Plant 10

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, NATIONAL IRANIAN OIL COMPANY,
Esfahan Project '
Esfahan, Iran ,
FLUOR ENGINEERS AND CONSTRUCTORS, INC.
, ' For The
, FLUOR-THYSSEN J'OINTVENTURE-ESFAHAN PROJECT
, ' Contract 4573 '
CONFI DENTIAL'
ASPHALT~ PLANT'
, \
OPERATING MANUAL
, 'Material contained in this manual is confidential and rest'ricted to'
the use ,of properly ,authorized NIOC personnel.' This manual and all
material herein remain the property of National I,ranian Oil Company.
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I I'll I IIII III III II III II I ~ I : I I ~
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TABLE OF CONTENTS
NATIONAL IRANIAN OIL COMPANY
Esfahan Project
Esfahan, Iran
I. INTRODUCTION
II. DESIGN BASIS,
. : For The
FLUOR-THYSSEN JOINT VENTURE-ESFAHAN PROJECT
Contract 4573
CONFIDENTIAl
TABLE OF CONTENTS
OPE.RATING MANuAL
. ASPHALT PLANT
A. Feed Products
B. Heat and Material Balance
III.,' DESCRIPTION
A. Nature of Process
B. Process Flows
IV. ,OPERATING VARIABLES
V'. AUXILIARY SYSTEMS
A.Flushing Oil
. B. Steam .
C. "Loading Facilities
. D. ' Utilities Summary
VI. EQUIPMENT OPERATION'
A. Pumps'
B. Rupture Disc
.C. Water Sprays '
D. Flushing oil Circuit
VII. STARTUP. PROCEDURES
A.. 'Preparation Prior to. Initial Startup
B. Asphalt: Cooler,s and Incinerator
C. Normal.Startup
.VI I I . .N'ORMALSHUTDOWN :PROCEDURES
I I I'II IIII
I
,1111 III, II III II i III i'
. "
Project
Esfahan, Iran
" " "" For. The ""
FLUOR-THYSSENJOINT VENTURE-ESFAHAN PROJECT
Contract 4573 .
CONFIDENTIAL
TABLE "OF CONTENTS
OPERATING MANUAL
ASPHALT PLANT
IX. . EMERGENCY."SHUTDOwN PROCEDURES

A. Internal of Fire
B. . Foaming
C. Power Failure . "
" Instrument Air Failur"e
E. Loss of
F. Loss of" Fuel Gas
G. Loss of Raw Feed
X. SAFETY
A. General
B. Safe Place to Work
C. . Hazards
D. Good Housekeeping
E. for Welding Permits
F. "Specific Procedures to This Unit
XI.

XIII.
ANALYTICAL TESTS
CATALYSTS, CHEMICALS, AND PACKINGS
DRAWINGS
I I II ,III: 'Ii III II !II II, 'Iii I i -
I I'll II IIIII1 1 'III II l
I. Introduction
EsfahanProject
Esfahan; Iran
I INTRODUCTION
. FLUOR ENGINEERS AND CONSTRUCTORS, INC.
For The ..
Contract 4573
CONFIDENTIAt
ASPHALT PLANT
The purpose of the AsphaltPlarit is to convert straight-run Vacuum
Column residuum into paving-grade asphalt. The straight-run
residuum is not hard enough to s.erve directly as paving-grade
asphalt .. The residuum is 'hardened by blowing air through the hot
feed.
The finished product is transferred to the loadinq area ,for stor-
age and final transfer directly. into road
I I 'III III II1I III' II 111 II i '1'1,,' II I III !
I I 1'1 III, l
II. Design Basis
NATIONAL IRANIAN Oil COMPANY
Esfahan P'roject
Esfahan, Iran
II. DESIGN BASIS
.. For The
JOINT VENTURE-ESFAHAN PROJECT
Contract 4573
CONFIDENTlfAL
ASPHALT PLANT
A. Feed and Products
STREAM
Feed
Vacuum Resid
Plant Air
Products
Asphalt Product
QUANTITY
36,143 Kg/hr
4,0'78NIli
3
/hr
35 ,940 Kg/hr
PROPERTI'ES
690 Centistokes
.60-70 Penetration
Index
B. Heat and Material Balance
The following table provides a. complete heat and' ma.terial .
balance for the unit
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Page 1 of 1
I I 'III III "'11 III II IIII II I 'III", II I' ,III I' I . II" I III' I I

MOLS FLOWING
110 Nm
3
/d
'STREAM API K MW SP. c bar
@OoC&
FLOWING PER kg/h ' kJ/kg kJ/s
(kg/m ) absolute
1.013 bar)
dm
3
/s HR.
"
VACUUM RESID FEED 9.4 11.3 -- 850 232 2.1 .866. 11.8 -- 36143 464
'4659 .
COLD RECYCLE 3.2 11.0'
-- .950 182 1.4 839 10 7
--
36636 351
-=\1'\71'\
,
COMBINED FEED TO BLOWING C:OLTTMN -- --
707 1 7 1701'\
-- --
i7?7:J!J 407 R714
AIR TO BLOWING COLTJMN
-- --
28q '? 17) 7 q (0 1())
--
17? 4qRl 9 12
HEAT OF REACTION
-- -- -- -- -- -- -- -- -- -- -- 3546
26() 1 0 (0 l'T)
'.
f,qq 1()()6 EFFLUENT VAPORS -- -- 26.1 -- --
lqq I:\lR4
BLOWING COLUMN BOTTOMS 3.2 11.0 -- 820
. 182 1. 2 16f1? . 74 6
--
72576
1:\-=\4 1()774
('()(Yr,T;>O nT'l'V ':I.e::.o')
,#
.ASPHALT CbOLER EFFLUENT 3.2 11.0 -- .950 182 4.3 1662 21.2. -- 72576 351 7082
ASPHALT TO STORAGE 3;2 11 0
--
ql:\()
1R7 -=\ f, R?-=\ l() 1:\
--
-=\l:\q40 -=\t:;()7
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-
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Esfahan Project
Esfahan, Iran
ASPHALT PLANT
HEAT AND MATERIAL BALANCES

CONFIDENTIAL

For The
Contract 457304
SHEETNO. 1 __
DATE __
DHJ BV__-,-:.-__CHK'D_---'-__
I :1 III "I II II , ,
III. Process Description
, Esfahan Project
,Esfahan, Iran '
, , . For The: . . '
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
III. ,PROCESS DESCRIPTION
A. Nature of Process
I
,
The Asphalt Plant comprises the equipment necessary to con-
vert the straight-run vacuum column residuum from the Crude
Unit into a marketable paving-grade asphalt, as well as the
equipment necessary for storing the asphalt and loading it
onto road tankers. '
The "vacuum resid
Jl
from the Crude Units will not have the
properties desired. The softening tempera'ture will be .low,
and the Penetration Index, which 'is a measure of softness,
will' be high ,Howeve,r, by blowing air through the 'hot
"resid,JI penetration is reduced (that is, the bitumen is made
harder). -
This is basically 'an oxidation reaction; oxygen from 'the air
combines with the asphalt. The reaction evolves ,some lighter
oxygenated oils, which pass off with the spent air. Heat is
'also evolved, tending to raise the temperature,of the asphalt.
The evolved 'heat is removed by circulating a stream of asphalt
through a cooler, which generates ,steam, and back to join the
incoming feed. product stream is withdraWn from the' .
cooled circulating stream. The hbt spent air from the
tion is disposed of in an
The products are kept hot in the storage tankS by steam
heated coils; product lines are kept hot by jackets.
It is not necessarytb empty the lines.whenasphalt is not
mOVing through them.
For operating purposes, the Plant is composed of two sec-
tions. The first section comprises the asphalt blowing
column and associated equipment in which the asphalt is made.
The ,second section 'comprises 'the storage and loading facili-
The first section may be shut down 'from time to time,
and'its lines flushed out. The second section should never
have flushing oil admitted to any'of,the lines.
Section II of this mariual contains the heat 'and material
balances. 'In the last 'section of this manual, section XIII,
are the process flow'sheets which indicate the principal
flows. This' section should be read and understood in light
of the preceding discussion be,fore going ori to' consider the
Page 1 of 4
I I '1I1I II 1,111 II1I II III II, II, I II I "'11 I I ' II' I 1111'1, I I IIIIII I I IIIII I I III II II II
NATioNAL IRANIAN Oil COMPANY
Esfahan Project
Esfahan, Iran'
.
. .
III. PROCESS DESCRIPTION
. 'For The .
FLUORTHYSSENJOINT VENTURE-ESFAHANPROJECT
. . Contract 4573
CON.FIDENTIAL
ASPHALT PLANT
. Nature, of Process (Continued)
\
.mechanical flow sheets. The flow rates and conditions shoWn
in those items are for design purposes only and should not be
used to predict performance or set operating conditions.
B. Process Flows
1. .Asphalt Plant
The hot vacuum residuum is pumped to the Asphalt Plant
from the Crude Vacuum Uriit. The Crude Vacuum Unit
operator has control of' the temperature of
however, he not control the flow rate, which must
be set by the Asphalt Plant operator with FIC-l003.
This stream joins the stream of cooled recycle and at a
lower temperature enters the asphalt blowing column,
V-IOOI. Air is bubbled through the hot asphalt. This
is controlled from the control room by a flow control-
ler, FIC-IOOI. An air distributor in the bottom of the
blowing column makes sure: the asphalt evenly contacts
the air.
The hot air from the top of the column, which contains
some hydrocarbons, is disposed of by burning in the
incinerator, IN-IOOl. Fuel gas is provided for startup
and for complete combustion of the hydrocarbon in the
spent air.
The asphalt is pun;pedthrough the asphalt cooler, E.1001,
and then to either storage or recycle. The net produc-
tion goes to storage through a level controller, LIe-IOOl.
The asphalt product pump, P-IOOl, is a "gear pump driven
by a constant-speed motor, and it is accordingly a
constant throughput type of .
To control this circuit, therefore, the cooled recycle
goes back to the'blowing column through a backpressure
controller;'PIC-I002,with a manually positioned control
. valve, HIC-I002, between the pump discharge and suction.
And so, with the level controller steady, if HIC-I002 is
partialiy throttled, PIC-I002 must open a corresponding
amount and the rate of recycle will be corr,espondingly
increased.
Page 2 of 4
I I II! "I II' II III I II I I '
Esfahan Project
Esfahan, Iran'
For The "
FLUORTHYSSEN JOINT VENTURE-ESFAHAN PROJECT
, Contract 4573
CONFIDENTIAL
ASPHALT PLANT,
B. Process Flows (continued)
'.
1. Asphalt Plant (Continued)
The level controller, LIC-IOOl, is not a float or dis-
placer type, but operates by measuring the pressure
differential across a high and a low point on the vessel.
Air is continuallyfbrged through, each of the instrument
leads to keep asphalt from filling the leads and to keep
the pressures at the differential cell equal to the
pressures at the points where the leads enter the vessel.
The measured variable is actually the weight of asphalt
above the lowest pressure ,tap. The presence of bubbles
is not measured; therefore, the top of the frothing
surface may be above its apparent level. However, the
weight of material above the'lower tap is the most
important variable. Variations in air rate, for'
instance, give the least upset to the Unit by using this
method. Since the ,lower tap is not at the bottom of the
vessel, the level will surge a bit as the air rate is
increased or decreased.
The blowing column is equipped with three special tem-
perature indicating points which provide for'level
indication. The thermocouples are mounted in external
loops on the sides of the vessel. If the liquid level
is beiow anyone point, this c::ouple "sees" the rela-
tively cold surface of the loop. 'When it is covered by
liquid, the couple reads about thirty degrees higher. '
These p o i ~ t s , of course, cannot indicate any level
reading between, them, but serve as a warning if the '
vessel is being operated, at too high or low a level.
The asphalt cooler, E-IOOI, consists of two shells and
generates 60 psig steam. This is necessary to avoid
exposing the asphalt to a very cold, stream, such as
cooling water or air, which could result in local plug-
ging of tubes; in this cooler the asphalt is never
exposed to a surface at a temperature below its soften-
ing point.
Boiler feedwater enters the, coolers on level controls
LC-I002and LC-l003. Steam is generated in, proportion
Page 3 of 4
I 1'1 III II I I I

Esfahan Project
Esfahan, Iran'
. ' ' For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
B. Process Flows (Continued)

1. ,Asphalt Plant (Continued)
to the circulation of asphalt; its production is mea-
s u ~ e d by FR-l004 and FR-lOOS. The asphaltcoole.rs are
equipped with me.ans for a regular blowdownand with a
sample system for taking samples,' 6f water.
, I
The cooled asphalt is transferred to the asphalt tanks,
TKS-2052, 2053,and'20S4.Asphalttransfer pumps,
P-l002A and B, are used to transfer the 'product asphalt
to the asphalt loading area. ' '
;Page 4, of 4
. \
IV. Operating Variable
Esfahan Project
Esfahan, Iran
IV. OPERATING VARIABLES
, ' '
For The
Contract 4573
CONFIDENTIAL
-.
The principal\ ,operating variables in the control of the asphalt

process are temperature, ,retention time, and of aeration.
These have the following effects on the process:
(1) The reaction rateqoes more rapidly as the'temperature
is raised.
(2) The reaction goes more rapidly as the air rate is
raised, approximately proportionately.
(3) The rise in softening point is proportional to the
residence time.
, The reaction is very slow at 204C and lower. Normally the mate-
rial to ,be blown should be at least 216C to begin the reaction.
At 288C the reaction goes extremely fast. Above this tempera-
ture, there is a danger of explosions in the vapor space.
If the rate of heat removal is constant, increasing the air rate
will increase the temperature", and vice versa.
On the other hand, in order to achieve-the proper relation of
softening point to penetration-characterisCt;ics 'While operating at
a lower column temperature ,'-mQr,.eair ,is required than in high-
temperature operation to attain the s'arne softening point. Under
these conditions, more heat, is evolved and must ,be removed.
These ,plants have been equipped with the following means of con-
trolling the reaction:
(1) The aeration rate is directly controllable using a ,flow
recorder controller.
(2) The retention time is principally a function of the rate
of charge. Operating the coluiim at low levels to decrease
residence time is not advisable, since this may, allow
the incoming liquid to fall freely through the rising
hot spent air and presents a danger of internal fire.
(3) Reaction temperature is controlled by varying the rate
. of cold recycle. Instruments are provided for measuring
and controlling these .
Page 1 of 1
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1 I -
V. Auxiliary System
Esfahan Project
Esf.ahan, Iran
v. AUXILIARY SYSTEMS
AND CONSTRUCTORS, INC.
For The'
FLUORTHYSSENJOINT VENTURE-ESFAHAN PROJECT
Contract 4573
CONFI DENTIAL
ASpliALT PLANT
A. Flushing Oil
Flushing oil is piped under pressure from the Crude Unit
(diesel). The operator of the Un1t'concerned should be
notified when it is necessary to send fltishingoil to the
Asphalt Plant. This flushing oil
(1) At Unit shutdowns, to flush all lines and equipment
prior to shutting off steam to steam jackets ..
(2) When sending off-test . a.sphalt to refinery slops, to
cut back the asphalt in the line 'and reduce the
danger of setting up:.
B.
C.
Steam'Generation
4 bar steam is generated in the Asphalt Plant from cooling
the combined net production and recycle streams. The steam
will be saturated rather than superheated.' a.s is the. case of
the rest of the refinery 4 bar steam system. Boiler feed-
water is received and admitted to each cooler on level con-
ttol. Individual lines must. be emptied to p.revent freezing
if the Unit is shut down in winter. A vent has been placed
in each line and should be opened" under these conditions.
'Loading FaciIities'
Asphalt is loaded directly into .road tankers from. the asphalt
tanks TK-2055,2056, and 2057 in the loading area. The
loading pumps are positive displacement pumps. :The trucks
should be positioned; the. loading hose or loading'arm placed
in filling position, and all valves opened up ..
Estimate the loading time from the required. "load. . Stop the
pump in order to gauge the tanker from time to time. Do not
stand on the tanker or near the loading hatch while the,pump
is . At the conclus.ion ofloading;,'s'top the pump and
close the valve at the loading arm or hose. Normally the
pump suction and discharge valves should be left Qpenwhile
not loading if the lines are left full of product.
leaves the pump relief valve to protect the'lines' against
possible The storage tanks ate to be kept
at 30Q
O
F. Care required in handling the hot asphalt
Page 1 of 6
'1'1 1111' I'll I : !

.Esfahan Project
Esfahan, Iran
v. AUXILIARY SYSTEMS .
'. FLUOR ENGINEERS AND CONSTRUCTORS, INC.
For The'
Contract 4573
CONF.IDENTIAl
ASPHALT PLANT
D. utilities Summary
A tabulation of e ~ e c t e d utilities consumption by these units
is included in this section of the manual:'
Table I ... Cooling Water S_arY
. Table.II - Electrical Power swnmary'
Table III - Steam and Oonderis'ateSlimmary
Table IV - Fuel G ~ s Summary
These summaries are approximate only and are based on'
the refinery being operated at the de.sign capacity of
200, 000 BPSD Utilization of equipment within a unit
in a manner bther than shown in the summaries may
s.ignificantly affect the unit summary and may .alter the
plant balance. .
, .
I
Page 2 of 6

Esfahan Project
, Esfahan, Iran
For The '
Contract 4573
CONFJ DENTIAL
ASPHALT 'PLANT
TABLE.I
COOLING SuMMARY
ITEM NO. SERVICE dm
3
Js (GPM)
. TEMP. OUT
c m
P-lOOl
P-1002 .
Blowers
BL-1001
Asphalt Product Pumps 0,06
. (I)
. -;
Asphalt Transfer 0,06 (I)'
, .
Asphalt Air Blower 6,.9 (109)
TOTAL 7,02 (Ill)
43,3. (IIO)"
43,0 (lID)
45,0 . (113) .
Page 3 of 6
I II II I I I I III I II' I I 1,111 I 11
1
'1 I II' IIII III I
.'
Esfahan Project
Esfahan, Iran
. . For The .
FLUOR-THYSSEN JOINT VENTURE-ESFAHANPROJECT
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
TABLE II
ELECTRICAL POWER SuMMARy
Item No.
P-lOOl
P-1002
P'-1003 .
P-1004
Blowers
BL-100l
. Service
Asphalt Product
Asphalt Transfer
Asphalt Loading

Asphalt Air Blower
TOTAL
u.S .
BliP
38,9
45,1
25.;0
. (2',4)
376,0
485,0
%EFF.
90
88
89
.(80)
95
94
KW
32,2
38,2
21,0
. (2,2)
Intermittent
295,3
386,7.
NOTE: Normal process consumption only, :exclusive of .lighting and

instrumentation.. Ptimps do hot include spares in service.
KW based. upon a sy.stem .power factor of 1.0.
page 4 of 6 II
II' 'III II II 'II II I II II 'II, ' I i III I 'II' I I, III I I IIII I

Esfahan Project
Esfahan, Iran
. For The .'
FLUORTHYSSENJOINT VENTURE-ESFAHAN PROJECT
. Contract 4573
CONFIDENTIAL.
ASPHALT PLANT
TABLE IV
FUEL GAS SUMMARY .
ITEM NO.
.SERVICE
HEAT F'IRED
KJ/S (MMBtu/hr)
-.
IN-IDOl
Incinerator 1 'S17 (6,20)
Page 6 of 6 I r
I 1'1 11" IIII II" II 'III II I " I
VI . Equipment Operation
NATiONAL IRANIAN OIL COMPANY
Esfahan Project
Esfahan, Iran
VI. EQUIPMENT OPERATION
A. Pumps
. .' For The .
FLUOR.THYSSEN JOINT VENTURE-ESFAHAN PROJECT
. . Contract 4573
CONFl DENIIAL
ASPHALT PLANT
The pumps on these units are all positive displacement,
screw-type pumps. The .asphalt product, transer and loading
pumps are steam jacketed. The jacket steam should be. left on
at all times except when the pumps are flushed out .. The.
pumps should never be started against a closed discharge.
B. Rupture Di$c
C.
The asphalt blowing cp1umn,is.equipped with'a rupture disc.
This is set to relieve at 1.3 bar. Normally, of course, the
pressure in the vessel will never rise over 0.3 bar. The
rupture 'disc affords protection mainly against internal'
explosion. If the 'rupture disc should be ruptured, the Unit
must be shut down, emptied out, cooled off, so the disc
may be replaced.
Water Sprays
A water spray inside the asphalt blowing column is only to be
used to cool the' column after it has been emptied and before
maintenance work is done inside the column. A blind must be
inserted in this line' at other times. The line to this spray
must be drained to avoid of water.
.'
D. Flushing Oil Circuit
Provision is made for pumping .flushing oil to a selected
number of points.' Flushing 'oil should never be introduced
into during the and. the operator
must take care that it is not inadvertently .
Flushing oil is used to ,cut: back asphalt being slopped, since
the slop line is only steam traced and not steam jacketed.
It is also used at the shutdown of .the Unit when it is
desired toshut off the steam jackets and allow the unit to
cool off. If the lines and equipment are to be required in
any empty condition, they may be steamed. out at the same
points. Additional steam-outpoints and drain points have
also been provided. When a line has'been steamed out, it
must be .cleared of condensate before returning it to hot
asphalt service. .
Page. 1 of 1 r (
I III Ii' I III I II I II 'I I I I
VII . Startup Procedure

NATIONAL IRANiAN OIL COMPANY
Esfahan Project .
Esfahan, Iran
VII. STARTUP PROCEDURES
. For The .
FLUOR.THYSSEN JOINT Vt=NTURE-ESFAHAN PROJECT
. . Contract 4573
CONFIDENTIAL
ASPHALT PLANT
A. Preparation Prior to Initial Startup
This section covers the work of inspecting, test-
ing, and otherwise preparing new equipment for service. The
procedures described are carried out as a' whole only once:
at the completion of opera-
tion of the unit (apprQpriate phases should be repeated after
any major repair, alteration, or replacement .during subse- .
quent Some parts of the program maybe performed
by'the construction crew; the division of respo.nsibility
between construction and be rigidly
. defined in advance Insofar as the .. .
should witness or supervise any they do not do themselves.
The phases of preparation for initial startup are described
in'the following sequence:
(1) . Operational Checkout List
(2) Hydrostatic.Testing
(3) Inspection of Vessels
(4) Flushing Lines
(5) Instruments
(6) In Pumps
(7) Breaking 'InCompressors
(8) Inspection of Heaters
1.. Operational Checkout List
a. Check line by line against flowsheet and locate all
items'. .
b. Know the location of .
c. Know the location.of all critical valves including
valves at critical vent 'and drain locations.
d: Check control valves, .check valves, and globe
valves to see that 'theyare installed properly with
Page. 1 of 21
I I I III II: I II11 I I I: II I I 1, II ,: i
NATiONAL IRANIAN Oil COMPANY

Esfahan Project
Esfahan, Iran
. . For The
. FLUOR-THYSSEN JOINT VENTURE-ESFAHAN PROJECT
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
A. Preparation.Prior to .Initial Startup (Continued)
1. Operational Checkout List (Continued)
d. (Continued) .
respect to flow through respective lines.
Special a'ttention must be. given check valve's
regarding their direction of flow.
e. In a cold weather plant, review all piping and
instrument connections for
. f.
g.
Check that startup bypass lines, purge connections,
steam-out connections, drains, temporary jumpovers,
etc., have been installed so that the plant can be
commissioned and put on stream.
. . . .
Check pumps and-compressors for strainers,
bleeders, drains, etc.
Check sewer system for operability.

i. Check fired heaters for burner refractories, return
bend closures, stack damper controls, and burners.
2. Hydrostatic Testing
Hydrostatic tests are made on new or repaired equipment
items and piping to. prove the' strength o.- body materials
and welds. They are conducted by filling the equipment
involved with water 'and building pressure with a port-
able test pump. .
The initial hydrostatic testing is ordinarily done by
construction personnel in the course of erecti9n. If,
for any'reason, it becomes necessary for the operators
to carry out such tests, the specified hydrostatic test
for -each item must be obtained. The hydrostatic
test pressure is the maximum pressure to which the item
may be subjected under 'any circumstance; and it must not
be exceeded. Before testing a line, for example, the
line must be blinded off from any connected vessel .
having.alower hydrostatic-test pressure than that of
the line.
Page' 2 of 21 I J.-
1'1 III III II II "III 'I I 1'1 I

Esfahan Project
Esfahan, Iran
For The'
FLUOR-THYSSEN JOINT VENTURE-ESFAHAN PROJECT'
.Contract 4573
CONFl DENTIAt
ASPHALT pLANT
A. Preparation Prior to :Initial Startup (Continued)

2. Hydrostatic Testing (Continued)
Relief valves must be removed or. blinded prior to hydro-
static testing. . If the settings of these valves have
not been this is a good time to
check their relieving pressures.
An operator's hydrostatic testis normally done under
the direction of. the operator prior to charging oil to
the The unit is completely assembled and the test
is made on each operational circuit as a whole, since
individual elements (i.e., vessels, exchangers, lines)
have been previously tested each to its own test
A hydrostatic test pressure of 1.5 x relief valve setting
is used, but this must not exceed the lowest test pres- .
sure limit of any element of the unit undergoing testing.
All joints, exposed welds, valves, equipment, etc., are
ins.pected..' Visible leaks are noted and fixed.
The system should not suffer a pressure loss, but this
requirement may be relaxed where repairable items, such
as leaking valve stem packings, are the apparent
Subsequent tightness tests may be made with air or gas
press1;lriz'atiori, using a soap test solution' to detect
leaks. .
When hydrotesting stainless steel piping and equipment,
controlled test water must be used in order to prevent
stress cracking.
The'followingcriteria is recommended:
a. Water containing more than two hundred (200) ppm
chlorides shall not be used' for hydrotest.
water. containing more than fifty (50) ppm' chlorides
shall be treated with an inhibitor of 1.5 percent
soda ash and 0.5 percent nitrate. The
chloride content of the soda ash shall not exceed
500 ppm. These' percents are by weight .
Page 3 of 21 l v
III 1111' IIII I II IIII II I I' II l

Esfahan Project
Esfahan, I ran'
VI I .' STARTUP PROCEDURES
,FLUOR ENGINEERS AND CONSTRUCTORS, INC.
For The
, Contract 4573
CONFIDENTIAL
ASPHALT PLANT
A. Preparation Prior to Initial Startup (Continued)

2. ,Hydrostatic Testing (Continued)
c. Water containiilq less than fifty (50) ppm chloride
does not require the use of an,inhibitor.
,Equipment should be drained thoroughly after testing.
Where complete drainage is impossible, it is necessary
to flush with chloride free water, alcohol, petroleum
distillate or suitable ,flushing solution. Hot air
drying is not acceptable in lieu. of flushing but" water
may be blown out of pocket's with air.
At the conclusion of the test;' the system must be, drained.
If pumps have been included, they must each be drained
and refilled with oil to prevent rust from forming in
the seals. If fractionating columns ate' included, the
water must be displaced with sweet gas, nitrogen, or an
inert atmosphere rather than air to avoid corrosion and
sticking of ,the valves on,the fractionating trays.
3. Inspection of 'Vessels
Before the final bolting of coverplates and'manheads,
vessel interiors should be inspected for cle'anliness,
completeness, and proper installation of internal equip-
mente A suggested inspection list follows:
a. Catalyst 'supports and screens'.
b. Tray installation; satisfactory testing; where
required.
c. Internal drawoff piping.
d. Internal distributors.
e. Internal risers and vortex breakers.
f. Liquid entrainment separators.
g . Thermowell location and length.

,Page 4 of 21 J 1
e
Esfahan Project
Esfahan, Iran
. For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
e
e
3. Inspection of Vessels (Continued)
h. Level instruments, location and range, internal
float, external displacement, differential
pressure type.
4. Flushing Lines
All fluid-handling equipment - particularly piping -
should be thoroughly cleaned of scale and the internal
debris which accumulates. during construction. This is
accomplished by blowing or washing with air, steam,
water or other suitable'medium.
Some utility systems, such as water and high-pressure
steam, may be satisfactorily cleaned with their normal
media, introduced through normal channels. Other sys-
temsmust, or preferably shouid, be flushed with foreign
media, admitted via temporary hose or pipe connections.
Thus, flushing may be accomplished on exhaust steam
lines with high-pressure steam or air,.and on fuel oil
lines with steam, followed by air. The best way to
clean a typical utility or auxiliary system is to first
flush the supply main from source to end, making an end
outlet by breaking a flange or fitting if necessary;
then, flush each lateral header in the same manner; and
finally, flush the branches which take off from the
headers. In many instances the weld cap on the end of
each header must becut off and rewelded after the line
has been flushed.
Flow meter and restriction orifices should not be in-
stalled until lines are clean. Any orifices installed
before cleaning should be removed.
All connections to instruments should be closed off
during flushing, or disconnected, at the. instrument and
flushed. Instrument air lines must be blown with spe-
cial thoroughness using clean dryair.
. Page 50f 21 19
. NATIONAL IRANIAN OIL COMPANY

Esfahan Project
Esfahan, Iran
For The
FLUOR-THYSSEN JOINT VENTURE..... ESFAHAN PROJECT
Contract 4573
CONFI DENTIAL
ASPHALT PLANT
A. Preparation Prior to Initial startup (Continued)
4. FlushingL1nes (Continued)
a.
b.
Steam .Piping
Before blowing a steam line for cleaning, provide
an open end forthe free passage of steam and
debris. If the open end is a temporary provision,
make certain it is tied down to prevent possible
whipping caused by flow. All drains
must be open and the line free of water. Valving
to steam traps is closed and the traps willremain
out of service until the line cleaning is completed..
Take all safety precautions prior to starting the
steam flow. The area should. be cleared and guarded
to prevent injury to personnel. Steam is slowly
.introduced from the source and the line heated
gradually. The steam flow rate is limited to the
rate o.f condensate drainage. Condensate must not
be permitted to accumulate in order to avoid water
hammer.
As the piping heats and the condensate diminishes,
the stea,m rate is increased. As the line heats, .
observe its expansion and determine that there is
no'binding or distortion.. After the piping is
thoroughly heated, increase the steam rate to
provide a hard blow. After blowing, permit the
line to c061 and contract, then repeat the pre-
ceding blowing. The expansion and contraction of
the piping loosens much of .the mill scale and i.t
is blown free during the succeeding steam blow.
The cleaning procedure should be repeated three
times, always unobstructed.
ProcessLines
Process and au.xiliaryoil systems are washed mainly
with water. Any lines inaccessible to water, or
lines that trap water so that could not be
drained, may be blown out air.
f
Page Q of 21 '\,
Esfahan Project
Esfahan, Iran
For The "
FLUOR-THYSSEN JOINT VENTURE-ESFAHANPROJECT
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
4. Flushing Lines (Continued)
b. Process Lines (Continued)
Most of the process and auxiliary lines may be
flushed from vessels through established circuits,
the vessels being filled with water for the purpose.
whatever extent the lines are connected at the,
time, they may be flushed with the water contained
within vessels after hdrostatic testin9. A sin9le
I ' :..1:"
fillins of a vessel may provide insufficient water
to flush all lines .for which it is the reservoir;
in this case, a continuous or intermittent flow of
water into the vessel should be maintained. Water
may be admitted to most vessels by a temporary
connectionto a nozzle on the bottom outlet line.
If washing of the vessel itself "is a primary objec,-
tive as well, introduce water into the top of the
vessel by hose connection to a top reflux line or '
other entrance. Overhead lines and exchangers may
be flushed by overflowing the related vessel. When
washing exit lines of a vessel, always be certain
the vessel is adequately vented to prevent.a vacuum
condition. Inadequate venting of vessels not
designed for vacuum service could rupture them.
TO the greatest extent possible in'any system,
flush downward, or horizontally,' and discharge at
low points.' The low point discharge opening will
usually be a temporary one made by di'sconnecting'
flanges or fittings; normal drains may be used for
flushing outlets, provided they are equal to'line
size or nearly so. For best results, there should
be no restrictton at the outlet - or at "any other
point in a line undergoing' cleaning; where it.is
necessary to throttle the flushing flow, do so at"
the supply end. .
The higher the velocity' of flushing, the more .
thoroughly a line will be scoured. With a limited
supply of flushing medium, do not flush too many :
or openings at' once. I
Page 7 of
Esfahan Project
. Esfahan, Iran
. For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
4. .Flushing Lines (Continu.ed)
b. Process Lines {Continued}
Some lines, such as buried pump suction lines, must
be flushed in the following manner: a temporary
spool":'piece and line-sized valve is flanged to one
end, and pointed to a safe location (not to the
pump suction); compress.ed air is introduced to the
other end and 'the pressure allowed to build. When
the valve is suddenly opened, the sudden release of
pressure will effectively clean the line. Flush
through all vents, drains and other connec-
tions. Flush bypasses .and their .main channels
alternately (see subsequent remarks on control
valves) .
Try to avoid flushing lirie debris' into equipment
where it may become trapped or lodged. So far as
. it can be done conveniently and economically,
divert the initial flow ahead of or around such
equipment until the lines' upstream are clean; then
flush into or through the equipment concerned.
This applies to such things as exchangers (both
sides), distributor piping with small holes, and
other points of discharge into vessel
Some where this practice is particularly
important are given' in the following' paragraphs..
All control valves should be blocked off and by-
passed until the major part of foreign matter has
been removed from their systems. At
the bottom plate of the control valve, or if
the valve is closed, remove the valve itself from
the line, and flush through the opening so created.
Finally, replace the plate, or valve, .and flush
through the valve in normal alignment (if the valve
is open or .can be opened).
Flow meter and restriction orifices should not be
installed until lines are clean. Any orifices
installed before cteaning should be removed..
Page 8 of 21

Esfahan Project
Esfahan, I ran
VI I. STARTUP PROCEDURES
. FLUOR ENGINEERS AND' CONSTRUCTORS, INC.
For The
FLUOR-TH'YS$EN JOINT VENTURE-ESFAHAN PROJECT
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
A. Preparation Prior to Initial Startup (Coiltinued)

4. .Flushing Lines (Contihued)
b. . Process Lines' (Continued)
All connections at pumps and drivers must be closed
off or disconnected While the .lines running thereto
are thoroughly flushed. This applies to the main .
pump suction and discharge lines, drive and exhaust
steam, gland oil, and,other
auxiliaries.' . .
The flushing outlet.point should be as the
pump or drivers as conveniently possible. Gener-
ally this will require disconnection of a flange or f
fitting. " 'Where this 'is done on the pump (or driver)
side of the block valve, cover the open'pump connec-
tion if necessary to prevent entry of the flushing
flow.' In the main discharge lines containing a
check valve immediately adjacent to the pump' (gen-
erally the case with centrifugal pumps), a flush
outlet-may be made by removing the check valve
coverplate, provided the' flapper or disc remains in
place to seal off the pump itself. '. Where it is
desirable to 'flush through a check valve, the
flapper must be removed and the' cover replaced..
All connections to instruments should be closed'off
during flushing, or disconnected at the instrument
and flushed. Instrument air lines. must be blown
with special thoroughness.
Bypass steam traps untii the lines are fairly'
clean. Check the operation of traps after
have been opened to the flow, and remove for
inspection and cleahing'those'which are not" working
properly.
Disconnect furnace burners until the fuel gas line
to them .is clean'; then reconnect them and blow
through the burner and pilot.
'Page 9 of 21 r f'
,I'I III' I
'
II III II 'III II I I', II II I I i
NATIONAL IRANIAN <?IL COMPANY

Esfahan Project
Esfahan, Iran
_ - For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
A. PreparationPtior to Initial Startup (Continued)-

4. Lines (Continued)
b. Process Lines -(Continued)
At the conclusion of flushing any system, carefully
check to see that -normal alignments are restored -
that temporary connections are broken, and tempo-
rary breaks reconnected, check valve flappers
and/or replaced, -and orifices installed,
etc. In the case ofliries-which will receive
further cleaning subsequent pump break- in, --
this instruction may be qualified in part.
When of process lines is finished, drain
water from the system as completely as possible.
Provide ample top venting during the draining
operation, or whenever the level is being lowered
in a vessel,- to avoid pulling a vacuum on the
equipment. Blow lines with air to further
water removal.
The basic utility systems - steam, water and air -
should be put in normal working order after they
have been cleaned so that supplies will be avail-
able for further operations.
5. Instruments-
As far as time permits, the operators should check in-
struments against-design data, working in cooperation
with the instrument personnel, who will carry out the
installation, calibration, and operation checks on each
instrument according to the -following- -list:
a. Installation Check
(I) The instrument is properly installed and
accessible for operation and maintenance.
(2) All wiring is. checked
Page 10 of 21 rf
NATIONAL IRANIAN OIL-COMPANY
Esfahan Project
Esfahan, Iran
For The
ContrC!ct 4573
CONFIDENTIAL
ASPHALTPLANT.
5. Instruments (Continued)
b. Calibration Check
(1) The instrument is calibrated for operation.
(2) Orifice plates are installed after hydrotest
and line flushing.
(3) The proper charts are installed on all record-
ers.
c. Operation Check
(I) Power:l.s supplied to all instruments. Where
actual operations would be difficult, they are
simulated.
(2) All alarms are test actuated and interlock
systems' checked.
(3) Instruments, connecting piping, and pneumatic
tubing are checked'for leaks.
6 Breaking In Pumps
New pumps should be given..a preliminary run, with strain-
ers in their.suction lines, in order t.o test mechanical
performance 'and reveal any defects attempting to'
start 'up the unit. This circulation also
serves as a supplemental cleaning operation, instrument
and control valve check, a leak check, and allows a
ge_neral performance test of the lines' and equipment
involved in the flow... Flow meter orifices should be
installed. Pumps not equipped'with permanent strainers
or strainer holders should be furnished with temporary
basket-type screens inserted in the nearest accessible
suction flange. This pump "run-in" is usually done by
circulating water through the unit, which requires
temporary piping. Before starting pumps, go through,the
following checklist:
Page 11 of 21
.Esfahan Project
Esfahan, Iran
VI I . STARTUP PROCEDURES
For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
e.

6. Breaking In Pumps (Continued)
a.Check driver rotation.
b. If turbine drivers, check the turbine overspeed
trip and governor with the turbine
.. disconnected from pump.
c. Be sure there is a bleeder on the pump so that the
case can be filled with liquid before starting.
Check multistage pumps for minimum flow bypass.
d. Check lube oil in bearing housing of both pump and
.driver .
Checkout pump cooling water and seal oil systems
where .applicable ..
f. If pumps are run in on a fluid other than that for
which the pump was specified, it may be necessary
to throttle the pump discharge to keep from over-
loading the driver. -
g. Be sure mechanical seals or packing is installed.
For reciprocating pumps following should be checked:
h. On power pumps, check driver rotation and lube oil
in gear1:;>ox.
-i. Check oil level and operation of .piston rod lubri-
cators.
j. On direct-acting steam pumps, check out steam
piping and cylinder drains. warm up steam end
before starting pump.
Before' starting a centrifugal pump, rotate it by hand to
make sure that it turns freely. This is a' good-practice;
always, but it is especially important during the first
few starts. If 'the pump is at all tight, it should be
Page 12 of 21 If
NATI"ONAL IRANIAN OIL COMPANY
Esfahan Project
Esfahan, Iran:.
VI I . STARTUP PROCEDURES
For The
FLUOR-THYSS'EN JOINT VENTURE-ESFAHAN PROJECT
. . . Contract 4573
CONFlDE.NTIAL
. ASPHALT PLANT
A. p.repar.ation Prior .to Initial Starttl.p (Continued)
dismantled and inspected for grit in the casing,
,'sive friction in the packing box, or inadequate clear.-
ance in rotors or bearings.
If .the pump is free,' open its suction valve wide and .
vent the casing to ensure that.it fills, with liquid.
Leave the discharge valve closedor open it
The pump is now' ready for starting, assuming that
suction and discharge circuits are properly aligned and
. that its driver is also in readiness.
Once it has beep put in rotation, a centrifigual pump
must be quickly brought up to normal speed - or at least
to a speed which develops substantial discharge pressure,
as read on the local gauge - In order. to provide internal
lubrication of the rotor. The pump discharge valve
should remain in its initial closed or throttled position
until the pump comes up to speed and establishes full
discharge pressure.. The valve may then be opened gradu-
ally until the desired liquid'flow is obtained, or until
an automatic valve assumes control; in the latter instance,
manual valve is then 'opened wide. If the pump does
not quicklydevelop a discharge pressure close to its
normal value" try venting the pump whIle it is running.
If this. does not help,' stop the pump and vent it freely
before starting again. In case :of persistent loss'of
suction (low ot fluctuating' discharge pressure), look
for closed or throttled valves, plugged strainer or .
other restrictions in the suction line. If
of this sort is not located, the system must be examined
for sufficient net suction head.
A reciprocating pump is started with its suction and
discharge valves wide open..Reciprocatingpumps do not
ordinarily require venting prior to starting, but it is
sometimes desirable that this be done.
All pumps should be watched closely during preliminary
. circulation, and par'tl.cularly when fir,st started. If
bearings or packing boxes begin to overheat
Page 13 of 21 \V
Esfahan Project
Esfahan, Iran
FLUORENGINEERS AND CONSTRUCTORS, INC.
For The '
Contract 4573,
,CONFIDENTIAL
ASPHALT PLANT
VII., STARTUP PROCEDURES
this means hot to the touch) or give other evidence of
trouble, such as" noisy bearings, shut the :pumps down for
inspection.
To ensu:re against overloading, electricians should
measure current with IITong
ll
-type ammeters.
Pumping rates should be' ,kept as high' 'as possible for
thorough lineflus;hing. , The collection 0, solids on the
strainer screen restricts suction line flow, and may
eventually lead to loss of suction.
A pump should be stopped after several hours' running,
or whenever it shows signs of losing suction, and re-
. moved for 'inspection and of the strainer. The
strainer will be replaced, the pump, started, and the
process repeated until the strainer shows itself'clean.
If temporary screens were installed for the pump break-in
,procedure, they may be permanently removed at time.
Time permitting', all centrifugal pumps should be run
for a total of at least 24 hOli'rs. ,- Recip'rocatingpumps,
in general, need less breaking in. Standby pumps should
be run alternately with their counterparts. It will be
,found helpful to keep a record for each pump of running
time, screen 'inspections and condition,' and final dis-
position of strainer. '
'Following the' run-in period, the pump, should be iso-
lated, drained, and filled with oil'to protect the
mechanical seal against rusting.
7. Breaking In Compressors
Compressors and rlrivers of, all types 'must. be properly
installed and opera,ted forllrun-iri
u
similarly to plimps
to, assure their satisfactory service.
The detailed instructions issued by the manufacturer for
the installation ,and operation 'of the machine must be
closely followed. The following checklist should be '
observed:
Page 14 of 21
I 1"1 II' IIII III II "II 'I I II II' 'I, I I III I '11'1' I I 11,1,1 I I lilli' I" III 11 I, ,
NATIONAL IRANt-AN OIL COMPANY
Esfahan Project
Esfahan, Iran
\
\ For The
Contract 4573
CONFIDENTIAL
ASPHALT .PLANT
- VII. STARTUP PROCEDURES
A. . .Preparation Prior to Initial Startup (Continued)
7. Breaking In Compressors (Continued) .
. a. Except for very simple machines, vendor field
service engineers should be present.
b. Check lube and seal oil system on compressor and
driver. Circulate IIrun-in
ll
oil'in lube and seal
oil system to clean all lines. ,Heat oil as neces-
sary. IIRun-in
ll
oil should be changed. See manu-
facturer's instructions.
c. On turbine driven machine, check trip and
governor with turbine disconnected.
d. On motor driven centrifugals and .turbine driven
. reciprocatingcoinpressor> check gearbox lubrication.
e. Check out suction and discharge. piping vent and
drain connections, block valves, bypasses and
relief valves. .
f. On gas engine driven compressors, check out fuel
system and starting air On turbine driven
equipment, check out all the turbine and condensing
equipment. .
g. Check operation valve unloaders and clearance
pockets on reciprocating machines.
h. Check out intercooler and.irlterstage knock-out
drums.
i. Be sure there is no .liquid in suction piping and
bottles on reciprocating starting
compressor.
j. Check out control system and emergency shutdown
devices.
k. Both centrifugal and reciprocating compressors may
be run in on' gas different from that specified for
the design of the machine. However, if there is 'an
Page 15 of 21 \' '1
'NATIONAL IRANIAN OIL,COMPANY ,
Esfahan Project
Esfahan, Iran
For The ,
Contract 4573
CONFl DENTIAL
ASPHALT PLANT
j
A. Preparation Prior to Initial Startup' (Continued)
7., Breaking In Compressors (Continued)
k. (Continued)
appre'ciable difference in gas properties, the
manufacturer should be consulted. is espe-
cially true, for centrifugal machines.
1. Check both reciprocating and centrifugal machines
for adequate instrumentation.
m. Cooling water, to oil coolers, intercoolers, and
aftercoolers must be made available'.
n. If permanent strainers are not installed, temporary
strainers at each suction flange must be installed
and removed after run-in.
B.
Reciprocating compressors are initially operated at no
load, with valves removed, to check lubrication, piston
clearances, and that moving parts operate without undue
noise or rubbing. the run-in; all of
the lubricating .system must be 'made to function correctly
and satisfactorily. All alarms and safety devices must
be verified 'f<?r proper ,setting and,correct functioning.
If the compressor has carbon parts, the run-in period is
used to polish and seat the carbon parts before pressure
is applied to them'.
8. Inspection of Heaters
,The fired heaters are inspected for completeness.
Before inspection, their tubes and auxiliary piping
should have been cleaned during the flushing of con-
necting piping detailed in Paragraph VII-A-4. A check
is then made of the,heater1s readiness for service.'
Asphalt Coolers and Incinerator
The asphalt coolers are steam generators, 'while the incin-
erator is refractory lined. Both require break-in before
Page 16 of' 21
'I III I 'II I: l

Esfahan Project
Esfahan, Iran
VII . STARTUP PROCEDURES
FLLJOR ENGINEERS AND CONSTRUCTORS, INC.
For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT .
B. Asphalt Coolers and Incinerator (Continued)

they can be put into full operation. The asphalt coolers
need to be boiled out with a dilute alkali solution to remove
residual grease. The refractory of the incinerator.needs to
be cured. Subsequent startups do not require repeating these
procedures unless maintenance work has been performed which
reqnires cleaning the coolers or recuring the refractory.
The asphalt coolers require the following;
(I) Inspect the steam side of each cooler. Any excess
grease or oil should be wiped out and any loose
scale should be wire brushed.
(2) When the Unit is ready for startup, add boil-out
chemicals.
This requires a solution containing 0.4% soda ash, 0.4%
trisodium phosphate, and 0.05% Dow detergent. This
solution may be prepared in suitable added to each
cooler through the 3/4-inch connection on the boiler feed-
water inlet. A temporary guage glass should be installed and
a normal liquid level established in each cooler .. Thetop
vent must be opened and the coolers isolated from the 4 bat
steam system. Steam should be injected into the coolers to
heat up the water and to avoid any tube plugging problems
when starting to circulate vacuum
The normal startup procedures are followed by venting the
steam generated to the atmosphere. After about four.hours,
the coolers should be blown down about 2 inches. The water
should be sampled for alkalinity, dissolved oil, and sili-
ceous material. The water level should be restored, chemi-
cals adjusted, and the boil-out continued.
This procedure is repeated until succeeding water samples
show no increase in dissolved oil or siliceous material.
\
C. Normal startup
The text of this section is based upon starting the Unit from
a complete shutdown or after the unit has been prepared for
initial after construction. If a less extensive
Page 17 of 21
NATIONAL'IRANIAN OIL COMPANY
Project
Esfahan, Iran'
VII.. STARTUP PROCEDURE .
For The
. FLLJOR-THYSSEN JOINT VENTURE-ESFAHAN PROJECT
Contract 4573
CONFIDENTIAL'
ASPHALT PLANT
C. Normalstartup (Continued)
shutdown has'been made, omissions in the foliowing procedure
may be made as indicated by the operating supervisor.
111 blinds should be made normal operation_
warming up the asphalt blowing column, with 20 bar
steam through the air spider. Drain condensate away through
the 3-inch bottom drain in the pumpout line. the
incinerator following the startup instructions provided by
the vendor.
Before commencing a run.on the blowing column, the unit must
be cleared of the flushing oil left in it during the previous .
shutdown. Initially the operator must line tip to take vacuum
residuum from the Crude Unit and divert it out'the slops
line. The lines should be filled graduaiiy until acircula-
tion is established temperature ofthevacuum.residuum is
lined out at 210C.
A level of boiler feedwater must be established in the asphalt
coolers E-I001, with the'feedwater level control .. Open up
the steam main .block valves, vent the Boiler thoroughly; and
start continuously blowing down. The steam will heat up the
water and avoid any p'roblem of .plugged .tubes. whenstarting to
circulate vacuum resid.
, \
When the blowing column is hot and dry, the bottom drain may
be closed off and filling the column with hot vacuum resid
from the Crude Unit may commence. '1t should be filled through
the normal' filling point while continuingto steam the column.
When the bottom thermowellis covered, indicating a level at
that point, open the suction to the asphalt: product pump
P-lOOI, and start pumping asphalt through the asphalt cooler
and to the slops line. Before each line is put in service,
the steam jacketing must be commissioned.' ..
Control the pump discharge flow with the bypass valve, HIC-l002,
to'avoid emptying the column. Switch to the spare pumps for
a time. Clear 'all lines of possible flushing oil in this:
manner, including the recycle lines.' Sample' the .circulating
resid and test for viscosity to determine if the flushing oil
is cleared from the ,system.
'Page 18 of 21 f'(
Esfahan Project
Esfahan, Iran
For The '
Contract 4573 '
CONFIDENTIAL
ASPHALT PLANT
C. Normal startup (Continued)
When the system is of flushing the column can be
filled; and while filling, air blowing can commence so that
when the column is full, tpe asphalt ,in ,it will be close to'
penetration grade. During this operatibn, the asphalt product
.pump should be stopped, and the slops line 'should be, blocked
in. The line, need not be flushed at,this'stage.' The 3-inch
plug-cock on the 'bottoms' filling line should,be opened, and'
the valve to the 'normal, filling point closed. , Filling should
continue from the bottom at the normal rate, and this should
be measured by the Crude Unit ,operator, it cannot be
measured by the Asphalt Plant operator.,. When this is under
way, the snuffing steam to both snuffing steam points may be
commissioned; be absolutely sure that the snUffing steam trap
is working and the steam is d'ry. ,Also, a't this time the air
purge to the leads of the level indicator, L1'-lOOl, may be
commissioned and the indicator put in service. At this time,
if the bottom level'thermowell is covered, and the tempera-'
ture of the vacuum resid in the column is between 193C and
210C, the 20 bar steam to the air spider may be shut off and
air blowing may initially at a very low rate,
increasing until the temperature of the vacuum resid in the
column rises and lines out at
'When LIC-IOOI indicates that the level in,'V.i.IOOl is 'over the
normal inlet, close the bottom fill valve and start feeding
"through the normal inlet., ' Blowing, shbu:;Ld continue while this
is done.
Line' up to pump product to slops on level control. wi th the
hand indicator control valve in the pump byPass wide 'open,
start the asphalt product pump, P-I001. Close in the bypass
until some pressure is built up. Set PIC-l002 in the cold
recycle line to open at 5.5 bar and:adjust the pump bypass
Until the level controller is working properly and a small
amount of asphalt is recycling.
Increase the air rate and amount of recycle, together 'so as' 'to
hold the required temperature until the right amount. of air
is being used. Base this on past experience as well as
constant sampling and testing.
Page 19 of 21
I III I IIII III I 'II I I II I II I II I I II I r I I \I HI I I II I I III I ""
r::. NATIONAL IRANIAN OIL COMPANY
Esfahan Project
Esfahan, Iran
. 'For The
Contract 4573.
CONFIDENTIAL
ASPHALT' PLANT
--
\ .
c. Normal Startup (Continued)
Sample the recycle stream constantly. The quickest test to
determine the proper of air blowing is the .ring and
ball softening point test .. When the blowing column is first
filled, the material in it should be c10s'etothe required
'softening point as 'a result of the preliminary blowing..
Ohs.erve trends closely. Adjust air rates and recycle together
to and thus obtain the required '
softening point and penetration. When the product is on
tggt, held And switch it into the
storage tank. After unit is on stream, flush out the asphalt
in the slops lines with flushing
Once on stream, test regularly to keep the softening point
and penetration index at the required value', adjusting air
rates and recycle as required. If the temperature .and proper-
ties .ofthe vacuum resid .charge stays constant, the operating
conditions in the Asphalt Plant will remain stable.
Rundown tanks should be sampled at the beginning and end of
filling.' . If one should be put "off-test," it can be adjusted
.by blending with higher or lower penetration product, or it
can'bepumped to the slops line.
Any rundown tank can. also betra,n$ferred to any other rundown
tank, but it must be one to which.current.proquct iS90ing.
Reprocessing is possible but inconvenient .and ordinarily
neither neces.sa,ry nO.r desirable.
Asphalt of 60-70 penetration may be made at temperatures
between 232C and 260C. If a temperature in excess of 260C
is inadvertently reached, the air should be reduced or shut
off and steam put through the aeration spider'with' recycling,
until the temperature is reduced. If a temperature of below
204C,is reached, it .is possible the reaction may stop. The
'asphalt will then get colder and .colder. If, this' should
happen', pump it to the Refinery slops and start over.
. .
Blow down the water leve1'in the asphalt coolers a minimum of
once a shift. The amount of. blow down should be sufficient
to keep the total dissolved solids in the sampled water ,at
the level specified.

Page' 20 of 21 "

Esfahan Project
Esfahan, Iran
VII ~ STARTUP PROCEDURES
For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
C. Normal Startup (Continued)

Keep steam in the coils or the asphalt tanks to keep the
required temperature. Keep the steam jacketing-on at all
times while the unit is rounning.
Page 21 6f 21 f
Q
.
II III IIII III II ' I
-
VIII.Normal Shutdown

Esfahan Project
Esfahan, Iran
FLUORENGfNEERS AND CONSTRUCTORS, INC.
For The
FLUOR"THYSSEN JOINT VENTURE-ESFAHAN PROJECT
Contract 4573
c0 NFl 0 ENTIAL
ASPHALT PLANT
c. '.
VIII. NORMAL SHUTDOWN PROCEDURES
For a planned .shlitdown, it is only' necessary to stop the flow of
feed and shut off the aeration air at the same time, . since the
blowing column and recycle lines are full of asphalt at the cor-
rect penetration. Shut off the cold recycle stream and put the
contents of the biowing column to asphalt storage. Block in the
rundown lines at the control valves L I C ~ l O O l . Block in the steam
side of the asphalt coolers and drain out all the boiler feedwater.
Block in vapor line from the knock-out drum to the incinerator.
After the blowing column is emptied, steam purge and pump flushlng
oil into it. Circulate flushing oil through all lines except the
asphalt loading lines, suction lines from the asphalt storage
tanks, and rundown lines to the asphalt storage tanks. These
lines must not be contaminated. Pump flushing oil to refinery
slops line until the lines are clean. Shut off the steam jackets
and allow the lines to cool. Never completely block in any length
of line that is full of oil or asphalt. 'If this is required to do
mechanical work on any line, the flushing oil may be blown out by
air or steam.after the line has cooled off. High-point bleeds and
low-point drains have been provided for the lines, and'these
should be used for steaming out, clearirig, draining, etc.
Page 1 of 1
IX.EMERGENCY SHUTDOWN

Esfahan Project
Esfahan, Iran
FLUOR EN,GINEERS AND CONSTRUCTORS, INC.
-For The
, FLUORTHYSSEN JOINT VENTURE..,..ESFAHAN PROJECT
Contract 4573
CONFlOENTIAL
IX.
ASPHALT -PLANT
EMERGENCY SHUTDOWN PROCEDURES
A. Internal E!plosion or Fire
B.
Occasionally, due to allowing the temperature or'rate of
reaction to escalate, the internal temperature of the asphalt
blowing column will rise very sharply, indicating the onset
of combustion. Sometimes will be an internal explo-
sion, rupturing the rupture disc and blowing clouds of smoke
out through the line. In such ,case, stop feed
to the unit, shut off air flow to the blowing column and
start flow of 4 bar snuffing steam to this column. In the
event the temperature of asphalt in this vessel continues to
increase and an internal fire exists, a flow of 20 bar steam
may gradually be started through the aeration spider into the
blowing column required. There is also a plant water
supply to a spray head inside the vessel, but this should not
be used for fire fighting as it may cause the asphalt to
froth and foam. Pump out the contents of the blowing column.
Foaming
The introduction of small amounts of water in the hot asphalt
will cause it to foam over.' This may fill the vapor line and
knock-out drum, rupture the rupture disc, or overflow the
tanks. When this happens, stop pumping into the vessel in
question, make every effort to cool it off"and eliminate the
source of water, which may, for example, come from wet snuf-
fing steam (although once the foaming has started, there is
not usually any way to stop it until the water has all boiled
off). Earthmoving machinery can be pressed into action to
contain the spilL
C. Power Failure
Pumps will stop. Stop the aeration air; suspend operations
until power is restored. Depending on the duration, product
mayor may not have to be slopped for a while when coming
back on stream until sampled and tested. Check levels in
steam generators. Check temperatures during this period.
-.
D. Instrument Air Failure
The Plant is 'designed to shut itself down in a safe condi-
tion. The charge, asphalt to storage, and aeration air
Page 1 of 2
fv
I I II :1 : !
NATIONAL iRANIAN OIL COMPANY

Esfahan Project
Esfahan, I ran
. For The
FLUOR-THYSSE;N JOINT VENTURE-ESFAHAN PROJECT
.. Contract 4573
CONFIDENTIAL
ASPHALT PLANT
IX. EMERGENCY SHUTDOwn PROCEDURES
D. Instrument Air Failure (Continued)
streams will all shut off; cold recycle will increase.
B01ler feedwater will shut off; this level should be watched
since the water may boil off to a low level. If the air
failure is prolonged, shutoff the product pump; or pump the,
asphalt to storage through the coolers, watching the water
level in the coolers and regulating it by hand.
E.
F.
Loss of.Boiler Feedwater
This may cause loss of recycle cooling and a rise in tempera-
ture of the blowing column. Stop the aeration air and the
charge to the unit immediately_ stop the asphalt product
pUmp. If the boiler feed.water is prolonged, it may be neces-
sary to keep the asphalt hot with 20 bar. steam; arid if this
will not keep it hot, it may be necessary to pump the asphalt
to storage.
t.oss of Fuel Gas
The loss of fuel gas will cause the incinerator to shut down.
This will result in venting foul. odor fumes into the atmo-
sphere. Stop the. aeration air and the charge to unit. Stop
the. asphalt product pump, and see that the unit is in shape
to come on stream as soon as fuel gas is again available. If
the fuel gas failure is prolonged, it may be necessary to
keep the asphalt hot with 20 bar steam; and if this will not
keepdt hot, it may be necessary to pump the asphalt to
storage.
G. Loss of Raw Feed

Shut off both the recycle and the aeration air. Either wait
until the raw feed is again available, at which time the
process may be restarted, or if the Plant is becoming cold,
pump it out to storage.
Page 2 of 2
X . SAFETY
Esfahan Project
. Esfahan, Iran
x. SAFETY
A. General
For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
The best available engineering know-how, materials of con-

struction, and construction have been used in the
building of the Asphalt Unit. The expertise of Fluor-
Engineers and Constructors, Inc., . in' the,fields of design
engineering and construction was used in the design of the
unit to make an efficient, profitable, easily operable, and
above all, ' safe processing facility.
Petroleum refining processes have-an inherent hazard: you
are dealing with all threeelelllents of the fire triangle,
fuel, oxygen,' and a source of ignition.Fuel is present in
the form of hydrocarbon liquid and vapor in the lines and
vessels of the equipment. - The atmosphere is a ready source
of oxygen. Sources of ignition are always present, both from
heater fires and from hot work that will have to be done at
certain times. .
We: must be constantly on alert to prevent the combination of
the three elements of the fire triangle ..EXplosive air-fuel
mixtures or urinecessarysources of ignition'must not'be
allowed to exist inprocessateas.
B. Safe .Place to Work
A plant such as this one can be a safe place to' work when
safety procedures and precautions are constantly observed.
It is the responsibility of each employee to think and work
safely. Remember that death or serious disability may result
from unsafe practices and accidents.
Safety and good housekeeping depend upon each other. A clean
plant is one safe 'to work in. Operators should take pride in
working in a clean, well-ordered
C. Hazards
Some' possible hazards and the methods' for their prevention
are listed below:
1. Leaking flanges, glands, or broken gauge glasses can
release gases and liquids into an area,' creating a fire
hazard. All equipment should be tested for leaks before
startup.
Page 1 of 6 \ .'\
\

Esfahan Project
Esfahan, I ran
x. SAFETY
FLUORENGINEERS AND CONSTRUCTORS, INC.
For The
. Contract 4573
CONFrOENllAL
ASPHALT PLANT
C. Hazards (Continued)
2. Water getting into the fresh feed or reflux pumps will
cause excessive pressures on furnaces and columns. Keep
water drained from reflux drums.
3. Ignition of air and gas mixtures in the system may be
caused by improper purging before heating up. .All
systems are to be purged to give a nonexplosive atmo-
sphere. .
4." Excessive pressure on vessels, exchangers, cocks, valves
and lines may result from improper setting of intercon-
necting lines. Check that equipment is properly lined
up before starting a stream into it.
5. Excessive pressure may develop from improper control of "

heating equipment. For example, excessive pressure on
heaters results if they are blocked off while full of
liquid and heat is still on the tubes. Always properly
vent heaters when closing them off, and be sure the
source of heat is positively shut off and vented.
6. Pumping hot fluid through exchangers which are blocked
off on the other side can cause the cold fluid to expand
and blow out gaskets. Be sure exchanger valves are
. open.
7. Water getting into acid lines and equipment will dilute
the acid, resulting in excessive corrosion.
8. Climbing on pipes and equipment can cause damage to
equipment and injury to personnel. Use ladders or
stairways. Use a solid stepladder if and
ladders are not close enough. One man at a time on any
ladder is a good rule.
9. Trash and rubbish are a fire and stumbling hazard. Pick
i'l: up. An operator should be proud of a clean unit.
10. Dropping pressure too rapidly through valves will cause

the moisture in the stock to freeze and consequently
plug the valve. When draining mixtures which contain"
propane and butane, "be sure double blocks are provided.
Page 2 of 6

Esfahan Project
Esfahan, Iran
x. SAFETY
. FLUOR ENGINEERS AND CONSTRUCTORS, INC.
For The'
FLUOR-THYSSEN JOINTVENTURE-ESFAHAN PROJECT
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
C. Hazards (Continued)
10.' (Continued)
Open inside valve wide open and control with the outer
valve; the inside valve can be shut off if the outside
valve freezes open.
11. To prevent hydrogen sulfide gas poisoning resulting from
sudden gas leaks, do not mix spent caustic and acid.
Operators must be familiarwitih the hydrogen sulfide
operating standard. .
12. Too rapid cooling or heating of vessels may cause uneven
stresses, thereby weakening or possibly cracking the
vessels or interconnecting lines ..
13. Spilled oil or chemicals around units or in trenches

should be cleaned up at once.
14. Liquid samples shall be taken in accordance with sam-
pling procedures. Draw sample carefully. In drawing hot
samples, be sure cooling water is on sample cooler. Hot
samplers can cause burns.
15. Smoking in the process, loading or storage areas' can
cause fires. and explosions. Smoke only in designated
areas.
I
16. Welding or other work that can cause sparks in the
process area can cause fires and explosions. Make the
area safe for such work and obtain the necessary permits
from the properauthorities before starting. .
17. Water hammer in steam lines can rupture lines and valves.
Never throw open a steam line or any other line by
suddenly opening a valve wide open. Gradually open
blocked in valves. Always drain condensate from steam
. lines. .
18. Cold liquids can shatter carbon steel. Any material not
specifically designed to handle cold temperatures, -30C
or lower, can shatter,upon c o n t ~ c t with cold liquids .
Never allow cold liquids to drain into carbon steel
headers.
Page 3 of 6

Esfahan Project
Esfahan, Iran
X.' SAFETY
. For The
JOINT VENTURE-ESFAHAN PROJECT
. Contract 4573
CONF.l DENTIAL
ASPHALT PLANT
C. Hazards (Continued)'
19. Injury results from improper handling of hazardous
chemicals. Hazardous chemicals present in .the operation
of this plant, together with. their characteristics, are
tabulated' elsewhere in this section..
2Q.Horseplay - probably more accidents are
caused by this than any other factor. .If you must
indulge in horseplay, do it away from the plant.
D. Good Housekeeping
Good housekeeping means keeping each unit in the plant in a
clean, orderly condition. The operating group can keep its
areas clean with.a minimum of effort by dividing the work and
doing routine cleaning each shift. It will be found that
900dhousekeepingis easy when practiced from the beginning.
The following suggestions are made to provide a neat" orderly
and therefore safe plant:
1. Control room floors should be cleaned daily.,' Keep
and control boards clean.
2. The'entire unit area should be washed down as often as
required to keep it clean.
3. Keep unit area, includingwalks'andplatforms on equip-
ment, clean and free of loose bottles, rags,
etc., at all times.
4. clean up oil or chemical keep pump
base drains unplugged; and keep all pipe trenches ,washed
clean of oil and debris.
s. Except when in use, keep all tools in the locker pro-
videdfor them. Keep tools clean and in good condition,
ready for use.
6. Waste containers should be provided for oily rags and

garbage. There should be a regUlar schedule for empty-
ing these containers .
Page 4 of 6

Esfahan Project
Esfahan, Iran
, x. SAFETY
FLUOR,ENGINEERS AND CONSTRUCTORS, INC.
For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
11.
D.' Good Housekeeping (Continued)

7. Replace all air, and water hosesin'ilnediately
after use.
8. Good maintenance promotes cleanliness as well as safety.
Leaking flanges, valves, etc. should be repaired' or
replaced, as soon as possible.
9. Maintenance workers should be instructed tjlclean up
pump packing, nuts, bolts, gaskets, insulation, etc.,
upon completion of a job. Leave the area as clean as it
was found should be the motto of men.
10. Remove all, maintenance tools, equipment and scaffolds
from the unit area immediately upon completion of a job.
Keep all lubricating oil, as well as the oil cans and
lubricating equipment, clean. Keep pumps and turbines
clean, particularly around the bearings. Keep covers in
place over
12. The use of light naphtha, solvents, or gasoline for
washing hands and clothing should be prohibited. Kero-
sene is provided for the use of' operators in the TEL
plant for washing off TEL compound.
E. Requirements for Welding Permits
If it is found necessary to weld in any process area during
the operation of the units, the shift foreman must call
qualified safety personnel.' They will inspect the designated
area, request the covering of open sewers, insist on portable
or hand operated fire extinguishers being present, and check
the area forithe presence of explosive mixtures. If the area
is found to be safe, a signed welding permit will be issued.
All operating personnel the area must be alerted that,
welding is to take place in their zone of operation. '
F. ' Specific Procedures for Asphalt Units
1. All operators should wear a hard'hat at all times
, Page 5 \of 6 <: rJ4

Esfahan Project
, Esfahan, Iran
For The
Contract 4573
CON'FI DENTIAl
ASPHALT PLANT
X. SAFETY
F. Specific Procedures for Asphalt Units (Continued)
'2. All operators should wear work covers arms
and legs, and wear gloves when sampling the hot asphalt.
3. The operator should not carry hot asphalt samples in
such a manner that they will be slopped around if he is
bumped. Many an operator been badly burned in this
manner.
"
All spills must be cleaned up immediately.
Neither operator nor driver is. allowed to stand on the
road tanker while loading it. 'Stand clear.
The operator is responsible for making all equipment
safe for the attention of maintenance' personnel.
Every operator iS,responsible for the safe condition of
his plarit;the operator is responsible for,correcting
all unsafe conditions or initiating steps to correct
them.'
4.
5.
6.
7.
.'
Page 6 of 6 (<'
XI . Analytical Test

Esfahan Project
Esfahan, Iran
For The '
Contract 4573
CONFIDENTIAL
ASPHALt PLANT
XI. ANALYTICAL TESTS
The tests required to be performed on the various streams of
the Asphalt ~ l a n t in order to control the process are tabulated
below.
Page 1 of 1
'.
Esfahan Project
Esfahan. Iran
FLUOR E;NGINEERS AND CONSTRUCTORS. INC.
For The .
FLUOR-THYSSEN JOINT PROJECT
Contract 4573
.. CO", FI DEN11AL
ASPHALT PLANT
XII. CATALYSTS, CHEMICAL, AND PACKiNGS
The chemical requirements for an initial charge of boil-out
chemicals are tabulated below.
DESCRIPTION
Soda Ash
Trisodium Phosphate
Dow F-48
Water
77
10
19,250
Page 1 of 1
XII . Catalysts Chemical
& Packing
NAT10NAL IRANIAN OIL COMPANY
Esfahan Project
Esfa.han, Iran
For The
Contract 4573
CONFIDENTIAL
ASPHALT PLANT
XIII. DRAWINGS'
The- following drawings are included in this section:
DESCRIPTION
1. Process Flow Diagram
Asphalt Plant
2. Mechanical Flow Diagram
Asphalt Plant,
3. Mechanical' Flow Diagram
Asphalt 'Loading
4. -e--OtJ.-ri-fi1---F10W -Diagram'---- --
Asphalt Plant
DRAWING NUMBER
'
E"'10-R-OIO !'
<'
E-IO-R-020 ./
(e
i
)
S.
6.
Plot Plan
Asphalt Blowing
Flow'Diagram Legend and General Notes
E-IO-R-OSO
'E-OO-4-001 /'
Page 1 of 1
II III I
I
II I' 'II IIII II I 1'1 I II "I I I I

Plant 10

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',1

IX. . EMERGENCY."SHUTDOwN PROCEDURES

NATIONAL IRANIAN OIL COMPANY

HEAT AND MATERIAL BALANCES

FLUOR ENGINEERS AND CONSTRUCTORS, INC.

NATIONAL IRANIAN OIL COMPANY

B. Process Flows (Continued)

The principal\ ,operating variables in the control of the asphalt

NATIONAL IRANIAN OIL COMPANY

NATIONAL IRANIAN OIL COMPANY

NOTE: Normal process consumption only, :exclusive of .lighting and

NATIONAL IRANIAN OIL COMPANY

VII . Startup Procedure

NATiONAL IRANIAN Oil COMPANY

Check sewer system for operability.

NATIONAL IRANIAN OIL COMPANY

A. Preparation Prior to :Initial Startup (Continued)

NATIONAL IRANIAN OIL COMPANY

A. Preparation Prior to Initial Startup (Continued)

g . Thermowell location and length.

. NATIONAL IRANIAN OIL COMPANY

NATIONAL IRANIAN OIL COMPANY

A. Preparation Prior to Initial Startup (Coiltinued)

NATIONAL IRANIAN <?IL COMPANY

A. PreparationPtior to Initial Startup (Continued)-

A. Preparation Prior to Initial Startup (Continued)

NATIONAL IRANIAN OIL COMPANY

B. Asphalt Coolers and Incinerator (Continued)

NATIONAL IRANIAN OIL COMPANY

C. Normal Startup (Continued)

NATIONAL IRANIAN OIL COMPANY

NATIONAL IRANIAN OIL COMPANY

NATIONAL iRANIAN OIL COMPANY

G. Loss of Raw Feed

The best available engineering know-how, materials of con-

NATIONAL IRANIAN OIL COMPANY

5. Excessive pressure may develop from improper control of "

10. Dropping pressure too rapidly through valves will cause

NATIONAL IRANIAN OIL COMPANY

13. Spilled oil or chemicals around units or in trenches

NATIONAL IRANIAN OIL COMPANY

6. Waste containers should be provided for oily rags and

NATIONAL IRANIAN OIL COMPANY

D.' Good Housekeeping (Continued)

NATIONAL IRANIAN OIL COMPANY

NATIONAL IRANIAN OIL COMPANY

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