continues, the interlock closes the gas inlet
and the outlet SDVs and solution inlet FV to each of the columns, after a certain time
delay.

After CO2 absorption, the rich amine solution is collected at the bottom of each
absorber column. This solution at 51.7kg/cm2a and 71.4°C, is routed to the Rich Amine
Flash Drum (VV-102) on column bottom level control. A shut-down valve (SDV-
OlO2ISDV-0201) is provided on rich amine outlet line at the bottom of each Absorber,

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upstream of the level control valve. A temperature indicator (TI-0103m0203) and a

sample point is provided on rich amine bottom outlet line of each Absorber. A level
indicator controller (LIC-OI06/LIC-0206). along with LAH and LAL is provided at the
bottom of each column for level control. A very low level trip alarm (LALL-OI04/LALL-
0204) is also provided at Absorber bottom. This actuates interlock to close SDV on the
Absorber bottom liquid outlet. Thus preventing gas blow by to the downstream section.
Along with this, gas and lean amine flow through the Absorbers is also stopped by
closing the gas inlet and outlet SDVs. amine inlet FV and the Amine Charge Pump (PA-
101AIB/C).

The treated gas flows out from the top outlet of each of the Absorber Column through a
flow control valve. Flow controller (FIC-0102/FIC-0202) is provided on gas outlet line of
both the Absorbers for controlling the gas flow. Since flow controllers are provided for
both. the gas and the lean solution flow. gas to amine ratio can be always maintained.
Gas outlet streams from individual Absorber columns are combined together
downstream of SDVs (SDV-0204 & SDV-0205) and fed into the bottom of Sweet Gas
Water Wash Column (CC-103).

Treated gas at the outlet of each Absorber can be lined up to the online analyzer (AI-
0201) for determination of CO2 concentration. Normally this analyzer would be kept
lined up with gas outlet from the Sweet Gas Water Wash column. However, the analyzer
can be lined up to the individual Absorber outlet when it is required to ascertain
performance of a particular Absorber. A PSV set at 58kg/cm2a is provided at the top of
each Absorber to protect the column against overpressure (fire case). A differential
pressure indicator (PDI-Ol05/PDI-0205) along with a high differential pressure alarm
(PDAH) is provided across each of the Absorber Columns to indicate flooding in me
column. For each column a 10" connection between the lean solution flow, control valve
upstream and the Absorber bottom level control valve upstream’ is provided to bypass
the Absorber columns during chemical cleaning of the DBA circuit before start-up.

2.2.2 Treated Gas Water Wash and Cooling

(Refer P&ID No. 4288-6111-0021)

After CO2 Absorption the treated gas is fed into the bottom of Sweet Gas Water Wash

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Column (CC-103). Here the gas is counter currently contacted with circulating water to
remove any DEA solution carried over with the gas. The water wash column is equipped
with a packed bed of Pall rings. Circulating water from the discharge of Sweet Gas
Water Wash Pump (PA-103 AIB) having capacity 25 m 3/hr, is fed from the column top.
After absorbing DEA from the treated gas, water is fed to the suction of PA-103A/B for
recirculation, from the draw off tray. A small stream of wash water from the draw off tray,
is sent to Rich Amine Flash Drum (VV-I02) through a level control valve LV-0202. Level
controller LlC.Q202 along with LAH and LAL is provided to control the draw off tray level
by manipulating this level control valve. A flow indicator (FI-0205) is also available on
this stream to VV-I02 to have an additional flow indication. A very low draw off tray level
trip alarm, LALL-0208 is also provided which on actuation trips the Water Wash Pump
(PA-103) and LV-0202. Treated gas from Absorbers enters at the bottom of CC-103 and
the DEA solution droplets entrained in the treated gas get collected at the bottom of
Water Wash Column. This is manually drained into the Rich Amine Flash Drum with the
help of a globe valve on the bottom outlet line. An SDV is provided on the bottom outlet
line upstream of the globe valve. A level gauge provided on the column bottom helps
manual draining operation. High level and low level switch alarms (LAH-021O & LAL-
0203) are also provided on the column bottom. LAL-0203 on actuation closes the
bottom outlet SDV-0202. The loss of water in the purge stream and along with the
outgoing gases compensated by fresh make-up water supplied by the Water Wash
Booster Pumps PA-I06 AIB. These are metering pumps having a capacity of 2.0 m)/hr
each. A flow indicator (FI) along with FAL is provided to indicate the make up water flow.
A PSV (set at 58 kg/cm2g) is provided on the Sweet Gas Water Wash Column (CC-703)
to protect the column against overpressure (fire case).

The treated gas at 50.3 kg/cm 2a and 45.C leaves from the column top outlet and enters
the Sweet Gas Cooler (EE-I0S) where it, is cooled down to 40°C. Temperature
indication for the sweet gas is provided upstream as well as downstream (TI-0204/TI-
0206) of the Sweet Gas Cooler.

A pressure indicator (PI) along with PAH and PAL and a sample point are provided
down stream of the cooler. A slip stream of cooled treated gas is taken to the CO2
analyzer for determining concentration. After cooling the treated gas leaves the GSU

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battery limit at 50 kg/cm2a and 40°C.

2.2.3 Rich Amine Circuit

(Refer P&JD No. 4288-6111-0023)

Rich amine streams from the bottom of HP Absorbers is combined together and taken
into the Rich Amine Flash Drum (VV-102). The purge stream from Sweet Gas Water
Wash Column is also taken into the flash drum. Rich amine flash drum is a horizontal
vessel of carbon steel construction having diameter 3.0m and length 9.6m. The vessel
operates at 6.5kg/cm2a. Most of the hydrocarbons co absorbed in the rich amine
solution are desorbed in this drum because of the lower operating pressure. The flash
gas is routed to the plant fuel gas header. A line to route this gas to the flare header has
also been provided. Pressure in the Rich Amine Flash Drum is controlled by PIC-0302
which manipulates the control valves PV-0302 A&B, operating in split range. Software
alarms PAL & PAH are available on the PIC-0302. TI-0301 & FI-0301 are also available
on the flash vessel. A sample point is provided on the fuel gas line to facilitate periodic
analysis of the fuel gas. The flash vessel is provided with a nitrogen connection so as to
prevent a low pressure condition in the vessel.

For protection against high pressure two sets of two safety valves set at 9.0 kg/cm 2g are
provided on the flash drum. At a time, only one set is required to be lined up.

After removal of co-absorbed hydrocarbons, rich amine solution at 6.5 kg/cm2a and
72.8°C is routed to Lean/Rich Amine Exchanger (EE-101 A/B/C). In the exchanger, rich
amine exchanges heat with lean amine leaving Regenerator bottom and is heated up to
110 °C. Rich amine level in the flash drum is controlled by LlC-0304, through LV -0304
located downstream of EE-l 0 1 on rich amine line.

Software alarms LAH and. LAL are available on the LlC. A very low level trip alarm
(LALL-0301) and a very high level trip alarm (LAHH-0302) are provided on the flash
drum. LALL on actuation closes the SDV on bottom outlet line. LAHH (very high level in
the flash drum) on actuation leads to the stoppage of gas flow and amine flow through
the Absorbers and ultimately to emergency shutdown of GSU.

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The Rich/Lean Amine Exchanger (EE-101) is a plate-frame exchanger with three units
of 50% capacity in parallel. At a time. two exchangers will be operating and one will be
kept spare. Rich amine solution temperature indication, TI-0303, along with T AH and
TAL. is available downstream of EE-101. Rich amine solution, after being heated. is fed
to the Regenerator Column (CC-102) on tray no.3.

2.2.4 Regenerator Section

(Refer P&ID no. 4288-6111-0024)

The Regenerator has 22 trays, out of which 19 are used for stripping of CO2 from the
amine solution. Top two trays serve to minimize DEA carryover with the overhead
vapours. Additionally, one chimney type seal tray is used for reboiler feed draw-off.

Regenerator top operates at 1.9 kg/cm 2a and 97.C. The overhead vapours are routed to
Regenerator Overhead Condenser (EE-103) and the condensed liquid is taken into
Regenerator Reflux Drum (VV-I03). The overhead condenser is a shell and tube type
exchanger with cooling water used as cooling medium. The uncondensed gases, mainly
CO2, from EE-103 are vented at 50.C to atmosphere at a safe location through the
Reflux drum top outlet. A pressure controller, PIC-0401. on the top outlet controls the
pressure in reflux drum at 1.6 kg.cm2a. Software alarms PAH and PAL are provided on
the PIC. TI-0401. FI-0405 and a sample point are also available on the top outlet line of
the reflux drum.

The reflux drum is a vertical vessel of carbon steel construction having diameter 2.4 m
and height 3.6m. The drum is tined with a demister pad to prevent any liquid carryover
with the outgoing gases. Liquid in the reflux drum is pumped back to the column as
reflux flow, with the help of Regenerator Reflux Pumps (P A-102 AIB). The reflux flow is
controlled by FIC-0403 which is cascaded with reflux drum level controller LIC-0403.
Software alarms FAH & FAL are available on FIC and LAH and LAL are available on
LIC. A very low level trip alarm (LALL-0402) is provided on the reflux drum which on
actuation trips the reflux pump. Total or part of water makeup for the unit can be fed to
the reflux drum.

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Regenerator bottom operates al 2.2kg/cm 2a and 126.C. The bottom heating to the
column is provided by the Regenerator, Reboilers (EE-102A/B/C/D). Regenerator liquid
from the draw-off chimney tray enters the reboilers from the bottom. Vapours generated
are sent back to he column via top outlet of the reboilers where as overflow liquid flows
into the column bottom under gravity. Temperature indications are available on the
reboiler vapour return lines. Low pressure steam is used as heating source in the
reboilers. The steam condensate is carried into the Condensate Drum(VV-I04) which is
maintained at the same pressure as the steam pressure. Condensate from the drum is
pumped with the help of Condensate Pumps (PA-l04A/B), cooled down in the LP
Condensate Cooler (EE-l06) and sent to the LP condensate header on flow control
(FIC-0409). PI & TI are provided on the condensate drum. Very low-level alarm, LALL-
04l2. which on actuation trips the condensate pumps is also provided on VV-l04. For
protection against overpressure a PSV set at 6.5 kg/cm 2g and discharging to
atmosphere is also provided on VV-I04.

The steam to the reboilers enters the reboilers, after it is desuperheated in the LP
Steam Desuperheaters (JX-101). LP condensate from Condensate drum is mixed with
LP steam for desuperheating the steam. The steam temperature downstream of
Desuperheater is controlled by TIC-0408 which manipulates the condensate flow control
valve TV-0408. Software alarm TAH is available on TIC. Also an FI with FAL is provided
on the condensate line to Desuperheater. The steam flow rate is controlled by FIC-
0402, which is cascaded with the column top temperature controller TlC-0402. Software
alarm FAL is available on FIC-0402.

Lean Amine solution leaves the Regenerator bottom at 2.2 kg/cm 2a and 126°C. The
solution is first taken to Lean/Rich Amine Exchanger (EE-101 A/B/C/D/E), then to Lean
Amine Cooler (EE-l04 A/B/C/D) and finally to Lean Amine Storage Tank (TT-101l). Very
low level trip alarm. LALL-0406 is provided on Regenerator bottom which on actuation
trips SDV on the bottom outlet line.

For protection of the column against overpressure a set of two PSVs set at 4.5 kg/cm2a
is provided on the column.

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Software alarms TAH and TAL are available on TIC-0402. A pressure indicator. PI0405
along with PAH and PAL is also provided for column top pressure indication.

2.2.5 Lean Amine Circuit

(Refer P&ID no. 4288-6111-0022 / 0024)

The Lean amine solution, at 126°C and 2.2 kg/cm2a is sent to Lean/Rich Amine
exchanger (EE-101 A/B/C/D/E). The lean solution exchanges heat with the rich solution
being fed into Regenerator column. Lean solution is then further cooled down to 45 °C
in Lean Amine Cooler (EE-104 A/B/C/D) with the help of cooling water. Lean Amine
Cooler is a plate-frame type of exchanger with four units of 50% capacity running in
parallel. At a time only two units are in operation and the others are kept spare. The
temperature of lean amine solution downstream of EE-I04 is controlled by TlC- 0306
which manipulates the temperature control valve TV-0306 on EE-I04 bypass line. After
cooling, the lean amine solution is routed to Lean Amine Storage Tank (TT-101) on
Regenerator bottom level control (LIC-0408).

2.2.6 Amine Storage and Recirculation

(Refer P&ID no. 4288-6111-0025)

Amine Storage Tank (TT -101) is a cone roof tank of carbon steel construction having
nominal capacity of 750m3. Amine solution (40%DEA soln.) up to 540m 3 can be stored
inside the tank at a temperature of 45 °C. The temperature of amine solution can be
maintained by providing heating with the help of steam coils. Amine storage tank serves
several functions:

 Its capacity allows the recovery of total amount of solvent inventory when the
columns and lines are drained for maintenance.

 Pure solvent make up and control of lean amine solution concentration becomes
very easy.

 Hold up time of tank allows efficient decantation of amine solution before being
sent to filtration section.

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 The surge available permits steady lean amine feed rates to Absorbers while
return liquid rate to tank is unsteady due to level controller actions in the process
equipments.

The tank is nitrogen blanketed to avoid solvent contact with air which degrades the
solvent. The nitrogen flow to the tank is controlled by a downstream pressure control
valve (PCV-0501). The tank is provided with a PVRV-0501 at the top which protects the
tank against over-pressurization as well as under vacuum conditions. For level
indications. LI-0508 and LI-0502 along with LAH and LAL are provided on the tank. A
very low level trip alarm. LALL-0506 is also provided, which on actuation trips the Amine
Charge Pumps (PA-101 A/B/C). A make-up water line with flow controller FIC-0502 is
also provided to maintain the DEA concentration. A sample point is provided on the
solution inlet line to determine the lean amine composition entering the tank.

Lean amine solution from Amine Storage Tank is sent to the Absorber columns with the
help of amine Charge Pumps (PA-101 A/B/C). The Amine Charge Pumps are multistage
with high head (587 m) and high flow rate (362 m 3/hr). The standby Pump is designed
for auto start i.e. with discharge valve in open position. Out of three pumps two are
running at a time and the third is standby.

For fresh amine solution preparation one underground Amine Preparation Pit (JX-105)
has been provided. Pure DEA drums are unloaded into this pit and the amine is diluted
with make up water as per specifications. A steam connection is provided in the pit to
aid solution preparation. LI-0503 is provided to indicate level in the pit. After solution
preparation the contents of the pit are transferred to Amine Sump Drum (VV -105) by
gravity.

2.2.7 Filtration Package

(Refer P&ID no. 4288-6111-0026)

Continuous filtration is required to remove all the solid scales, dissolved hydrocarbons
and solvent degradation products, which can promote corrosion and foaming problems.

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The filtration package provided is designed to treat approximately 10% of the total lean
amine flow. It consists of following filters.

 Pre-coat filter, JX-102.

 Activated charcoal bed, VV-107
 Cartridge filter, JX -103.
 Activated charcoal bed, VV-117 A/B
 Cartridge filter, VV-113 A/B

A side stream approximately 10% of the total lean amine flow is drawn off from the
storage tank with the help of Amine Filtration Pump (PA-107). It is passed through the
pre-coat filters which are designed to remove solid panicles from the solution. After pre-
coat filters, the stream splits into two streams. A side stream, approximately 1 % of the
total lean amine flow is taken to the activated charcoal filter on flow control (FlC-0601).

The charcoal filters removes any degradation products and dissolved hydrocarbons
present in the solution. These filters are followed by cartridge filters which remove any
entrained activated charcoal particles from this side stream. The main stream is
returned to the Amine Storage tank through a flow control valve FV-0602.

A differential pressure indicator, PDI, with a high differential pressure alarm. PDAH, is
fitted across all the filters to give an indication of chocking of the filters. Charcoal filters
can be regenerated with LP steam through utility connection and vent provided. All the
filters are provided with a PSV, discharging to Filter Slush Pit (JX-104) for protection
against overpressure. The filter cake from the pre-coat filters is also transferred to the
slush pit. The contents of the slush pit are pumped to waste water treatment plant with
the help of Filter Slush Pumps (PA-108). The pumps starts automatically on high level
alarm and also trips automatically on low level alarm.

2.2.8 Antifoam Package

(Refer P&ID no. 4288-6111-0025)

Antifoam injection facilities are provided to overcome the foaming problems that may
occur during unit operation. The antifoam solution used is an aqueous solution of
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silicone oil. This is injected into the solvent circuit at the suction of Amine Charge
Pumps (PA-101A/B/C).

Antifoaming agent from Antifoam Surge drum (VV -108) is pumped with the help of
Antifoam Injection Pump (continuous), PA-109, and dozed into the lean amine circuit. In
case of severe foaming problems, Antifoam Injection Pump (intermittent), PA-110,
having higher flow capacity is used to inject the antifoaming agent. The Antifoam Surge
drum is fitted with a stirrer for preparation of solution and a low level switch alarm which
on actuation trips the injection pumps.

2.3 FLARE AND CLOSE BLOW DOWN

2.3.1 Flare
(Refer P&ID no. 4288-6111-0030)

The safely valve discharges, sample point discharges and CO2 analyzer outlet gas are
routed to the 24" unit flare header having carbon steel metallurgy. The unit flare header
is connected to the main 40" flare header in the C2/C3 battery limit.

A gate valve is provided on unit flare header at the battery limit which has to be kept in
lock open (LO) position.

2.3.2 Close Blow Down

(Refer P&ID no. 2741-02-41-06-1105/1108)

All the amine solvent drains in the unit are recovered via a closed circuit and sent to the
underground Amine sump Drum (VV-105). Amine Sump Drum is a horizontal vessel of
C.S. construction having diameter 2.4m and length 6.0 m. The vessel is nitrogen
blanketed to avoid solvent contact with air which degrades the solvent. The nitrogen
flow to the vessel is controlled by downstream pressure control valve, PCV-0502.

The drum is fitted with LI-0504 for level indication and with separate high & low levels
switch alarms, LAL-0509 and LAH-0505. For protection against overpressure, a PSV
set at 4.0 kg/cm2g is also provided. on the drum. The contents of the drum are pumped
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to amine filtration package with the help of Amine Sump Pump PA-105 is a submersible
pump fitted inside the sump drum. It starts on actuation of LSH-0505 and stops on
actuation of LSL-0509.

2.4 ISBL UTILITY SYSTEMS

(Refer P&ID no. 2741-02-41-06-1107)

The utilities are supplied from the common utilities area shared by GSU and C2/C3
Recovery Unit using separate headers. The utilities include:

a) Instrument air
b) Plant air
c) Nitrogen gas
d) Service water
e) Cooling water
f) Process water
g) Fuel gas
h) LP steam
i) LP condensate

Instrument Air
A 2" instrument air header supplies instrument air to the unit at a pressure of 7.5 kg/cm 2
abs. The various instrument air tapping’s are taken off this header. Normal requirement
of instrument air is estimated at 80NM3 / hr for the GSU.

Plant Air
Plant air is supplied to the unit at various hose stations through a 2” header at a
pressure of 7.5 kg/cm2abs.

Inert Gas (Nitrogen)

Nitrogen is supplied to the unit at a pressure of 7.5 kg/cm 2abs through a 3" header.
Nitrogen for the complex is generated in the air separation plant by turbo-compression
of air followed by its liquefaction and fractionation. The nitrogen available is 99.99%

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(v/v) pure and has got a dew point of -100 °C at atm. pressure.

In GSU Nitrogen is mainly used for blanketing of Amine Storage Tank (TT-101). It is also
required during start-up for inserting and pressurizing the unit

Cooling Water
Cooling water to the unit is supplied, through a 30" cooling water supply header at
pressure of 5.5 kg/cm2a and at a temperature of 33 °C to various coolers and
condensers. Hot water from exchangers is returned to the cooling tower through 30"
cooling water return header. Cooling water return header is provided with a flow
indicator FI-0702 with a low flow alarm (FAL).
Normally 3860 M3/hr of CW shall be required for the unit.

LP Steam
LP steam is supplied to LPG unit at a pressure of 4.5 kg/cm2a and at a temperature of
165 °C through a 24" header. LP steam is being used for supplying heat duty to the
regenerator reboilers (EE-102 A/B/C/D) for providing heat duty to the coils in Amine
Storage Tank (TT-101) and during amine solution preparation in Amine Preparation Pit.
It is also used at various hose stations. A pressure gauge and a temperature gauge are
provided on the LP steam header. Normal consumption of LP steam is 100 TPH.

Service Water
Service water is supplied to the unit from Utilities area at a battery limit pressure of
about 5.5 kg/cm2a through a 2" header. Service water is made available at various
hose stations.

Fuel Gas
Fuel gas is produced in the unit as a result of flashing of rich amine solution in the Rich
Amine flash Drum (VV-102). There is no consumption of fuel gas within the
unit. It is sent to the consumers outside the unit through a 4" header. A pressure gauge
and a temperature gauge are provided on the fuel gas header.

Process Water

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Process water is supplied to the unit through a 3" Process Water header. In GSU,
process water is required for the following purposes.

 For water make-up in Sweet Gas water wash column (CC-103). Regenerator
Reflux Drum (VV-103) and Amine storage tank (TT-101).
 For preparation of DEA solution in Amine Preparation Pit (JX-105).
 For preparation of Antifoam solution in Antifoam Surge Drum (VV-108)
 For preparation of cellulose solution in Filtration Precoat Drum (VV-106).
 For cleaning of filter cake in Amine Filter (JX-102).

An LP condensate stream, cooled in LP condensate cooler (EE-106) is routed to the

process water header to provide process water for the unit during normal operation.
During start-up BFW is used to cope with the process water demand. BFW from C2/C3
unit area is taken through a3" line (3".WB-06-10301-A3A-Is) cooled in the Lean Amine
Cooler (EE-104 B) and routed to the process water header (through 3". WP-06-10301-
A3A) and the other consumers.

A pressure indicator (PI-0704) along with PAL and a flow indicator (FI-0701) along with
flow recorder are provided on the process water header.

LP Condensate
LP condensate is pumped out from the Condensate Drum (VV -104) cooled in the
condensate cooler (EE-107) and routed to the 6" LP condensate header. Through the
header LP condensate is sent outside GSU battery limit at 5.5 kg/cm2a and 100°C.

2.5 INTERLOCK DESCRIPTION

Interlock Actuated by Action

11 LSLL-0104 (CC-101A bottom) Close SDV-0101

Close SDV-0204
Close SDV-0102
Close FV-0103

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Trip PA-101 A/ B/C

12 FSLL-0103 (Amine inlet to Close FV -0 103

Close SDV-0101
(Note-1) CC-101A) Close SDV-0204
Auto start of stand by
Pump PA-101A/B/C

13 LSLL-0204 (CC-101B bottom) Close SDV-0206

CloseSDV-0205
Close SDV-0201
Close FV -0203
Trip PA-101 A/B/C

14 FSLL-0203 (Amine inlet to

CC-101B) Close FV -0203
Close SDV-0201
Close SDV -0205
Auto start of the
stand by pump
PA-101 A/B/C
I LSL-0203 (CC-103 bottom) Close SDV -0202
I LSLL-0208 (CC-103 draw-off Trip PA-I03 AIB
tray level) Close LV -0202
15 LSHH-0302 (VV-102 level) Close SDV-0101
(Note-2) Close SDV-0204
Close SDV-0206
Close SDV -0205
Close SDV-0102
Close SDV-0201
Trip PA-101 A/B/C

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16 LSLL-0301 (VV-102 revel) Close SDV -0301

I LSLL-0402 (VV-103 level) Trip PA-I02A/B
I LSLL-0406 (CC-102 bottom) Close SDV-0401
I LSLL-0412 (VV-104 level) Trip PA-104A/B

17 LSLL-0506 (TT -101 level) Trip PA-101A/B/C

Trip PA-107
I LSL-0507 (VV -108 level) Trip PA-109
Trip PA-110
I LSH-0505 Auto start PA-105

I LSL-0509 Auto stop PA-105

I LSH-0601 Auto start PA-108

I LSL-0606 Auto stop PA-108

Notes:

1. When 12 and/or 14 are actuated it will first result in the auto start of the standby pump
PA-101A/B/C. In case, the standby pump fails to start, and the FSLL still continues
then closure of FVs and SDVs, mentioned above, will take place, after a time delay.

2. Emergency shutdown.

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TABLE-2.1
EFFLUENT SUMMARY

The effluent discarded from Gas Sweetening Unit is the filter wash water coming from
the amine precoat filter. This filter wash water contains cellulose and the retained solid
impurities (mainly iron sulphide or carbonate).

Typical effluent composition is as follows:

Water 99.6 % wt.

Cellulose 2500 ppm
Iron scale 1500 ppm
DEA Traces

Liquid effluent flows down from the filter into the filler slush pit and then it is pumped by
a submerged pump into a waste water treatment plant.

The effluent quantity to be treated depends on the filter cleaning frequency. The
estimated quantity is 1100 m3/year.

The cellulose sludge is recovered in the filter slush pit. The spent cellulose can be
disposed off by:

 Disposal of the wet sludge

 Dried cellulose can be land filled or incinerated.

The spent charcoal can be disposed off either by incineration or by returning it to the
manufacturer if possible.

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T ABLE-2.2
FLARE LOAD SUMMARY

FIRE CASE BLOCKED OUTLET GAS BLOW-BY

Flow T MW Flow T MW Flow T MW
1. PSV-0101 2250 273 18.0
2. PSV-0102 1300 273 18.0
24500 260 80.0
3. PSV-0201 2250 273 18.0
4. PSV-0202 2500 273 18.0
5. PSV -0305 710 90 20.6
A/B/C/D 2745 179 18.0 800 (**) 209955 30 19.2
T-Release ** Flow rate of amine soln.
Temp. in °C in m3/hr
Flow-Flow rate in Kg/hr Max temp= 90°C

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SECTION - 3

PREPARATIONS FOR START-UP

3.1 INTRODUCTION
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As the new unit nears completion, there is a large amount of preparatory work which
should be performed by the operating crew. A planned check of the unit will not only set
the foundation of a smooth start-up but will also provide a firm basis for acquainting
operators with the equipment. Start-up is a critical period and the operator must know
thoroughly his plant and the operation of each equipment.

Some of the preparatory works such as hydro testing of headers will be performed by
the construction agency. A great deal of additional preparatory work can be finished
before erection is completed. Though some care in the organization of this work is
necessary so that it will not interfere with construction work. It is important to plan and
schedule all the preparatory works required to be completed before start-up. It is
advisable to prepare a network for the prestart-up activities which will be of great help in
monitoring.

Indeed, a good amount of co-ordination shall be required with construction group for
execution of the preparatory work. It should be ensured that appropriate action has
been initiated for procurement of lubes. chemicals. etc. and the same are available for
start-up. It should also be ensured that adequate number and the right types of fire
extinguishers are available.

3.2 INSPECTION OF EQUIPMENT

Inspection of the following items is primarily Contractor's responsibility. Nevertheless. it

is important for operating crew to participate in the inspection to the fullest extent. since.
for many of them. this may be the only opportunity before start. up to examine the
internals of some of the equipments. Vessels etc.

a) Inspection of vessels and columns:

Inspection of the interior of the vessels columns and other equipment not normally
accessible during operation wil1 be made to ensure that they are complete. clean, and
correctly installed. Rust and debris, if found in these equipment should be removed.
b) Piping and accessories:
Piping and accessories will be checked against drawings and specifications. Piping
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support and hangers will be inspected to ensure that all anchorages are firm. Valves will
be checked for proper packing mounting direction and accessibility for operation and
maintenance. Spring supports are to be checked for the cold settings and later for hot
settings while plant is in operation.

c) Instruments:
Instruments will be checked, starting from the controller and proceeding logically
through the control loop. Cascade control system will be checked from the impulse point
of primary loop. Operating crew should check proper mounting of control valves. 1be
shut-down systems of the equipments should be checked by simulating various
conditions in the control circuits. Including the fail safe positions.

d) Rotating equipment:
. Rotating equipment (pumps) will be generally inspected in the presence of owner's
representative together with the vendor's representative accompanied
by the vendor's commissioning engineers.

e) Relief Valves:

Relief valves will be checked against specifications. Relief valves will he set
at site and mounted before the system tightness test. Block valves ahead and
after relief valves will be checked for lock open position as per P&ID. Calibration record
of the relief valves./ PSVs would be reviewed.

3.3 PREPARA TION OF THE UNIT

1. Check the unit for completion and correctness against P&IDs.

2. Remove all construction tools and materials lying around in the unit and cleanup
the area.
3. Install blinds as per master blind list.
4. It is preferable to install safety valves after flushing. If safety valves could not be
removed their inlet should be blinded during cleaning operation and blinds
removed afterwards. Before installation all safety valves are to be tested at site
and set at stipulated values as mentioned earlier.
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5. Check that communication between units. control room. Offsite and utilities is
complete and in working condition.
6. Ensure that the required lube oil. grease and other consumables are available in
the unit.
7. Ensure that necessary temporary strainers are available.

8. Ensure all utilities like service water. air, nitrogen etc. are available at the binary
limit.
9. Cleaning and flushing of piping and pipeline is done as given in 3.5. Procedure
adopted is same for lines from generation area to battery limit of the plant. as
well as within the plant battery limit.

3.4COMMISSIONING OF ISBL UTILITY SYSTEMS

The ISBL utility systems include instrument air. plant air. Nitrogen, service water,
process water. cooling water. LP steam. LP condensate and fuel gas. The
commissioning of the OSBL utility systems must be complete before commissioning of
the ISBL utility systems.

3.4.1 Instrument Air and Plant Air System

To ensure that the lines are clear and completely free of dirt, instrument air and plant air
lines should be first flushed with water. After flushing, water is completely drained from
the lines. The vents on the lines are to be kept open while draining water. The lines are
then dried out completely by blowing air. All the instrument air lines should be dried out
using instrument air itself. Drying of the instrument air lines should be continued till the
dew point of air coming out of these lines is equal to that of Instrument air.

After dry out, tightness test of the lines is carried out using respective fluids as per the
procedure given in section 3.6.

3.4.2 Service Water. Cooling Water and Process Water System

Flush all service water and cooling water lines with water until lines are clear and free of
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dirt, welding slag, etc. Some of the drains on the lines should be kept open during
flushing.

For the cooling water lines, flushing should be done up to and around the exchanger
using bypass line. It should be ensured that dirty water from initial flushing does not get
into the exchanger. Wherever bypasses are not available. The flanged joint at the inlet
of heat exchanger should be first opened and the line flushed till clear water starts
coming out. Then flange is reconnected and flushing is done through the exchanger.
After water flushing chemical passivation of the cooling water lines should be carried
out.

The process water system includes 3"-P-06-10301-A3A-ls, EE-I04B, condensate drum

(VV-104), LP condensate cooler (EE-106), process water utility header and distribution
tapings from the header. After thorough flushing and cleaning of this system, process
water lines should be rinsed with process water of BFW quality.

3.4.3 LP Steam and LP Condensate System

The steam and condensate lines should be initially flushed with water so that the lines
are completely cleaned and free of dirt. Steam traps should be kept bypassed during
flushing the lines. The lines are then drained completely of water. Vents on the lines
should be kept open while draining the lines.

After water flushing, LP steam is blown through the steam and condensate lines and hot
bolting of-the flanges are done. During steam flushing, the steam traps should be
initially kept bypassed and brought in line after some time.

3.4.4 Fuel Gas and Inert Gas System

The fuel gas and inert gas lines should be initially flushed with water so that the lines
are completely cleaned and free of dirt. After water flushing, the lines are drained
completely of water. Vents on the lines should be kept open while draining the lines. The
lines are then dried out completely by blowing plant air.

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After dry out, tightness test of the lines is carried out using plant air as per the
procedure given in section 3.6. Both the fuel gas and inert gas lines are then purged
with inert gas (nitrogen) as per the procedure given in section 3.9.

3.4.5 Sewer and Drain System

Test flow each drainage system (except the Amine Sump Drum) with water to remove
any blockages caused by construction debris.

3.5 PIPE FLUSHING AND CLEANING

Considering the type of fluid handled. pipe material, and internal wall conditions pipe
cleaning method shall selected from the following list.

 Cleaning by water
 Air blowing
 Steam flushing
 Chemical cleaning

a) Cleaning by water:

As a rule water flushing shall be done for pipes in liquid service. If cleaning by water is
unsuitable another method will be used. Following procedure shall be adopted for water
flushing.

1. Low point drains and high point vents should be opened.

2. Low point flanges should be opened during initial flushing, wherever possible.

3. All instrument connections should be isolated, orifice plates removed control

valves isolated and by-passed. In case there is no by-pass, remove control
valve and flush the line. The valve will be installed after clear water starts
coming out and further flushing may be continued. Turbine meters should be
dropped.

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4. If there is any heat exchanger in the line flushing should be done up to and
around the exchanger using bypass line. It should be ensured that dirty water
from initial flushing does not get into the exchanger. Wherever bypasses are
not available. the flanged joint at the inlet of heat exchanger should be first
opened and the line flushed till clear water starts coming out. Then reconnect
flange and flush through the exchanger.

5. At each opening of the flanged joints. a thin metallic sheet should be inserted
6. to prevent dirty water from entering the equipment or piping.

7. Flushing should be carried out with maximum possible flow of water till clean
water starts coming out.

8. Vertical lines which are long and rather big (say over 4" dia) should preferably
be flushed from top to bottom. This will ensure better flushing. Filling the lines
and releasing from bottom is also helpful. Temporary water connection at
suitable points can be made to carry out flushing operation. The run down
lines should be flushed from the unit to the respective tanks or tanks to unit.

9. It should be ensured during all flushing operations that design pressure of

lines and equipment are never exceeded. After flushing of lines and
equipment. water should be thoroughly drained from all low points lines and
equipment containing pockets of water should not be left idle for a long time.
It is preferable to dry these lines and equipment with air after water flushing.
Demisters in all the equipments shall be installed only after flushing and
subsequent drying with air is completed.

10. In case the piping which is used in gas service is being cleaned by water
temporary pipe supports may have to be installed.

b) Air blowing:

Air flushing is done for pipes in gas service. If sufficient air is not available. Pipes can be
cleaned by pressurizing and depressurizing by bursting discs of cardboard or gasket
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material. Pressure should not be increased beyond the design pressure. Large diameter
pipelines such as flare headers which cannot be properly flushed with water shall be air
blown completely with strong flow of air to clean the lines. The instruments and control
valves shall be carefully isolated from the system. Equipments shall be disconnected to
prevent entry of flushed material.

c) Steam flushing:

Steam flushing will be done mainly for steam lines. It is preferable that insulation should
be complete otherwise when steam flow is opened lot of condensate formation will take
place. Hot un insulated pipes may cause injury to person on job. When cleaning by
steam is performed thermal expansion of pipe should be taken into consideration.
Following procedure should be followed. .

1. Remove orifice plates.

2. Spool piece to be put in place of control valves, flow meters etc. In case the
above instruments have been provided with a bypass isolate the instrument
and open bypass.

3. Disconnect equipments to avoid entry of the flushed material.

4. If necessary, make temporary arrangements for steam blowing at open end of

the pipe.

5. Open steam trap bypass valves. and isolate steam traps.

6. Slowly allow steam to heat the pipe and then flush thoroughly with a strong
flow of steam. A void steam hammering by draining condensate properly.

7. Check pipe line supports and loops for expansion.

8. After blowing is over. allow the pipe to cool With vent open to prevent vacuum
pulling. Open dripleg flanges and remove accumulated muck. Then box up
the line.

d) Chemical cleaning:

In addition to water flushing and air blowing for lines and vessels, DEA system would be
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required to be further cleaned by circulating a hot solution of sodium carbonate at near

about operating flow rates. The detailed procedure for this operation given in section 3.

e) Oil flushing:

Oil flushing is generally done for lube oil circuit after cleaning of system as per vendor's
instruction. Normally lube oil circuit is chemically cleaned and passivated by vendor at
his shop and the circuit arrives as a sealed unit. At site it is generally required to oil flush
the circuit as per the following procedure.

1. Oil is taken in the sump and wire mesh of size 200 mesh is installed in the
circuit.

2. A good flushing oil is circulated. It is continued till no extraneous substances

are found in the wire mesh.

3. After flushing is over, flushing oil is replaced by normal lube oil.

3.6 FUNCTIONAL TEST OF ROTATING EQUIPMENT

All rotating equipment will undergo functional test to check their performance with
water/air. All instruments will be checked/calibrated.

a) Motors

Manufacturer’s lubrication schedule should be used to ensure that all lubricationpoints

have been serviced. Each motor should be checked and started on no -load. Ensure
that it has the correct direction of rotation. The motor speed should be checked with
tachometer to ensure that RPM is correct. After a short run each bearing should be felt
to ensure that it is free and not over-heated.

b) Pumps

Generally, the pump casing is opened and checked to ensure that it contains no foreign
materials. Pump casings need not be opened up in case the pump had been stored
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carefully and the blinds covering suction and discharge nozzles were not removed in
storage or in transit. Cleanliness of suction line and installation of fine mesh strainer
should be ensured. Pump and motor should be aligned and then tried on water.

Temporary connections may have to be made if required. When running a pump

designed for hydrocarbons on water, the discharge valve may have to be throttled. so
that the rated amperage is not exceeded. Ensure that the vents and drains of the pump
are clear. Pressure gauge tapping will be flushed and filled with sealing fluid wherever
necessary.

3.7 INSTRUMENTS

The following procedures may be adopted to carry out checking of the instruments.

i) Orifice plates:

Before each orifice plate is installed the orifice taps should be blown clear. The orifice
plate should be callipered ro check if the correct size orifice plate is being installed. The
plate should then be installed after checking for the correct direction.

ii) Differential pressure Transmitters and Receivers:

Ordinarily these should be calibrated locally. The calibration should be checked at the
receiver, which may be a board or locally mounted recorder or indicator.

iii) Transmitters and Receivers:

All indicators and recorders for temperature Pressure. Flow and level should be
checked and it should be ensured that all points in the recorders and indicators
correspond to the proper thermocouple in the plant. Also that proper controller reacts to
the simulated conditions in the plant.
All these instruments should be checked in place. The calibration of the receiver should
be checked at the same time.

iv) Alarms and Interlocks:

All alarms, auto start and cut off system should be checked by simulating the alarm
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conditions to ensure that the signal activated corresponds to the proper alarm
mechanism in the unit.
Similarly, all the interlocks should be checked by simulating the conditions as done
above.

v) Control Valves:

Stroke checking and checking of their fail safe positions should be done for all the
control valves.

vi) Unit Shut Down System:

The entire Emergency Shut Down (ESD) system of the unit should be checked
thoroughly. All shut down valves (SDVs) should be checked for tripping by de energising
the corresponding solenoid valves from the control room.

3.8 TIGHTNESS TEST/ VACUUIM TEST

The purpose of this test is to check the tightness of flanges. Joints, manholes etc. for
systems handling gas or liquid at a pressure higher than atmospheric. Testing is done
with air using soap solution for leak detection. The stepwise procedure for leak testing is
given below.

1. Ensure that the system which is to be tested is isolated from rest of the
system.

2. Take the system gradually to a pressure of 1-1.5 kg/cm 2g or the operating

pressure whichever is lower. Check all flanges. joints, manholes etc. for any
leakage with soap solution.

3. If the operating pressure of the system is more than 1.5 kg/cm 2g slowly
raise the pressure of the system at the rate of 1.0 kg/cm2 at a time. After
each stage check for leaks using soap solution. Attend the leaks if any.

4. Further testing for pressure higher than 7.0 kg/cm2g for gas systems is
done when feed gas is taken into the system, keeping in mind that
pressurization is at a slow rate and in stages.

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3.9 DRYING. PURGING AND 1l\'ERTISING

a) Drying:

Systems that have been water flushed may need complete drying before hydrocarbon
can be taken in. This operation becomes critical due to problem of hydrate formation at
high pressures and low temperatures

If slugs of water are to be removed, the system is initially blown hard with a strong flow
of plant air. Necessary temporary connections for inlet and outlet are to be made. Since
plant air can give rise to 7 kg/cm 2g pressure on blocked out conditions. care should be
taken to make sure there is no inadvertent closing of valves during air blowing. When
major port on of water has been removed. the air drying can be continued with
instrument air to make the system completely dry.

It is advisable to take small systems at a time and after drying, these are to be isolated
and kept sealed with nitrogen.

b) Purging and Inertising:

Before feeding any hydrocarbon to the plant all piping and vessels' are to be purged out
free of air. If air is allowed to remain it will form an explosive mixture with the
hydrocarbon and will be a potential hazard of explosion. Hence it is imperative to
remove oxygen (Air) from the system. Normal criteria is to bring down oxygen content to
less than 1 % .Since all the hydrocarbon lines in the unit are not designed for steam
condition it is considered that the unit would be inertised using nitrogen.

The system is now purged continuously from one end to the other with unidirectional
flow that can sweep off all the air in the system. Normal requirement of nitrogen would
be 3-5 times the system volume. System designed for higher pressure can also be
purged by pressurizing and depress ring with nitrogen. for this. the system is
pressurized with N2 up to about 3 Kg/cm 2 and then depressurized through a high point
vent which will establish an unidirectional now. This procedure is repeated for a few
times so that whole system is completely inertised with N 2.

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After purging and inert sing the systems. all the flanges where blind removal has been
done should be checked for leaks. PSVs should be checked for leaks through their
seats.

Hydrocarbon is to be taken into the system while the system is still under slight positive
nitrogen pressure. The residual N2 inside the system can be replaced with hydrocarbon
gas by pressurizing the system with HC gas and depressurizing it through flare. At the
time of hydrocarbon charging the hydrocarbon-nitrogen mixture shall be initially routed
to flare to drive out all the nitrogen from the system.

3.10. CHEMICAL CLEANING OF DEA SYSTEM

In addition to water flushing and air blowing. chemical cleaning is required for the lines
vessels and columns in the DEA circuit. Hot solution of 2 % sodium carbonate is
circulated through the system for carrying out chemical cleaning. The filter package is
also required to be cleaned but filters must not have their internals installed during
chemical cleaning.

The procedure requires circulation rate of 2 % sodium carbonate solution near to normal
amine flow rate. To achieve this. Amine Charge Pumps would be utilised for transferring
the solution from amine storage tanks to the absorber. How ever. to maintain the normal
flow rates from Absorber to Amine Flash Drum (VV-102) the following steps are required
to be carried out.

1. LV-I06 and LV-206 are replaced with spool pieces so as to avoid a high
pressure drop across the valves for this operation.

2. Absorbers and Rich Amine Flash Drum are pressurised with nitrogen upto
6.0 kg/cm2G and 4.5 kg/2m" respectively.

The stepwise procedure for DEA cleaning is outlined below.

Pre-requisites

a. Absorber bottom level control valves (LV-oI06 & LV-0206) are replaced with 6"

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spool pieces. HP Absorber columns (CC-101 A/B) are pressurized up to about

6.0 kg/cm2g with inert gas (nitrogen).

b. Rich Amine Flash Drum and Regenerator column are also pressurized with
nitrogen up to about 4.5 kg/cm2G and 0.9 kg/cm2G to maintain carbonate
solution circulation through the unit.

c. All the PSVs are lined up either to flare or to atmosphere. as shown in the P&lDs
and unit flare KO Drum vent is open to atmosphere.

d. The steam-condensate. system for the Regenerator Reboilers is commissioned.

e. Process water generation system is commissioned

f. Amine storage tank is filled to appx. 75% level with process water through
3/4".WP-06-1052-A3A.

Line-up

g. The amine circuit is lined up as per sketch 3.1 (with spool pieces instead of
Absorber bottom level control valves LV-OI06 & 0206). The open/close positions
of various SDVs and control valves are shown in the figure.

Procedure

h. Two of the Amine Charge Pumps (PA-IOI A/B) are started. one by one. for
circulating process water through the DEA system. Initially. the Absorbers (CC-
IOI A/B) are bypassed and process water is routed through the Absorber bypass
line into the Rich Amine Flash Drum (VV -102). The flash drum is pressurized
with nitrogen pressure to push process water up to the top tray of Regenerator
column through the Rich/Lean Amine Exchanger (EE-IO 1 A/B/C). From the
Regenerator bottom water is flown under gravity back to the Amine Storage Tank
through Rich/Lean Amine Exchanger (EE-101 A/B/C) and Lean Amine Cooler
(EE-I04 A/B/C).
i. Continue this rinsing procedure for a sufficient time period (about 2 hrs).

j. After rinsing is complete, charge pumps are tripped and water drained from the
entire system. Process water is refilled into the Amine Storage Tank up to about
75 % level.

k. The Absorbers are now taken in line by opening the amine inlet FVs and amine
outlet SDVs. The line up is depicted in sketch 3.2. The Absorbers are rinsed
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along with rest of the system for a sufficient time period.

l. After rinsing is complete, charge pumps are tripped and water drained from the
entire system. Process water is refilled into the Amine Storage Tank up to about
75% level.

m. IWater circulation is initiated by starting two of the Amine Charge Pumps.

Absorber columns are bypassed while rest of the system is taken in line (as
shown in sketch 3.1).

n. When water circulation is established. Sodium carbonate is added to the storage

tank so as to prepare a 2% (w/w) solution in the tank. It should be ensured that
sodium carbonate is completely dissolved.

o. Using the Regenerator Reboilers (EE-102 A/B/C/D) the solution is heated to

about 100°C. The solution is circulated through the system with the Absorber
columns bypassed. in the same way as process water is circulated before. This
is continued for about 8-10 hours.

p. Similarly. Amine Filter Pump (PA-I07) is started and hot solution is circulated
through the filters (without internals) for about 4-5 hours.

q. After circulating for 8-10 hours, the solution is drained completely from all lines,
vessels, pumps and tank in the DEA system. The vents on vessels are to be
opened prior to draining to prevent vacuum formation in the system.

r. TT-101 is refilled once again with process water up to 75% level and the charge
pumps are started to establish circulation. Once again sodium carbonate is
added to the tank so as prepare a 2 % solution.

s. The Absorbers columns are taken in line by opening the amine inlet FV and the
amine outlet SDV in a similar way as done in case of process water circulation.
Refer sketch 3.2.

t. The solution is heated up to 100.C using reboilers and circulation is maintained

with Absorbers in line, for about 8-10 hours.

u. The solution is entirely drained from the DEA circuit.

v. After draining is complete. the storage tank is refilled with the process water and
the circulation is re-established as previously described. with Absorbers in line.
The circulating water is heated to about 80-1OO.C using reboilers.

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w. During water circulation. all the low point drains in the circuit are to be flushed to
ensure that there is no blockage due to sludge or solids.

x. The water being drained is tested for impurities. Sodium carbonate content and
pH. The cleaning is considered to be complete when sodium carbonate content
in the water is less than 0.1 % , pH is below 8.5 and when the circulation has
lasted for at least 10 hours. In case. the content (If sodium carbonate is more
than 0.1 %, the water flushing procedure is repeated once again.

y. After cleaning is complete, water is entirely drained from the system, drain valves
closed and the system is prepared for loading chemicals and other start up
operations.

3.11 LOADING OFCHEMICALS/PACKINGS AND FILTER MEDIA

a) Column Packing

Column packings are to be loaded into the Water Wash Column, CC-103. Following
things should be ensured before column packing is commenced.

i) Thoroughly clean and flush the column.

ii) Check that the bed supports (Multi Beam supports/Grid supports) are properly
fixed in place free from debris and have no holes.
iii) Air leak test of the column bas been done and leakages repaired Particularly the
nozzles and connections in the packed bed portion of columns.
iv) All packing have been degreased and cleaned.

Packing Loading Procedure

The first lot of packing' should be carefully and slowly dumped on support plate and
levelled by hand while standing on the support plate. The support plate is to be covered
to a depth of 200-300 mm by this method. This assures that packing will not get
damaged by dropping directly into support plate. Ensure that assembly of support plate
is $8tisfactory and no packing is falling down from the support plate. After the top of
packing is within 2.0 meter or less of column Manhole. packings may be dumped slowly
till the bed is height is reached. It should be ensured that packings remain horizontal
( i.e. level inclination within 30° or less)..

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As packing height reaches final elevation packing should be levelled carefully. Level off
the top of packed bed by lightly tramping on a wooden plank placed on packing. Ensure
to remove wooden plank immediately after use. Packing should be levelled with top of
the ledge.

It should be ensured that packings are touching bed limiter and there should not be any
empty space between the packing and bed limiter.

As far as possible walking on or excessive handling of packing should be avoided. It is

best to place sections of bed limiter into the tower and stand on these sections while
bed is assembled It absolutely necessary. a wooden plank to be placed for stepping on
the packings.

b) Filter Media

Loading of the filter media - for various filters shall be done as per the procedures
recommended by the respective Filter Package vendors.

c) Antifoaming Agent

Antifoam from drums is unloaded into Antifoam surge Drum (VV-108). During unloading
process water is also flown into the tank so as to prepare 3% (by weight) aqueous
solution of the antifoaming agent. Distribution line valves are kept closed and the
agitator is switched on during the unloading process.

After sufficient mixing the agent is ready for injection.

d) Diethanol Amine
DEA is loaded after chemical cleaning of the DEA System is complete.
Pure DEA from the drums is unloaded into Amine Preparation Pit (JX-105). Process
Water is flown into the pit so as to prepare aqueous DEA solution of concentration 40%
(Wt/\\1). Steam is sparged from steam nozzles provided at the bottom of the pit. to aid
proper mixing of the solution. The solution is then flown into Amine Sump Drum (VV -

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105) under gravity and then pumped into Amine Storage Tank (IT-101) with the help of
PA-105

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SECTION - 4

PLANT OPERATING PROCEDURES

4.1 GENERAL

This section covers operating procedures for start up, normal operation and shutdown

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of the process facilities. Steps to be taken during emergencies such as power failure,
instrument air failure and cooling water failure are also covered.

The most critical periods in operation are those of start-up and shut down. It is then, that
the hazardous possibilities of fire and explosions are the greatest. One of the hazards
most frequently encountered during start up and shutdown of units is accidental mixing
of air and hydrocarbons to form an explosive mixture. Other hazards primarily
associated with start-up/shutdown are pressure, vacuum. thermal and mechanical
shocks. These can result in fires. Explosions, destructive pressure,
surges and other damages to the unit as well as injury to personnel.

It is essential that the operations crew realise the potential hazards involved in the start
up and shut down operations and eliminate them by diligently following the
Procedures outlined below.

4.2 INITIAI. START-UP

4.2.1 Start up Preparation

Prior to actual commissioning of the unit. it should be established that all preparatory
works have been successfully completed and all equipments are ready to function.

Ensure that:

1. The blinds in product line battery limit valves have been reversed/removed
with proper entry in the blind register which will also give the correct position of
all blinds during start-up/shut down.

2. All vessels piping and equipment have been flushed and dried. leak tested and
ready for service.

3. All machineries such as motors, pumps, etc. have undergone functional tests
successfully.

4. All instruments have been calibrated and checked and controls are on manual.

5. All safety valves are in position after setting and testing. Isolation valves will be
left in lock open position with blinds in bypasses removed. Spare valves if any
should be kept isolated.

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6. Ensure that vents of the flare KO Drum is open to atmosphere.

7. Utility headers have been commissioned.

8. Fire hydrant system is energised and ready..

9. PW. OWS amine drain and sewer systems are ready.

10. Flare and blow down system is purged with nitrogen and is in operable
condition.

11. All pre-commissioning activities including LP leak test have been completed
and unit is under positive pressure of nitrogen. The nitrogen pressure in
various columns and vessels should be more than 0.5 kg/cm 2G but less than
the respective operating pressures.

12. The related units are informed of plant start up plan and good communication
is established with them.

13. Plant electrical systems are ready. Instrument power is available for main and
local control panels. Plant communication systems are ready.

14. Chemical cleaning of the DEA circuit is complete.

15. Inert gas blanketing system for Amine Storage Tank and Amine Sump Drum is
commissioned.

16. Antifoaming agent is charged into Antifoam Surge Drum.

17. The filtration package has been prepared as per the instructions given in the
vendor's operating manual and inlet and outlet valves to and from the filtration
package are closed.

18. Column packings and filter medias are installed.

4.2.2 Overall Start-up Scheme

The commissioning sequence is started after feed gas charging and high pressure leak
testing of the gas circuit is over.

Freshly prepared DEA solution. 40% (VIV) is taken into Amine Storage Tank (TT-101)
up to the maximum possible level. If required steam is introduced into the heating coils
of TT-101 to raise the amine solution temperature to near the required operating

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condition of 15° above the expected feed gas temperature. One of the Amine Charge
Pumps (PA-101 A/B/C) is started and DEA solution is routed to one of the HP Absorber
columns (CC-101). Through FV-0103 at a rate of 200 m3/hr with its bottom SDV-0201
closed. When level builds up in CC-101A bottom, Open SDV-0201 and route the
solution to Rich Amine Flash Drum (VV-102) which is already under nitrogen pressure.
Before routing the solution to VV-102 it should be ensured that SDV-0301 is in closed
position. When level builds up in the Flash Drum, open SDV- 0301 and route the
solution to the top of Regenerator Column with its bottom SDV closed. From bottom
most tray of the column the solution will flow into the Regenerator reboilers. EE-102
A/B/C/D.and then into the column bottom. As level builds up in the column bottom. SDV-
0401 is opened and solution is routed back to TT-101. In a similar way DEA circulation
is established through the other Absorber column by starting second Amine Charge
Pump.

LP steam is introduced into the Regenerator Reboilers to heat the DEA solution. At the
same time, cooling water flow is started through the Lean Gas Cooler (EE-I04) and the
Regenerator Overhead Condenser (EE-103).

With the help of Water Wash Booster Pumps (PA-I06A/B) process water is introduced
into the Water Wash column (CC-103). When water level builds up on draw off tray of
the column water circulation is established with the help of Sweet
Gas Water Wash Pumps (PA-101 A/B).

Feed gas is lined up to the Absorber Column by opening SDV-0101. Open Absorber
outlet SDV and introduce gas into the bottom of CC-103. The feed gas flow rate is
gradually increased through one of the HP Absorbers and taken up to 9Sooo Nm3fhr by
manipulating the gas outlet FVs on the Absorber Columns. Similar procedure is to be
followed for establishing the flow through the second Absorber.

Initially the treated gas at the outlet of CC-103 is routed. Through EE-105 to the lean
Gas Header in the C2-C3 unit. The treated gas composition is analyzed and when found
to meet required specifications it is routed to the (C 2-C3) plant.

The start-up procedure can be broken down into various steps as follows;
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a. Charging and filtration of DEA solution

b. Commissioning of GSU flare system
c. Pressurization of GSU with feed gas and nitrogen
d. Establishing DEA circulation
e. Establishing process water circulation through Sweet Gas Water Wash Column
f. Regenerator column start-up
g. Feed gas line up

4.2.3 Detailed start-up procedure

a) Charging and filtration or DRA solution

Before charging the DEA solution, the amine filtration package would be commissioned
and prepared to receive amine for filtration as per vendor's instructions
(Refer Section 6).

Ensure that Amine Storage tank, IT-101 and Amine Sump Drum. VV-I05 is drained of all
water and purged with nitrogen. Nitrogen blanketing of TT-101and VV-I05 should be
brought into operation. PCV-501 to be set at 50 mm WC PCV-502 to be set at 150mm
WC.

Amine Filter system to be also kept purged with nitrogen. Amine shall be filled into the
Amine Tank as per the following sequence.

1. Open 2" vent on Amine Preparation pit, JX-105. Pure DEA drums should be unloaded
into the pit. 10 drums of DEA can be unloaded simultaneous. (Drum may have to be
heated with steam during winters to overcome freezing of DEA at temperatures less
than 27.C).

2. Now add process water into the Amine preparation pit through 3"-WP-0610501-A9A.
The flow can be regulated with globe valve and quantity of process water added can be
ascertained through FQ-501. After the required amount of process water has been
added for a 40 % (w/w) solution of DEA, sparing of steam should be done in the Amine
Preparation Pit to aid mixing.
For this. Steam hose has to be connected with the steam connection provided in the
Amine Preparation Pit.
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3. From Amine Preparation Pit the DEA solution can be transferred to Amine Sump Drum,
VV-105 by operating the valve on the inter connection line. (This valve is operable from
grade).

4. After appreciable level is established in Amine Sump Drum start Amine Sump Pump on
manual and recirculate through JX-105. After circulating for some time, line up to the
Amine Storage Tank.

5. Prime amine filtrations pump PA-107 and establish circulation through Amine Filter
Package back to the tank as per filter package vendor's instructions.

6. FV-0601 should be set at 7m3/hr and FV-0602 should be set at 65m 3 /hr.

7. Preparation of amine solution transfer from Amine Sump Drum and filtration to be
continued till the

a) Level in the Amine Storage Tank has been established at 70%.

b) Amine solution in the tank has gone through cycle of filtration.

8. Ensuring that 00 inventory of amine solution is left in the Amine Sump Drum. put PA-
IOS on auto start/stop mode.

9. Analyze amine samples from the sample points and make correction as required. If
required. the concentration of DEA can be increased by adding concentrated solution
through Amine Sump Drum. High concentration of DEA can be corrected by addition of
process water directly into the Amine Storage Tank.

b) Commissioning of GSU Flare system

It is expected that plant flare header and the flare stack shall be commissioned along
with charging of gas to (C2/C3) unit.
As GSU and (C2/C3) recovery facilities are located in the same unit area it would be
required to inertise (C2/C3) unit. GSU and the common flare header, Simultaneously
only after doing this, gas charging in the Gas Sweetening Unit will be possible.

1. Feed Gas charging can be done in the following sequence:

2. lnertise GSU and C2/C3 unit as per the procedure given in section 3.9.

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3. Flare header should be purged with nitrogen through PSV bypasses. Inertisation
of offsite flare system to be done as per procedure described in the Utilities and
Offsite Manual.

4. Commission start-up fuel gas system in the C2/C3, unit section as per the
instructions given in C2/C3 Operating Manual. Ensure that all the PSVs are in line
before commissioning the start-up Fuel Gas System.

5. Flare stack pilot burner to be commissioned as per the procedure in Utilities and
Offsite Operating Manual. '

6. End purging of the flare header (40"-FL-08-S101-A4A) should be started.

7. GSU and C2/C3 flare system is now commissioned and feed gas charging in the
GSU can be undertaken.

c) Pressurisation of GSU with feed gas and nitrogen

Before feed gas can be charged to the GSU unit the lean gas pipeline would be kept
charged and under operation through the plant bypass. The lean gas pressure should
be maintained near to 50 kg/cm 2a with help of PCV-2506. Feed gas pressure to the
GSU should be 50 kg/cm2g with help of PIC/PV-2502.

Raw gas and sweet gas system should be pressurised with Feed Gas up to Battery
Limit with feed gas. Amine Flash Drum and Regenerator with associated piping should
be pressurised with nitrogen. The pressurisation should be carried out in the following
sequence.

1. Open SDV-0101/0206 on raw gas line to absorbers.

2. Open FV-0102, FV-0202, SDV-0204, 0205 on the sweet gas line from absorber.

3. Close SDV-0102, 0201 and LV-OI06. 0206 on the rich amine line from absorbers
to flash drum.

4. Close FV-0103 and FV-0203 on the lean amine line to the absorber.

5. SDV-0202 and LV-0202 on the water wash column bottom liquid outlet to be

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closed.

6. Battery limit valve and its bypass on the sweet gas line 24"-P-06-10201-DIA
should be in closed position but the spectacle blinds before these valves should
be reversed.

7. All the drain valves to the Amine Sump Drum should be closed.

8. Open 2" bypass slowly and pressurized raw gas sweet gas system up to 10.0
kg/cm2a. Check for leakages and attend accordingly.

9. Slowly raise the raw gas/sweet gas system pressure to 50 kg/cm2a in steps of 10
kg/cm2. Check for leakages at each stage and attend accordingly.

10. Close isolation valve upstream of PV -0302 A on the fuel gas line from VV -102
and put PIC-0302 on auto at 5.0 kg/cm 2g.

11. Close LV-0301 on manual (SDV-0301 is closed on interlock).

12. Pressurise VV-102 with inert gas through line no. 3"-14-06-1301-A3A up to 5.0
kg/cm2g.

13. Close LV-0408 on manual (SDV-0401 is closed on interlock).

14. Set PIC-0401 on auto at 0.8 kg/cm2g.

15. The Regenerator column and associated system should be pressurized up to 0.8
kg/cm2g through 3".IG-06-10401-A3A.

d) Establishing DEA circulation through the Absorbers

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Ensure that drain valves and SDV-OlO2/0201 at the bottom ofC-101 AIB are in closed
position. Also ensure that SDV-0101/0206 and SDV-0204/0205 are in closed position.
LV -0106/0206 should be closed on manual. Pressure in the Absorber should be 5-10
kg/cm2 below normal operating pressure.

Also ensure the following.

a. DEA Storage Tank level is about 70% of the total and concentration as specified.

b. HP Absorber pressure is about 5-10 kg/cm 2 below normal operating.

c. Rich Amine Flash Drum pressure is near to its operating pressure.

d. Regenerator pressure is near to its operating pressure.

1. Line up the system as follows:

TT-101------> PA-101 A------> FV-OI03-----> CC-101 A

2. Initially PA-101 A/B/C should be in manual mode.

3. Bypass trip interlocks I-1, I-2, I-3, I-4.

4. Start one of the Amine Charge pumps and operate on minimum flow.

5. Gradually open FV-0103 in manual mode and take amine flow into CC-101 A. As the
liquid level is established on trays, the pressure in the column will tend to increase.
Monitor pressure increase and if required vent through PSV bypass.

6. Ensure that drains valves and SDV -030 I at the bottom of VV -102 are in closed
position, and the vessel is under nitrogen pressure.

7. Ensure that isolation valves of PSV -0305 A&B are locked open.

8. Isolate PV-0302 A by closing its upstream isolation valve. PIC-0302 is set on auto at 5.5

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kg/cm2g and controlling through PV0302 B.

9. As level builds up above LSLL-0104 the SDV-0102 is reset to open position and is
opened. Start amine solution flow to Amine Flash Drum through LV-0106. Gradually
increase the flow rate by opening LV-0106.

10. As the level builds up in VV-102. LALL-0301 will disappear. Keeping LV-0304 closed on
manual. Reset SDV-0301 to open.

11. Ensure that CC-102 is purged with nitrogen and drain valves and SDV-0401 at the
bottom of CC-102 are in closed position. Also that drain valves of EE102 A/B/C/D are in
closed position. CC-I02 is pressurised with nitrogen to a pressure of 0.9 kg/cm 2. PIC-
0401 should be taken on auto and set at 0.9 kg/cm 2g.

12. Line up as follows:

VV -102---------> EE-101 A&B----------------> LV -0304----- > CC-102

----------àEE-102 A/B/C/D

13. As level builds up in VV-102 and when SDV-0301 has been opened. Start and gradually
increase OEA flow into the Regenerator Column. by manipulating LV-0304. When DEA
solution overflows from EE-I02 A/B/C/D level will start building up in the CC-102 bottom.

14. Now line up as follows:

CC-102-------> EE-I01 A&C------- > EE-I04 A&B---- --> IT-101

15. When the level builds up in CC-I02 bottom above LSLL-0406level it will be possible to
reset SOV-0401 to open.

16. When sufficient level builds up in the CC-102 bottom open SDV -0401 to take DEA
solution back into TT-101 through LV-0408.

17. Monitor the liquid level in CC-101A. If the level remains in the operating range for

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sufficient time put LlC-0106 in auto mode. Similarly when the level in VV -102 and at the
CC-102 bottom stabilizes in the operating range put LIC-0304 and LIC-0408 in auto
mode. Also put FIC-0103 in auto mode.

18. Line up as follows:

TT-101 -----> PA-101 B-------------> FV-0203------- > CC-I01B

19. Start the second Amine Charge Pump (PA-101B) and operate on minimum flow.

20. Gradually open FV-0203 in manual mode and take amine flow into CC-101B.

21. As level builds up above LSLL-0204, the SDV -0201 is reset to open position and is
opened. Gradually increase amine flow to the flash drum by manipulating LV-0206 in
manual mode.

22. When level stabilizes in CC-101 B bottom put LIC-0206 & FIC-0203 in auto mode.

23. After DEA circulation through the Absorbers is well established put the pumps PA-101
A/B/C in auto mode and adjust the Selector Switch, SS-0501 for the standby pump, PA-
IOIC.

The following parameters are to be carefully monitored while establishing DEA

circulation through the circuit.

LI-0502 TT-101level
LI-0508 TT -10 I level
FlC-0103 Lean Amine flow to CC-101A
LlC-0I06 Amine level at CC - 101 A bottom
PI-0I04 Pressure at CC-101A top
LlC -0304 VV -102 level
PIC-0302 VV - I 02 pressure
LlC-0408 CC-102 bottom level

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PI-0405 CC-102 top pressure

FIC-0203 Lean Amine flow to CC-101B
LIC-0206 CC-101B bottom level

e) Establishing process water circulation through Water Wash Column

1. Ensure that drain valves and SDV-0202 at the bottom of CC-103 are in closed
position and PSV isolation valves are locked open.

2. Ensure that LV-0202 on the purge line is in closed position. Also that SDV0202 is
in closed position.

3. Start one of the Water Wash Booster Pumps (PA-I06 A or B).

4. As Sufficient water level builds up on the draw off tray line up as follows:

CC-103 ---> PA-I03 (A or B)------ > CC-I03

5. Stop the running Booster Pump and start one of the Sweet Gas Water Wash
Pumps. PA-l03 (A or B).

6. Gradually increase the circulating water flow rate. Put AC-0204 in auto mode
near to its operating range of 25 m3) /hr.

The following parameters are to be continuously monitored during start-up of the Sweet
Gas Water Wash Column.

FI-Q20l Make-up water to CC-103

LIC-0202 CC-103 draw off tray level
FlC-204 Recirculation water flow rate
f) Regenerator column start-up

1. Ensure that drain valves of VV-103, VV-104 are in closed position.

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2. Start cooling water flow through the Condensate Cooler (EE-107), LP Condensate
Cooler (EE-106) and the .Regenerator Overhead Condenser (EE103).

3. Start cooling water flow through EE-104 A&B (Whichever are in line) before steam
start up.

4. Line up the LP steam circuit as follows:

JX -101--------> EE-102 A/B/C/D---------> VV -104

5. Gradually open FV -0402 manually, to route LP steam into the Regenerator Reboiler
EE-102 AIBIC/D. Steam condenses as it exchanges heat with DEA solution.
Condensate formed flows into VV -104.

6. As sufficient level builds up in VV-I04, line up the system as follows:

VV-104 ---> PA-t04 A or B ------> EE-107-------> FV-0406------>

LP Cond Header ----------> TV-0408------>JX-101----->

EE-106 --------- > Process Water Header

7. Start one of the Condensate Pump (PA-I04 A/B).

8. Gradually open TV -0408 and bring the desuperheater outlet steam temperature to its
operating value (145°C). When the temperature stabilizes put TIC-0408

9. Operate FV-0406 on manual to maintain level in VV-104. When level in VVlO4 stabilizes
in the normal operating range put LIC-0409/FIC-0406 in auto mode.

10. PIC-0401 is in auto mode and set at 0.9 kg/cm 2.

11. As vapours start condensing in EE-103 level will build up in VV-I03. When sufficient
level builds up in VV -103 and as soon as LALL-0402 goes off, line up the reflux system
as follows:

VV-I03--------> PA-103 A or B------ > FV-0403

12. Start one of the reflux pumps, PA-103 (A or B) and slowly increase the reflux flow by
manually operating FV-0403.

13. When VV-103 level stabilizes in the operating range put LIC/AC-0403 in auto mode.

14. When CC-102 top temperature stabilizes to its operating value put TIC/FIC0-402 in auto
mode (at 97C).
The following parameters are to be carefully monitored during start-up of the
Regenerator column.

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FIC-0402 Steam flow to reboilers

TIC-0408 VV-I04 level
FIC-0406 Condensate flow
PI-0407 VV -104 pressure
TI-0405 Reboiler vapour outlet temperature
TI-0406 Reboiler vapour outlet temperature
TIC-0402 CC-102 top temperature
TI -0401 Reflux Drum top temperature
PIC-0401 Reflux drum pressure
LIC-0403 Reflux drum level
TI -0403 Lean amine outlet temperature
TIC-0306 Lean amine temperature downstream
of EE-1 04.
LIC-0408 CC-I02 bottom level

TI-0503 . Amine tank outlet temperature

G) Feed Gas line up

1. When DEA solution temperature down stream of EE-I04 A/B/C stabilizes to its operating
point (4S.C) put TIC-0306 in auto mode.

2. Start Antifoam Injection Pump (continuous), PA-I09 to inject the agent into DEA solution.
The stroke length of the pump to be adjusted near to minimum. Pump PA-110 will be
kept lined up but will not be started.

3. Ensure that raw-gas is available at the GSU battery limit at about 52.0 kg/cm2a and
lean gas header pressure is maintained 2.0 kg/cm 2 below this value.

4. Ensure that drain valves at the bottom of VV-101 are in closed position and isolation
valves of PSV-0102 are locked open.

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5. Open 2" bypass across the battery limit valve to balance the pressure.

6. Line up as follow:

i. Battery Limit---------à VV-101-----------à CC ------à101A --------à

ii. FV0102------àCC-103--------àEE-105--------à

iii. GSU battery limit------------à Lean Gas header.

7. Open SDV-0101 & SDV-0204 through reset switch.

8. Start cooling water flow through (EE-105).

9. Gradually increase the flow through the Absorber Column (CC-101A) by opening FV-
0102 to approximately 94 tons/hr (120000 Nm31hr).

10. When column operation is satisfactorily stabilized, put FIC-0102 auto mode.

11. Now line up the second Absorber Column as follows.

i. VV -101 > CC-1O I B -------> FV -0202 ------ > CC-103

12. Open SDV-0206 and SDV-0205.

13. Gradually, increase the flow through the Absorber Column (CC-101 B), to approximately
equal to that of CC-101 A by opening FV -0202.

14. When column operation is satisfactorily stabilized at its operating point. put FIC-0202 in
auto mode.

15. Line up as follows:

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i. CC -103 ---- > LV -0202------> VV -102

16. Start one of the Water Wash Booster Pumps (PA-I06 A or B) and adjust the stroke
length so that the make up water flow rate is 1 to 2 m3/hr.

17. Gradually, open LV-0202 to sent a purge stream into VV-102. When the liquid
i. Level on the draw-off tray stabilizes put LlC-0202 in auto mode.

18. As soon as LAH-021O is activated manually drain the contents of CC-103 bottom into
VV-102.

19. The treated gas downstream of CC-IOI A & Band CC-I03 should be analyzed for CO 2.
Raw gas & treated gas samples should be collected from the following locations and
sent for testi!1g. The locations are:

1. Upstream of VV-101
2. Downstream of CC-101 A & B
3. Downstream of CC-103

20. Collect rich amine and lean amine samples from the sample points provided and send
them for testing.

21. When treated gas is reported to have CO: content less than 50 ppm(v/v) it is ready to be
routed to the C2-C) unit. In case specifications are not met check Lean Amine
concentration and quality and Lean Amine flow rate.

The following parameters are to be monitored during feed gas line up.

TI-0503 Amine tank outlet temperature

TI-OI04 Feed gas inlet temperature
TDI-OI04 Differential temperature
PI-O102 Feed gas pressure

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LI-O102 VV -101 level

PI-OI04 CC -101 A top pressure
FIC-0102 Feed gas now through CC-101A
PDI-0105 CC-101A differential pressure
PI-0208 CC -103 top pressure
TI-0204 CC-103 top temperature
PDT-0213 CC-I03 differential pressure
PI-0204 CC-101B top pressure
FIC-0202 Feed gas flow through CC-101B
PDI-0205 CC-101 B differential pressure

Rich amine solution will contain absorbed hydrocarbon gases which will get flashed in
the Amine Flash Drum. These can be now routed to the fuel gas system. Ensure that
electrical tracing for the fuel gas line is 'ON'. PIC-0302 is already set at 5.5 kg/cm 2 g.
Now open isolation valve to PV-302A. The flashed vapour will get lined up to the fuel
gas header.

Following parameters are to be carefully monitored with respect to Rich Amine Flash
Drum after feed gas line up.

PIC-0302 VV -102 pressure

TI -0301 VV -102 top outlet temperature
FI-0301 Fuel gas flow rate
LIC -0304 VV -102 level

Acid gas generation in the Regenerator will now start. Maintain Regenerator column
bottom temperature near to 128°C and column top temperature near to 100°C. Do not
exceed the column bottom temperature more than 130°C to avoid amine degradation.
Acid gas samples should be analyzed from the sample point upstream of PV-401.

4.3 NORMAL OPERATION

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4.3.1 Normal Start-up Procedure

During the course of operation of the plant, it will be necessary to start-up all or portions
of the unit after shutting down for various reasons.After each maintenance turnaround
the plant will have to be brought up from a depressurized ambient temperature state.
Portions of the unit will have to be restarted after a shut down due to a mechanical
malfunction or another operating problem. None of these reasons will dictate a start-up
sequence as time-consuming as the initial start-up procedure described above. The
following procedure is recommended with the understanding that the operator judgment
should dictate, according to the extent of the shut down. After any shut-down, the unit
should be checked prior to initiating restart operations.

The following procedure assumes that the plant has been shut down for a short time to
allow maintenance of a piece of equipment. It is assumed that the unit is ready for start -
up (purged of air. utilities available. all controls operating and pressure established to
normal operating conditions).

1. Before restarting the amine circulation, the filtration package should be commissioned.
a level should be established in the sump drum. and circulation should be started
through the tilters to the tank via the amine filter pump.

2. A flow of lean amine can now be established from the tank to the Absorbers one by
one. the Rich Amine Flash Drum and the Regenerator, via the lean Amine Charge
Pumps. The regenerator shall be commissioned with Temperatures brought to
normal operating values.

3. At this point. a flow of feed gas shall be established to one of the two Absorbers. The
amine flow should be brought up to the design rate.

4. Slowly increase the flow of feed gas at about 30 to 40 % of design and routing the
treated gas to the lean gas header.

5. Similarly start feed gas flow through the second Absorber. It is preferable to keep
process parameters same in both the Absorbers
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6 Check the treated gas quality (CO2 specification). Modify process parameters as
required to meet out gas specification (CO2), Increase lean amine flow rate adjust
steam rate to regeneration reboiler. Increase lean amine to Absorber temperature etc as
required. Commission the regenerator overhead temperature controller.

7 Slowly increase the throughput of the unit up to the design capacity.

8 After adjusting the steam rates to the regenerator reboilers commission the regenerator
overhead temperature control.

4.3.2 Normal Operation Parameters

Following operating parameters will be maintained during normal running of the unit at rated
throughput. These operating parameters are based 00 design data and may differ from actual
conditions in the plant due to changes in the feed rates. feed compositions and other
unforeseen eventualities. Only experience in operation of the unit will determine the optimum
conditions.

Particulars Measuring Unit Value

Instrument
Raw Feed Gas

1. B/L pressure PI-loo2 kg/cm2a 52.0

2. B/L temperature TI -01 04 °C 30.0

3. Temp. diff. between TDI-0104 °C 15.0

feed gas & lean amine

HP Absorber Columns

1. CC-101A to pressure PI-Ol04 kg/cm2a 51.4

2. Treated gas flow from FIC-OI02 Kg/hr 187300

CC-l01A

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Particulars Measuring Unit Value

Instrument

3. CC-101A bottom temp. TI-0103 °C 71.4

4. CC-IOIB top pressure PI-0204 kg/cm2a 51.4

5. Treated gas flow from FIC-0202 kg/hr

CC-101B

6. CC-IOIB bottom temp. TI-0203 °C 71.4

..

7. Lean amine flow to FIC-OI03 m3/hr 363

CC-IOIB

8. Lean amine flow to RC-0203 m3/hr 363

CC-IOIB

9. Differential press PDI-OIOS kg/cm2 0.3

across CC -10 1 A

10. Differential press. PDI-020S kg/cm2 0.3

across CC-101B

Water Wash Column & Sweet Gas to B/L

1. Make up water to CC-103 A-0201 M3 /hr 2.0

2. Recirculation flow FIC-0204 M3 /hr 28.0

3. Purge stream flow FI-0205 M3/hr 2.0

4. CC-103 top pressure PI-0208 Kg/cm2a 50.3

Particulars Measuring unit Value

Instrument

5. CC-I03 to temperature TI-0204 °C 45

6. Diff. pressure across PDI-0213 Kg/cm2a 0.2

CC-103

7. Sweet gas B/L pressure PI-0202 Kg/cm2a 50.0

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8. Sweet gas B/L temp. TI -0206 °C 40.0

9. Sweet gas composition AI-0201 ppm 50

Rich Amine Flash Drum

1. Flash drum pressure PIC-0302 Kg/cm2a 6.5

2. Flash drum temperature TI-0301 °C 30.0

3. Fuel gas flow FI-0301 Kg/hr 646

.

Regenerator Column

1. Rich Amine feed temp. TI-0303 °C 110.2

2. CC -102 top pressurePI-0405 Kg/cm2a 1.9

..
3. CC-102 top temperature TIC-0402 °C 97

4. CC -102 bottom pressure PI-0409 Kg/cm2a 2.2

Particulars Measuring Unit Value

Instrument
------------------------------------------------------------------------------------------

5. Reboiler liquid inlet TI-0412 °C 126

Temperature TI-0413

6. Reboiler vapour outlet TI-0405 °C 126

Temperature TI-0406

7. CC-102 bottom temp. TI-0414 °C 126

TI-0415
TI-0416

TI-0417
TI-0403

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Regenerator Column

8. Reflux drum pressure PIC-0401 Kg/cm2a 1.6

9. Reflux drum temperature TI.040 1 °C 50.0

10. Reflux flow to CC-l 02 FI-0403 M3/hr 19.7

11. Steam flow to reboiler FIC-0402 Kg/hr 83400

12. Steam inlet temp to TIC-0408 °C 143-148

reboiler

13. Condensate flow FI-0407 M3hr - 1.9

To JX-101

14 Condensate drum tem TI-0407 °C 134-148

Particulars Measuring Unit Value

Instrument
-------------------------------------- -------------------------------------------------

15. Condensate drum press. PI-0407 Kg/cm 2a 4.0

16. Condensate flow FIC-0406 m 3/hr 9.3

17. Diff. press across CC-102 PDI-0406 Kg/cm 2 0.3

Lean Amine Storage

1 . Lean amine inlet temp. TIC-0306 °C 45

to TT-101

2 Lean amine outlet temp. TI-0503 °C 45

from IT-101

3 Process water flow to FI-OS02 M3/hr 0.7

IT-IOI

The operating parameters for Package/Vendor items shall be taken from the

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Vendors/manufacturers literature.

4.3.3 Alarms and Trips Settings

A) Temperature Instruments

SI. Instrument Instrument Set Point

No. Tag No. Location (0C)

1. TDAL-OI04 Feed gas line 6

2. TAH-0303 CC-012 feed 115

3. TAL-0303 CC-102 feed 105

4.' TAH -0306 EE-I04 d/s 48

5. TAL-0306 EE-I04 d/s 42

6. TAH -0402 CC-I02 top 100

7. T AL-0402 CC-102 top 93

8. T AH -0405 EE-I02 A/B vapour 128

9. TAH-0406 EE-I02 C/D vapours 128

10. TAH-0408 Reboiler steam 150

11. TAH-0414 EE-I02 B bottom 128

12. TAH-0415 EE-102 C bottom 128

13. TAH-0416 EE-102 D bottom 128

14. TAH-0417 EE-102 A bottom 128

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B) Pressure Instruments

SI. Instrument Instrument Set Point

No. Tag No. Location Kg/cm2a)

1. PAH-0102 Feed gas line 5.0

2. PAL-0102 Feed gas line 50.0

3. PDAH-0105 CC-101 A 0.4*.

4. P AH-0202 GSU b/l 52.0

5. P AL-0202 GSU b/l 48.0

6. PDAH-0205 CC-101B 0.4*.

7. PDAH-0213 CC-103 0.25*

8. PAH-0302 VV -102 7.5

9. P AL-0302 VV -102 5.5

10. P AH.()4() 1 VV-I03 1.8

11. P AL.()4() 1 VV -103 1.4

12. PAL-0405 CC-102 top 1.7

13. PDAH-0406 CC-I02 0.35*

14. PAL-0409 CC-I02 bottom 2.1

15. PAL-0704 Process water header 6.5

* Unit is kg/cm2

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C) Level Instruments

SI. Instrument Tag No. Location Set Point

No. (mm)

1. LAH-0102 VV-101 650

2. LALL-OI04 (A/B) CC-101 A bottom 300

3. LAH-I06 CC-101 A bottom 3500

4. LAL-OI06 CC-IOI A bottom 1100

5. LAH-0202 CC-I03 (Water level) 4950

6. LAL-0202 CC-103 (Water level) 4650

7. LAL-0203 (A/B) CC-I03 (Amine level) 300

8. LAH-021O CC-I03 (Amine level) 2600

9. LALL-0204 (A/B) CC-IOI B bottom 300

10. LAH-0206 CC-IOI A bottom 3500

11. LAL-0206 CC-IOI A bottom 1100

12. LALL-0208 (A/B) CC-I03 (Water level) 4350

13. LALL-030 1 (A/B) VV-I02 150

14. LAHH-0302 (AlB) VV-I02 2350

15. LAH-0304 VV-I02 1950

16. LAL-0304 VV-102 750

17. LALL-0402 (A/B) VV -103 300

18. LAL-0403 VV -103 500

19. LAH-0403 VV -103 1000

20. LALL-0406 (A/B) CC-I02 bottom 300

21. LAL-0408 CC-102 bottom 700

22. LAH-0408 CC-102 bottom 3200

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23. LAH-0409 VV-104 1700

24. LAL-0409 VV-0104 700

25. LALL-0412 A/B VV-104 300

26. LAH-0502 IT-101 10400

27. LAL-0502 IT-101 2000

28. LAH-0505 (A/B) VV -105 1900

29 LAL-0506 (A/B) TT-101 100

30. LAL-0507 (NB) VV -108 300

31. LAH -0508 TT-101 10400

32. LAL-0508 TT-101 2000

33. LAL-0509 (NB) VV -105 500

34. (Note-2) LAH-0601 Filter Slush pit -200

35; (Note-3) LAH-0603 VV -106 1800

36. (Note-3) LAL-0604 VV-106 300

37. (Note-2) LAL-0606 (A/B/C) Filter slush pit

NOTE:
1. All level are from tangent line of respective vessels.
2. Level is from equipment top.
3. In precoat filter vendors scope

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D) Flow Instruments

SI. Instrument Tag No. Location Set Point

No.

1. FAH-0102 CC-0102 A top 2100

2. FAL-0102 CC-101 A top 9000

3. FAH-0103 Amine to CC-101 A 410

4. FAL-0103 Amine to CC-101 A 1700

5. FALL-0103 (A/B) Amine to CC-101 A 140

6. FAL-0201 Make up water to CC-I03 0.4

7. FAH-0202 CC-101 B top 21000

8. F AL-0202 CC-101 B top 90000

9. FAH-0203 Amine to CC-101 B 410

10. FAL-0203 Amine to CC-101 B 170

11. FALL-0203 (A/B) Amine to CC-101 B 140

12. FAH-0204 CC-103 water circulation 30

13. FAL-0204 CC-103 water circulation 13

14. FAH-0403 Reflux flow CC-102 21

I5. FAL-0403 CC-102 Reflux flow 7

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4.3.4 Relief Valve Settings

SI. Relief Valve Location Set Valve

No. Tag No kg/cm2g

1. PSV -0101 CC-101 A 58.0

2. PSV -0102 VV-101 58.0

3. PSV -0201 CC-101 B 58.0

4. PSV -0202 CC-103 58.0

5. PSV -0203 PA-106 A 63.5

6. PSV -0204 PA-106 B 63.5

7. TSV -0205 EE-105 7.5

8. TSV-030l EE-101 B 9.0

9. TSV -0302 EE-101 B 9.0

10. TSV -0306 EE-101 C 9.0

11. TSV -0303 EE-104 C 7.5

12. TSV -0304 EE-104 A 7.5

13. TSV -0307 EE-104 C 7.5

14. ,PSV -0305A/B/CI VV -102 9.0

15. PSV -0308 3" - WB-06-10301-A3A 5.0

16. PSV-0401 AID CC-102 3.5

17. PSV-0402 VV-104 6.5

18. TSV -0403 EE-103 7.5

19. PSV-0404 EE-102 A 3.5

20. PSV -0405 EE-102 B 3.5

21. PSV -0406 EE-102 C 3.5

22. PSV -0407 EE-102 D 3.5

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23. PSV -0503 PA-109 4.5

24. PSV-0504' PA-110 4.5

25. PSV -0502 VV -105 4.0

26. PVSV -0501 TT-101 150 mm (set press.)

27. PSV-0601 JX-102 8.3

28. PSV-0602 VV-107 8.3

29. PSV-0603 JX-103 8.3

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3.5 Control points during normal operation

a)Foaming.

Foaming in DEA solutions can seriously upset the vessels columns containing DEA levels. The
foaming can readily be detected by a change in level and a change in the differential pressure
across the vessel columns.

Foaming in DEA solutions can generally be attributed to suspended solids, liquid

hydrocarbons, organic acids that are naturally occurring in the inlet gas, surface active agents
confined in the compressor oils, pumps and valve lubricants, etc.

Foaming will reduce treating capacity and cause loss of solution. As a remedy for foaming,
antifoaming agent is continuously injected into the amine circuit with the help of Antifoam
Injection Pumps (continuous), PA-109. If the foaming is severe, antifoaming agent from
Antifoam Injection Pump (intermittent), PA-ll0 should be injected in addition to the continuous
flow.

Inject as much as necessary to control the foaming but do not inject more than necessary. Too
much anti-foam will sometimes encourage rather eliminate foaming.

One of the most frequent causes of foaming is the absorption of liquid hydrocarbons. This can
usually be prevented by maintaining the OEA temperature 10 to 15 -C above that of the feed
gas stream.

Other causes of foaming are the presence of degradation products or impurities carried over to
the absorber by the feed gas.

The following precautions should be observed :

 Test the amine solution regularly for colour or presence of suspended solid particles (if
any. the amine filtration system should be checked).

 Keep the reboiler temperature below 130°C to prevent amine degradation.

Considerable foaming is sometimes encountered during the unit start-up when the DEA

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system has not been thoroughly cleaned.

If once the DEA solution has been accidentally contaminated by massive arrival of solid
particles it might become necessary to shut down the unit. and clean mechanically the
equipment. The amine solution should be passed through the filtration system prior to being
returned to circulation.

b) Filtration

Observe the pressure differential across the DEA filter at 4 hour intervals and when this
differential reaches 1 to 2 bar. it is required to clean and recoat the filter.

The operation to be used after filtering cycle before back-washing will be detailed in the vendor
operating manual.

In order to reduce amine losses the amine contained in filter should be drained out. The filter
cake should be washed out with water (with a boiler feed water quality) until the remaining
DEA concentration is down to a 5% level. A usual run between precoating is 3 to 6 days.
However period will be much shorter on the initial start-up.

4.4 NORMAL SHUTDOWN

The shutdown of Gas sweetening unit is envisaged in the following cases:

 Shutdown of H.BJ. pipeline

 Shutdown of C2-C3 recovery unit
 Shutdown for maintenance purpose.

Depending upon the situation the normal shutdown can be of shorter duration or of longer
duration. The procedures for both is given below.

Short Duration Shutdown

Following steps should be carried out for taking short duration shutdown of the unit.

1. Take the gas flow control valves FV-0102 and FV-0202 in manual mode. Gradually
reduce the gas flow through both the HP Absorber columns and bring down to zero.

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2. Close the gas inlet and gas outlet SDVs of both the Absorber columns.

3. Stop water recirculation through CC-103 by tripping PA-I03. Also stop the make-up
water to CC-103 by tripping.

4. Continue DEA circulation till all the DEA solution is completely regenerated.

5. The steam to the Regenerator reboilers is reduced gradually. While reducing the steam
flow pressure in the regenerator column should be monitored. In case of the possibility
of vacuum formation inert gas should be injected into the regenerator column.

6. Stop DEA circulation after the solution has cooled down sufficiently by tripping the
amine charge pumps.

7. After the shutdown clean the amine precoat filters. This filter should not stand with cake
on it. as it may dry and become very difficult to clean

Long Duration Shutdown

Long duration shutdown is normally taken for maintenance purposes. During the shutdown
care should be taken not to admit air into the system till all hydrocarbon vapours have been
removed and the system is purged with inert gas. Utility areas must be informed about
shutdown of the plant. The stepwise procedure is given below.

1. Take the gas flow control valves FV-0102 and FV-0202 in manual mode. Gradually
reduce the gas flow through both the HP Absorber columns and bring down to zero.

2. Close the gas inlet and gas outlet SDVs of both the Absorber columns.

3. Stop water recirculation through CC-103 by tripping PA-IOJ. Also stop the make-up
water to CC-103 by tripping.

4. Continue DEA circulation till all the DEA solution is completely regenerated.

5. The steam to the Regenerator reboilers is reduced gradually. While reducing the steam
flow pressure in the regenerator column should be monitored. In case of the possibility
of vacuum formation inert gas should be injected into the regenerator column.
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6. Stop DEA circulation after the solution has cooled down sufficiently by tripping the
amine charge pumps.

7. After the shutdown clean the amine precoat filters. This filter should not stand with cake
on it as it may dry and become very difficult to clean.

8. Depressurize the gas circuit by opening the PSV bypasses on VV-101.CC-101 A/B
andCC-103.

9. Purge the gas circuit with nitrogen.

10. Pressure amine from the high pressure absorber to the Amine flash drum. Then
pressure the amine through the rich-lean amine' exchanger to the regenerator.

11. Pressure amine from the regenerator throughout he exchangers (Amine/Amine and lean
amine cooler) to the storage tank.

12. Drain all vessels, filter, pumps, reboilers, exchangers, coolers and low points in line to
the closed amine drain and then to the Amine sump drum.

13. Block in the liquid lines from all vessels after draining.

14. Transfer amine from the sump drum, using the sump pump to storage tank.

15. Depressurize the regenerator to atmosphere. This depressurization will also

depressurize the rich-lean amine exchanger.

16. After depressurization using blinds and block valves positively isolate any line or vessel
that is required to be taken for maintenance. The isolated system should be purged with
steam or inert gas followed by purging with air as a pan of preparation for entry.

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4.5 EMERGENCY SHUTDOWN

A quick shutdown of the plant may become necessary whenever emergency situations arise.
The main considerations during such situations are to overcome the potential hazards posed
by the emergency by taking a quick and safe shutdown.

Emergency can result from equipment failure, from interruption in utilities or feed supply or
from an interruption in the C2-C3 recovery unit. Certain features have been
designed in the plant to minimize the instances of emergency. These include interlocks spare
pumps, alarms etc.

Operators must be thoroughly familiar with the emergency shutdown procedures. As the nature
and degree of emergency varies with the situation a written procedure cannot cover all the
details of the problems faced during emergency. Good judgment must be exercised in such
situations.

Actions to be taken during various emergency situations are written below:

a) Loss of main Electric Power

The power supply to Auraiya complex is obtained from the Captive Power Plant. In case of
failure of power supply to the GSU following events will happen.

1. All the pumps including Amine Charge Pump will trip.

2. Stoppage of lean amine now to the Absorbers will actuate interlocks 12 and 14. In case
amine now is not restored within 30 seconds the interlocks will block the gas now
through the Absorber and will also close the FVs on the amine inlet line.

If the power supply to the unit is restored within soon time and if the C 2-C3 Recovery

Unit is in a condition to accept the sweet gas the GSU can be restarted as per the following
procedure.

1. Restart two of the Amine charge pumps. Ensure that other pumps which were running
earlier are also started

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2. Establish DEA circulation through the amine circuit and stabilize levels in the Absorbers.
Regenerator and other vessels.

3. When DEA circulation is established gradually increase gas flow through the Absorber
(as discussed in section 4.2.3).

4. Initially the treated gas is to be routed to the lean gas header in C 2-C3 unit battry limit.

5. Once the absorbers are stabilized and treated gas composition is meeting the required
specifications the sweet gas can be routed to C2/C3 unit for its start up.

In case the power supply is not restored within soon time then a shutdown should be taken as
per the procedure given below.

i) Close the following control valves.

 FV-0102/0202. Absorber top.

 LV-oI06/0206. Absorber bottom.
 LV-0304. VV-102 bottom.
 LV -0408. CC-102 bottom.
 LV-0202. CC-I03 draw off.

ii) Cut off steam flow to the regenerator reboilers and to the Amine storage tank.

iii) Clean the precoat filter, otherwise the filter cake will dry and pose difficulty in the cleaning
operation later.

b) Loss of Instrument Power

Instrument power to the unit is supplied through UPS. In case of failure of power supply to
instruments from the main source, the UPS will supply power to the instruments for a time
period sufficient enough to take safe shut down of the GSU.

On the loss of main power supply to the instrument first check whether the power supply can
be restored before UPS power is exhausted.

If there is no possibility of restoration of power supply proceed for quick shutdown of the unit
as per the procedure discussed for short duration shutdown of the unit.C2C3 recovery unit
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must be intimated before taking the shutdown.

The possibility of instrument power failure from the UPS back-up as well is remote. However,
in case of loss of total instrument power following events will occur.

1. All the control valves and shutdown valves will assume their fail safe positions.

2. Gas supply to C2-C3 will cease.

3. Amine circulation through the circuit will stop.

4. There will be no indication of the operating parameters in the control rooms transmitters
will cease to operate.

In such a situation an operator should visit the field to check pressure temperature and

Levels in various equipment.

c) Loss of Instrument Air

Instrument air is used in the unit for actuation of control valves. In case of Air compressor trip,
instrument air would be available for 20 minutes from receivers

Efforts should be made to check if instrument air is likely to be restored within 20 minutes time.
In case this is not possible then normal plant shutdown should be taken as quickly as possible.

As the instrument air is exhausted all the control valves would take fail safe position. However,
measurement and indication of all the parameters will be available in the control room as
usual.

d) Loss of Cooling Water

Loss of cooling water should be indicated audio-visually by low flow' alarm, F At0702 installed
on the C.W: return header. This is to be immediately confirmed with the concerned offsite
person. In the event of cooling water failure the following actions need to be taken immediately.

1. Cut off steam flow to the reboilers as well as to the amine storage (IT-IOI).

2. Gradually reduce gas now through the Absorber and bring it down to zero.

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3. Stop lean amine flow to the Absorbers by tripping the amine charge pumps.

4. Close the control valves mentioned below:

 LV -0106, 0206, Absorber bottom

 LV-0304, VV-102 bottom.
 LV -0408, Regenerator bottom.
 LV-0202, CC-103 bottom

5. Continue reflux flow to the regenerator till column temperatures come down or till the
inventory' of the reflux drum permits.

4,6 SAMPLING PROCEDURES

Sample connections are provided at strategic points to allow laboratory analysis of process
streams and solvent. The recommended frequency of testing and the type of analysis is shown
in table 4.1.

A sample connection is also provided where online analyzers are installed, to allow its
performances and calibration to be checked in laboratory. Initially, it is recommended to
perform this checking daily, to ensure confidence in the results from the on-line analyzer. When
experience shows that an analyzer is stable this frequency may be reduced.

Details of analytical procedures are provided with the process package of GSU.

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TABLE - 4.1
ANALYSIS SCHEDULE

Analyzed
Determination Frequency Analysis method
stream
Method n 01 or 2
Feed Gas CO2 Hydrocarbon 1 per day
chromatography
DEA 1 per day Method n04
Lean amine
CO2 1 per shift Method n04
Treated gas CO2 1 per shift Method n01
1 per week Method n01 or
Fuel gas CO2 Hydrocarbon
1 per week chromatography

For analysis method details refer process Design Package of GSU.

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SECTION-5

EQUIPMENT OPERATING PROCEDURES

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5.1 INTRODUCTION

This section covers the standard operating procedures for important equipment. For complete
details about any specific equipment refer vendor's manuals.

5.2 CENTRIFUGAL PUMPS

5.2.1 General

The centrifugal pumps provided in the unit are Amine Charge Pumps. Water wash Pumps.
Regenerator Reflux Pumps. Condensate Pumps and Amine Filtration Pump. All these are
motor driven centrifugal pumps. The pumps are provided with mechanical seals. The
mechanical seal ensures complete prevention of leakage and requires minimum attention
during service life.

The sealing is achieved by two mating faces. One rotating with the shaft and the other
stationary in the casing. A film of liquid between the two faces is necessary to act as lubricant
and coolant. Depending on the type of the product handled by the pump this liquid called as
seal flushing liquid is supplied either from the discharge of the same pump or from external
source.

5.2.2 Start-up

1. Inspect and see if all the mechanical jobs are completed.

2. Establish cooling water flow where there is such provision. Open external flushing liquid
to seal in pumps having such facility.

3. Check oil level in the bearing housing; flushing may be necessary if oil is dirt or contains
some foreign material.

4. Rotate the shaft by hand to ensure that it is free and coupling is secured. Coupling
guard should be in position and secured properly.

5. Open suction valve. Ensure that the casing is full of liquid. Bleed. if necessary. from the
bleeder valve. Keep discharge valve closed.

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6. It should be ensured that casings of the pumps are heated up/cooled sufficiently if
required prior to starting of the pump to guard against damage of the equipment and
associated piping due to thermal shock/vapour locking.

7. Energies the motor, start the pump and check the direction of rotation. Rectify the
direction of rotation if not right.

8. Check the discharge pressure.

9. Open the discharge valve slowly. Keep watch on the current drawn by the motor. if
ammeter is provided. In other cases check at motor control centre/PCC.

10. Check temperature of the bearings and if necessary adjust the cooling water flow (if
provided).

11. Check the gland/seal and if necessary adjust gland/tightness/flow of the coolant for the
seal.

5.2.3 Shut down

1. Close discharge valve.

2. Stop the pump.

A) Pump is going to remain as stand-by and has provision for keeping the pump
hot/cold proceed as follows:

1. Open the valve in the by-pass line across the discharge valve and check valve.

2. iThe circulation rate should not be so high as to cause rotation of idle pump or
overloading of the running pump.

B) If pump is to be prepared for maintenance, proceed as follows:

1. Close suction and discharge valves.

2. Close valve on check valve by-pass line, if provided.

3. Close cooling water to bearing. if provided.

4. Close external flushing liquid to mechanical seals. if provided.

5. Slowly open pump bleeder and drain liquid from pump. If the liquid is very hot 'or cold.
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allow sufficient time before draining is started. Ensure that there is no pressure in the
pump. Also drain pump casing.

6. Blind suction and discharge and check valve by-pass line.

7. Cut off electrical supply to pump motor prior to handing over for maintenance.

5.2.4 Trouble shooting

i) If the pump is not developing pressure then

a. Bleed/vent pump casing.

b. Check the lining up in the suction side.

c. Check the suction strainer.

d. Check the liquid level from where the pump is taking suction (physical verification). ..

e. Check pump coupling and rotation.

f. Check the temperah1re of liquid. If it is higher than for what the pump has been designed,
NPSH will come down.

g. Check for any air leakage in the pump suction line or pump casing. This may occur at
various joints and packing boxes as the packing ages.

ii)

a. Check if coupling guard is touching coupling.

b. Check for proper fixing of fan and fan cover of the motor.
c. Get the pump checked by a technician.

iii) In case the bearing temperature rises:

(Generally the bearing oil temperature up to 80 0C or 5O0C above ambient. whichever is lower
can be tolerated. Refer vendors' instruction manual for details).

1. Arrange lubrication if bearing is running dry or oil level is low.

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2. Adjust cooling water to the bearing housing if there is such provision.

3. Stop the pump, if temperature is too high, call the pump technician.

a. Adjust cooling water if facility exists.

b. Slightly loosen the gland nut, if possible.
c. Stop the pump and hand over to maintenance.
d. Arrange external cooling if pump has to be run for sometime.

v) Unusual vibration

a. Check the foundation bolts.

b. Check the fan cover for looseness.

c. Stop the pump and hand over to maintenance.
d. Check alignment.

vi) Leaky Gland

a. Check the pump discharge pressure.

b. Tighten the gland nut slowly, if possible.
c. Prepare the pump for gland packing for adjustment/replacement of mechanical seal
as the case may be.

vii) In case of mechanical seal leak stop and isolate the pump and hand over to maintenance.

viii) Refer to vendors' instruction for more details on operation of pumps.

AMINE CHARGE PUMPS

Vendor's instruction manual should be referred for details.

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5.3 POSITIVE DISPLACEMENT PUMPS

5.3.1 General

Positive displacement pumps are being used in the Gas Sweetening Unit for antifoam
Injection and as make-up water booster pumps for the column CC-103. These pumps have got
safety valves at the discharge which should be regularly inspected and pump is not to be
operated with discharge valve closed. Safety valve will bypass the excessive pressure from
discharge to suction so that casing is saved from getting overpressures.

5.3.2 Start-up

1. Check if all the mechanical jobs are completed.

2. Check oil level in the bearing housing, flush if dirty.
3. Check for proper lining up including the pressure control valve or safety valve in the
discharge. Open suction valve fully.
4. Rotate the shaft by hand to ensure that it is reasonably free and coupling is secured.
Coupling guard should be in position.
5. Energies the motor. Open discharge valve. Stan the motor and stop immediately. Check
the rotation. If there is nothing unusual, restart the motor.
6. Care should be taken to avoid dry running of pump and back flow of liquid. Bleed. if
necessary to expel vapour/air.
7. Check for unusual noise vibrations and rise of temperature of both motor and pump
bearings.

5.3.3 Shut-down

1. Stop the pump.

2. Close the suction valve and discharge valve.
3. Drain the pump liquid if the pour point is high.

5.3.4 Preparation for Maintenance

1. Close both suction and discharge valves.

2. Close the valve of recirculation lines, if provided.

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3. Slowly open the pump bleed valve to depressurize. Open casing drain also and drain
the liquid. If the liquid is hot allow sufficient time before starting the drain. Ensure the
pump is depressurized completely.

4. Provide blinds at suction and discharge valves.

5. De-energies the motor before handing over the pump for maintenance.

5.3.5 Trouble Shooting

i) Insufficient discharge pressure:

1. Bleed to expel vapour/air.

2. Check the lining up in the suction side.
3. Check the functioning of the safety valves.
4. Check the strainer in the suction line.
5. Check for insufficient liquid level in the tank.
6. Check the pump coupling and rotation.
7. Get the pump checked by a technician.

ii) High Discharge Pressure

a) Check the lining up on the discharge side.

iii) Rise of Bearing Temperature

Generally, the temperature should not exceed 50°C above ambient or 75°C whichever is less.

a) Check if bearing is running dry arrange lubrication if necessary.

b) Stop the pump if temperature is too high call the pump technician.

iv) Unusual Noise

a) Check for looseness of fan cover, proper fixing of coupling guard etc.
b) Get the pump checked by maintenance.

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v) Hot Glands

a) Slightly loosen the gland nut, where possible.

b) Stop the pump and hand over to maintenance.

vi) Leaky Gland

a) Adjust sealing fluid flow if provided.

b) Check the pump discharge pressure.
c) Prepare the pump for handing packing/changing of mechanical seal
over to maintenance for packing/changing of mechanical seal.

vii) Unusual Vibration

a) Check the foundation bolts.

b) Check the motor fan cover for looseness.
c) Stop the pump and hand over to maintenance.

5.4 HEAT EXCHANGERS

The heat exchangers used in GSU are of various types Rich/lean amine exchangers. EE-101
A/B/C and Lean Amine Coolers, EE-I04 A/B/C are of plate-frame type. The Regenerator
reboilers are of kettle type. Rest of the exchangers are mostly shell & tube type.

EE-101 and EE-104 each have three units running in parallel. At a time, two are in operation
and the third one is standby Isolation valves with blinds are provided for all these exchanger
units so that anyone unit can be taken under maintenance while the others are in operation.

For start-up details of the exchangers refer section 4.0.

For taking under maintenance the exchanger should be isolated with the help of isolation
valves, drained into the blow down system and depressurized. In case, Isolation valves are not
available the exchanger along with the connected system should be isolated, then drained into
the blow down system and depressurized. Temperature of drain line and rise in level of the
Amine Sump Drum will indicate whether the exchanger & connected equipment has been
drained. After carrying out the above procedure, the individual exchanger or the system should
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be blinded, purged with nitrogen and after checking for hydrocarbons should be handed over
to the maintenance personnel.

In case of condensate coolers, the cooling water side should be isolated and the hot water side
drained before handing over the equipment for maintenance.

5.5 FILTRATION PACKAGE

Vendor's instruction manual should be referred for details.

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SECTION – 6

SAFETY PROCEDURES

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6.1 INTRODUCTION

Safety of personnel and equipment is a very important consideration in the operation of the
unit. Though the design of the plant takes care of a number of emergency conditions and
makes the plant operationally safe. Proper operating procedures and use of safety equipment
are a must for the safe running of the plant and a safe environment to work in. This chapter
contains some safety guidelines which should be strictly followed in the plant. However these
procedures should be updated from time to time in the light of the experience gained in
operating the plant.

6.2 GENERAL HAZARDS IN THE UNIT

It is essential to recognize the various possible hazards in the operation of the plant so that the
remedial measures can be planned. Following are some of the common safety hazards
encountered in process plants.

6.2.1 Hazards of Petroleum Products

All Petroleum products give out vapours in amount depending upon the type of product. These
vapours in a confined space will tend to make the atmosphere leaner in oxygen content thus
make it difficult to sustain normal breathing (asphyxiation).

The hydrocarbon vapours also produce some adverse physiological effects. Fire and explosion
hazards are associated with these vapours under favourable conditions.

6.2.2 Electrical Apparatus

These include all machines equipment and finings in which conductors are used or
of which they form a part e.g. electric switches push buttons, Sockets, Plugs, Circuit breakers,
starters, and instruments motors and so on. These may act as a source of ignition by electrical
arcs and sparks or raising the surface temperature of the apparatus above the spontaneous
ignition temperature.

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6.2.3 Stray Electric Currents

It may occur because of high voltage electrified railway networks. Stray currents may emanate
from electric welding machines.

6.2.4 Static Electricity

1. Examples of electrostatic generation are:

2. Passage of liquid through pipes and filters.

3. Settling of solid particles in liquids as when rust and sludge particles settle in a vessel.

4. Settling of droplets of one liquid through another. e.g. water droplets separating out in a
tank or a vessel containing petroleum liquid.

5. Bubbling of gas through liquid e.g. air trapped in a liquid rising to the surface.

6. Splashing by the break up of jets or bubbles e.g. during splash filling of vessels and
high splash ejection of liquid from nozzles.

6.2.5 Lightening

Lightening can fall on metallic objects such as chimneys, towers, tanks, vessels and tall
buildings. These can damage the structures or lead to ignition of hydrocarbon-air mixture if
present.

The vent/safety relief valve discharges al high points to the atmosphere are especially
vulnerable to lightening.

6.2.6 Non-Electrical Sources of ignition

1. Smoking.

2. Spontaneous ignition. e.g. thermal insulation of hot pipes which have become
impregnated with oil.

3. Pyrophoric Iron: Iron sulphide formed out of contact with air is chemically very active
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and when exposed to air it rapidly oxidises and reaches a temperature sufficient to
ignite a hydrocarbon air mixture.
4. Frictional ignition due to impact or rubbing action.
5. Falling of iron tools.
6. Rubbing of iron tools on concrete or operation of grinding wheel.

6.2.7 Auto ignition

For combustion to occur, three conditions must be necessarily satisfied, these are availability
of combustible material, sufficient quantity of oxygen and a source of heat. In free air there is
no risk of ignition if the hydrocarbon vapour temperature is less than the ignition temperature.
However if the temperature of hydrocarbon vapours is equal 10 its ignition temperature, the
vapours can catch fire on mixing with oxygen from the atmosphere even without the help of a
flame or a spark. This is known as Auto-ignition.

The risk of auto-ignition is generally more as the molecular weight of the hydrocarbons
increases. The auto-ignition temperature of some important hydrocarbons is given below:

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TABLE-6.1

Product Auto-ignition Temp.. OC

Hydrogen 589
Ethane 516
Ethylene 450
Propane 466
Butane 430
Pentane 309
Hexane 247
Gasoline 256
Kerosene 254
Lubricating oil 417

Hydrocarbon dust clouds also can ignite and explode.

Sources of Ignition
Common sources of ignition are:

1. Auto ignition
2. Electrical Apparatus.
3. Stray Electric current
4. Static Electricity.
5. Lighting
6. Non electrical sources (Mechanical sparks).

Physiological effects

The hydrocarbon vapours which are heavier than air accumulate at low points near the ground
level. The vapours have un aesthetic effects. If air with hydrocarbon concentration of 0.1 % is
inhaled for about 5 minutes the person feels giddy. If concentration increases to 0.5% and a
person inhales such air for about four minutes he exhibits symptoms similar to alcoholism.
A concentration of 1.0% will cause rapid onset of "drunkenness". Which may lead to
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unconsciousness and death if exposure continues? At 2.0% concentration paralysis may occur
rapidly followed by death.

Explosion - Fire

When the proportion of hydrocarbon in the hydro carbon-air mixture falls within the explosive
limits (these limits for some important hydro carbons are given below). an explosion or fire
could occur in presence of a source of ignition such as spark or an open flame. A hydrocarbon
air mixture can spread on the ground over a considerable distance and catch fire when in
contact with a spark or an open flame.

An explosion occurs when the air hydrocarbon mixture is enclosed in a vessel and a fire takes
place when the above conditions exist in the open. Explosion produces a considerable volume
of gas which creates high pressures causing damage. One explosion could initiate another
explosion or fire at a distance of ten to hundred meters because of its physical nature.
Explosion is generally followed by a fire.

Explosive Limits of some Hydrocarbons are listed in the following Table.

T ABLE-6.2

Lower Explosive Limit Higher Explosive

Product
(LEL, % vol/vol air) (HEL, % vol/vol air)
Hydrogen 4.1 74.2
Methane 5.3 14.0
Ethane 3.2 12.5
Ethylene 2.75 28.6
Propane 2.37 9.5
Propylene 2.0 11.1
Butane 1.6 8.5
Pentane 1.45 7.5
Hexane 1.2 6.9
Gasoline 1.3 6.0
Naphtha 1.10 6.0
Kerosene 1.16 6.0
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6.3 SAFETY GUIDELINES

The following general safety rules are applicable to plant operations. These must be known
and strictly observed by all personnel.

6.3.1 General

1. Smoking should be permitted only at approved smoking locations.

2. If an employee's clothing become contaminated with acids caustics. Alcohols

hydrocarbons etc he must remove clothes immediately and take a shower.

3. Defective tools should not be used.

4. When using chisels, cold cuts, striking wrenches, hammers or punches, non sparking
tools should be used.

5. User proper tools for the work involved. i.e. do not use a file for a bar, a hand wrench for
a hammer etc.

6. Over-stressing tools or equipment causes serious injuries.

7. Safety belts or life lines shall be used when working 3 meters or more above ground,
where it is not practical to make other provisions to prevent falling.

8. Falls are the second largest cause of accidental deaths. Following acts are to be
avoided:

 Failure to look around while going round the plant.

 Running or jumping in work places.
 Standing on boxes, chairs and make-shifts instead of ladders or platforms.
 Neglecting to use handrails and running on stairs.

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 Falling to face ladder when carrying objects on the same.

9. Tools and materials should not be dropped from heights. They must be carried down.

10. Standing or walking under materials suspended by ropes, chains, or cables should not be
permitted. Stay in the clear until material is well secured.

Electrical Equipment:

1. Don't tamper with electrical apparatus. This is job of an qualified electrician.

2. Don't remove light bulbs to plug-in power equipment.

3. Use only approved electrical fittings. The covers of electrical fittings in hazardous areas
should be secured properly to avoid entry of explosive gases.

4. All electrical equipment must be properly grounded.

5. An electrical extension wire must not be used if it is in bad condition. laid through water
or in such a manner as to allow motorized equipment to travel over it.

6. Employee should regard all electrical wires as live and dangerous.

7. Never close a switch or breaker that has been opened unless authorised to do so by
your supervisor.

8. All electrical breaker must be de-energized and locked before process equipment can
be worked upon.

9. All live fuses. Lighting and power cabinets must be kept closed.

10. If an electrical power unit motivates moving machinery and if it is necessary to repair the
same then refer to and follow the electrical lock-out procedure laid down by the plant

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management.

6.3.2 Safety Rules For Particular Operation

The following safety instructions are for the operations carried out frequently in the plant.
These must, in addition to the General Safety Rules, be understood and observed strictly by all
personnel.

Sample and Purge Connections

Before opening a purge or sample connection, ensure that the product temperature is such
that there is no risk of initiating a fire or causing burns. Hot and heavy products are most
dangerous, as they are near their auto-ignition temperatures. Sample connections for hot
products are normally connected with a sample cooler. Vents and drains of hot products which
are not used regularly should be capped or blinded. If a hot product is to be vented, connect
the vent to a cooling coil fall’s before proceeding with the venting. Vents should always be
opened slowly. Operator who opens the purge or sample connection should be present till the
same is closed. The plug blind if provided should be put back when the operation is complete.
Sample and purge connections on liquefied products have two valves. Always open the
upstream valve fully and adjust the flow by the downstream valve. This is done so that
upstream valve is always operable in case of frosting. Draining etc. of vessel should not be
done unattended. Operator should be present as long as draining/venting is going on.

Isolation of Safety Valves

Many safety valves are provided with isolation valves at upstream and downstream of the
safety valve. This is to facilitate the repair of the safety valve. It is important to ensure that
these isolation valves are kept in open position. When a safety valve is to be taken out of line
bring the spare safety valve in line or shutdown the equipment if the spare safety valve is not
provided.

6.3.3 Preparation of Equipment For Maintenance

Process Equipment: Tanks. Vessel etc.

Before opening any equipment, it should be purged to render the internal atmosphere non-
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explosive and breathable. Operations to be carried out are:

1. Isolation with valves and blinds.

2. Depressurization and draining.
3. Replacement of vapours or gas by steam, water or inert gas.
4. Proper isolation and draining of instrument tapping.
5. Washing of tanks and vessels with water.
6. Ventilation of equipment
7. Opening of top manhole. Testing of inside atmosphere inside for O 2 content and any
poisonous gas.

NOTE:

Open a vent on the upper pan of the vessel to allow gases to escape during filling
and to allow air inside the vessel during draining. Ensure proper ventilation inside the
vessel by opening all manholes.

Precautions Before Handling Over Equipment

Following items should be checked by a responsible operating supervisor before equipment is

handed over for maintenance after it has been purged.

1. Ascertain that equipment is isolated by proper valves and blinds.

2. Ascertain that there is no pressure of hydrocarbons in the lines. vessels and equipment.

3. Check that steam injection lines and any inert line connection are disconnected or
isolated from the equipment.

4. Put tags on various blinds to avoid mistakes. Maintain a register for blinds.

5. Check for pyrophoric iron and if existing keep this wet with water.

6. Keep the surrounding area cleaned up.

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7. Get explosive meter test done in vessels, lines, equipment and surrounding areas.

If welding or hot work is to be done, then also:

1. Keeps fire fighting devices ready for use nearby?

2. Close the neighbouring area to cool down any spark bits etc.

3. Keeps water flowing in the neighbouring area to cool down any spark bits etc.

4. Keep steam lancers ready for use.

After the above operations have been made. a safety permit should be issued for carrying out
the work. A responsible operating supervisor should be personally present at the place of hot
work till the first torch is lighted. Hot work should be immediately suspended if instructed by the
supervisor or on detecting any unsafe condition.

When people have to enter a vessel for inspection or other work, one person should stand
outside near the manhole of the vessel for any help needed by the persons working inside.

6.3.4 Fire Fighting Guidelines

General

In case of fire, operating personnel should identify the source of fuel and cut out the same as
soon as possible. Movement of all products to the affected area should be stopped. Attempt
should be made to extinguish fire using sand, water, steam, foam, dry power or portable
extinguishers available at site. Supervisor should be informed immediately. The operating
personnel should be fully conversant with fire fighting system provided in the plant which
generally comprises of the following:

1. Fire Signal

Fire alarms are provided at several convenient places throughout the plant. TI1e alarms should
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be sounded whenever fire is sighted and fire station should be informed of the location and the
extent of fire on arrival of fire engine, necessary information regarding location condition and
equipment involved should be given to the fire squad.

2. Portable Fire Extinguishers

Fire should be killed at the incipient stage before it can cause any major
damage. Portable fire extinguishers are very useful for fighting small fires. All strategic areas
are provided with CO2, foam or dry powder extinguishers. They also must know when and
which to use and how to use them. For example for electrical fires, CO2 and dry powder
extinguishers will be used. Water or foam shall not be used on live electrical equipment. The
used extinguisher should be checked and refilled by the fire station personnel.

3. Fire Water Network

A reliable and adequate supply of water for fire fighting at all points on the plant is assured by
an independent pressurized fire water network. Fire hydrants are generally located on this
network at 30 meters intervals. Water is the most effective cooling agent and it can be utilized
successfully to control the fire and protect nearby equipment from fire damage. Some tanks
are provided with water sprinkler system which should be made operative in case of fire in the
vicinity.

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6.4 HAZARDOUS PROPERTIES OF CHEMICALS HANDLED

a) Diethanolamine (DEA)

DEA is strongly alkaline material, with a slight odour of ammonia which can cause severe
irritation to the eyes, skin and mucous membranes. It has a melting point of 27.S.C and may
exist either as colourless crystals or as a viscous liquid depending on ambient conditions.
Though DEA is not considered as poisonous, it bas toxic properties. It should not be ingested
or allowed to come into contact with the skin. Short term animal toxicity tests indicate that skin
and eye irritation are the principal health hazards. Toxicity by accidental ingestion or absorption
through the skin is 'minimal.

 Oral toxicity : moderate

 Dermal toxicity : practically non-toxic

 Eye irritation : severe

 Skin irritation : moderate

No occupational exposure standard has yet been established for DEA. Its vapour pressure is
less than I mm Hg at 20.C, hence no appreciable hazard exists in exposure to any
concentration of vapour likely to develop under ordinary conditions of handling and use.
However, adequate ventilation should be provided whir a large quantity of DEA is exposed.

Chemical safety goggles (cup type or rubber frame type) equipped with approved impact-
resistant or plastic lenses should be worn whenever handling DEA. Rubber or plastic alkali-
resistant gloves or aprons should also be worn to reduce danger of irritation of the hands and
skin from DEA impregnated clothing. Clothing that has been contaminated should be removed
immediately and laundered or dry cleaned thoroughly before reuse.

Spills should be cleaned up immediately and area well washed down with utility water.
Symptoms of exposure are severe irritation of the eyes or slight irritation of the skin and
mucous membranes. In case of contact, immediately flush the affected area with
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large quantities of water for minimum of 15 minutes. In case of eye contact, obtain medical
attention immediately after applying first aid. In the case of ingestion, the victim should be
given salt water to induce vomiting. Medical attention should be obtained immediately.

Being an organic compound, concentrated DEA will undergo combustion but the solution is not
classified as flammable. In case of fire, use water spray, dry chemical, alcohol foam or carbon
dioxide fire extinguishing agent. Use water to keep fire exposed containers cool and disperse
the vapours and flush spills away from exposures and also to dilute spills to non-flammable
mixtures, thus preventing the spread of fire.

Important chemical and physical properties:

Colour : Colourless crystals or viscous liquid

Odour : Faint ammonia

Density : 1095 kg/m3 at 15.6.C

Melting point : 27.S.C

Boiling point : 268.S.C (decomposes)

Flash point : l51.7.C

Auto-ignition : 662.2.C

Corrosiveness : Non-corrosive

Flammability : Non-flammable

Reactivity : DEA is fairly reactive, having the chemical properties that are

associated with its amine group although none are hazardous.

Solubility : Water - 95.4 Wt. % @ 20.C

Acetone. Alcohol - Very soluble

Ether, benzene - slightly soluble

CCI 4heptane - hardly soluble

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