Section 1 Chapter V - First Start Up Printed

Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.
DHDT Unit – Phase-3 - Operating Manual F ……….

Section-1-Chapter V – First start-up 20-6-2012
First start-up
1. Status of the unit

2. Preparation
3. Chronology of Start-Up Operations
4. Amine Section
5. Closed loop short oil circulation
5.1. Schematic for the start-up oil loop
5.2. Procedure for establishing vessel levels
5.3. Dewatering pump-out to slop (off spec)
5.4 Closed loop circulation
6. Catalyst Treatment
6.1 Hydrogen circulation
6.2 Pre-wetting
6.3 Catalyst sulphiding procedure
7. Fresh Feed-in
7.1 Switch to Normal Feedstock (at 100% design capacity)
7.2 Increase Throughput to Design
7.3. Stripper
7.4 Splitter
First Start-Up
As the hydro treating process gives rise to a highly significant production of

hydrogen disulfide (H2S), the units that are connected with the operation of the
DHDT unit have to be correctly commissioned and be ready for duty, in all respects,
before an initial start-up of unit is envisaged.
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1. Status of the unit
 The leak tests and vacuum tests have been successfully completed.
 The reaction section & heaters have been dried out.
 The reaction section is under a hydrogen pressure.
 The amine section has been degreased, rinsed and is under an oxygen-free
gas positive pressure.
 LP sections are under fuel gas or nitrogen pressure.
 The other parts of the unit are under fuel gas or nitrogen positive pressure
and water has been drained as far as possible. Water may still be trapped on
certain column trays and in other equipment items.
 All utilities are in service. Blinds in the headers have been removed, and
valves open to all users.
 The catalysts are correctly loaded in the reactor.
 All instrumentation has been checked.
 All safety devices and emergency sequences have been tested.
 Safety valves for all equipment items shall have been lined up, and these
actions recorded on a checklist.
 The reaction section is isolated from upstream and downstream equipments.
(ie, From feed section & LP section)
 The washing water drum has been filled with boiler feed water; the drum
level control and split range pressure control are in automatic operation.
 Pumps and compressors (and their drivers) have been aligned and run-in.
 Heat exchangers/ fin fan coolers have been checked and are ready for
operation.
 Start-up gas oil is available (hydro treated gas oil) from tank No. 70046A/B.
 H2 plant is running.
 Lean amine is available.
 Chemical injection systems have been prepared and chemical pumps
calibrated. The chemical injection lines have been filled up to the injection
points.
 A start-up feedstock is available: usually a straight run gas-oil, with following
specifications:
o ASTM distillation close to the ASTM of design feed.
o Specific gravity as close as possible to the design feed.
Note: A start-up feedstock means a distillate essentially free of diolefins and olefins
with low sulphur and nitrogen contents.
 As the reaction section produces a significant amount of hydrogen disulfide,

LP amine absorber, amine regeneration unit, sulphur recovery unit and sour
water stripping units have to be in service before the initial start-up of hydro
treating reaction section.
 For equipment under N2 atmosphere (or hydrogen), dead zones need to be
purged just after oil in, to remove non-condensable gases.
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 During all these steps, care should be taken of all level indications. As density
of gas oil could be different from normal operating fluid, indications can be
erratic. Levels should be checked on site with the corresponding level glass.
2. Preparation
 1 Ensure that sulphiding injection line is in service and DMDS is available to

DHT unit from OSBL (CHTU).
 2 Fill the antifouling agent drum (FA-33317) with the antifouling chemical
(CHIMEC3110), 10% and test the electric agitator and the antifouling pump.
 3 Fill the corrosion inhibitor drum (FA33316) with the inhibitor chemical
(CHEMIC1044)10% for the stripper OVHD and test the corrosion inhibitor
pump.
 4 Commence flow of lean amine to the HP amine absorber and set up
absorber level controller for normal operation. During catalyst activation HP
amine absorber is by passed by recycle gas by using HIC333002.
3. Chronology of Start-Up Operations
The chronology of the various start-up tasks is shown on the attached schedule.
The duration shown are those required to perform the tasks. The time gap between
two consecutive operations has not been taken into account.
Start-Up Schedule - TASKS
 Pressurize the Stripper And Splitter, LP absorber to operating pressure

using fuel gas / N2.
 H2 Pressurization of the Reaction Section, (Including HP Absorber &
MP Separator)
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 Start-up of the Amine Section (except the HP Absorber – establish

level in this vessel but do not circulate)
 De-watering of feed /LP section with gasoil
 HP section H2 tightness test
 Start Recycle Gas Compressor
 Start Gasoil Closed Loop Short Oil Circulation
 Circulate gasoil through the Reaction Section (catalyst wetting)
 Sulphiding of the catalyst
 Establish wash water circulation on spillback.
 Close By - Pass on HP absorber + start Amine Circulation
 Design Feed-in and Adjustment Of Operating Conditions
 Product to Storage
4 Amine Section
 Amine inventorying
 Amine circulation
4.1. Amine Inventorying

- Confirm that the amine relief valve to flare system has been air freed and is in
service. Also confirm that any isolation blinds previously installed to isolate the unit
from the flare system have been removed.
- Start receiving lean amine from ARU to the lean amine surge drum (FA-33314).
Follow the level rise in this drum on the local LG (LG-333065) and cross-check with
the LIC indication on DCS (LIC-333062). When the level reaches 50% put the LIC-
333062 on auto at a 50% set point. Check to see that the LIC-333062 begins to
close the LV-333062 on the import flow to the drum.
- When a 50% level has been established in the lean amine surge drum (FA-33314),
start one of the lean amine pumps (GA-33303 & GA- 33312) on mini-flow operation
before starting to send amine to the HP amine absorber (DA-33301) and to the LP
amine absorber (DA-33305) respectively.
- Monitor the level rise in the bottoms of the HP amine absorber (DA-33301) and
the LP amine absorber (DA-33305) using the local LG-333034 and LG-333070
respectively. Also cross-check these levels with LIC-333030 and LIC-333069
indication respectively in DCS. When the level in the absorbers reaches 50% stop
the amine flows to the absorbers. Keep the lean amine HP pump (GA-33303 A/B) in
mini-flow operation. Check that TDI-333086 and TDI-333205 is commissioned and
ready for operation on HP & LP absorbers respectively.
- Increase the set point on the lean amine surge drum (FA-33314) to 80% and allow
the level to follow this new set point. This additional volume of amine, and probably
more, will be required when hydrocarbon flow to the absorbers causes an increase
in amine inventory on the absorbers trays.
- Prepare the anti-foaming tank (FA-33318) using chemical CHEMIC8049, 10% and
using one of the anti-foaming pumps (GA-33316 A/B), fill the anti-foaming line up to
the injection point.
4.2. Amine Circulation

 Set the flow controller on lean amine to the LP amine absorber (DA-33305),
FIC-333086, at mid scale (50%) and verify its operation. Start anti-foaming
solution to the LP absorber injection points.
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 Verify that the LP amine absorber bottoms have a working level and unblock
the level control valve LV-333069. Verify that the level control is operating
correctly and relevant amine is being returned to the amine regeneration unit
through rich amine line.
 Circulation of amine to and from the HP amine absorber (DA-33301)

will not be started until the sulphiding of the catalyst is complete. This
is to reduce the consumption of DMDS as operation of the HP amine
absorber (DA-33301) during this procedure would reduce H 2S levels in
the recycle gas.
The level of amine established in the HP amine absorber (DA-33301) will act as a
liquid seal during the hydrogen test of the reaction section. During sulphiding. the HP
Amine Absorber (DA-33301) by-pass line will be opened. The lean amine HP pump
(GA-33303 A /B) can remain in mini-flow operation (or stopped) until it is required.
These pumps can be switched to stand by from time to time so that both can be
thoroughly checked out.
5. Closed loop Short Oil Circulation

The purpose of this procedure is to fill up the unit (reaction section excluded) with
start-up gas oil, to circulate this fluid around the bottom of each column (meaning
Stripper (DA-33302) & Splitter (DA-33303) and associated piping and exchangers)
and to remove water accumulations, prior to routing start-up gas oil through the
reactors for the catalyst sulfurization step. This flow may be referred to as "closed
loop short oil circulation". The term "short" means that the reaction section is not
included in the circulation at this point of time.
During stripping and splitter sections drying out, ensure that the reaction
section is well isolated.
5.1. Schematic for the Start-up Oil Loop
 Start-up gas oil circulation is represented in the following schematic:
o configured as follows:
 Start-up gas oil from storage –

 Feed filter (FD-33301) –
 Feed Surge Drum (FA-33302) (pressurized with fuel gas)—
 Feed Pumps (GA-33301 A /B)—
 Kerosene Product / Stripper Feed Exchanger (EA-33305) (shell side)---
 Diesel Product / Stripper Feed Exchangers (EA-33306 A / B / C) shell side—
 Reactor Effluent / Stripper Feed Exchanger (EA-33303)---Shell side--
 Stripper (DA-33302)---
 First Splitter Feed / Bott Exchangers (EA-33307 A / B / C / D) (shell side)—
 Second Splitter Feed / Bottom Exchangers (EA-33308) (shell side)---
 Splitter (DA-33303)---
 Diesel Product Pumps (GA-33308 A / B)---
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 Second Splitter Feed / Bottom Exchangers (EA-33308) tube side—

 Kerosene Side Stripper Reboiler (EA-33309) tube side---
 First Splitter Feed / Bottom Exchangers (EA-33307 A / B / C / D) tube side--
 Diesel Product / Stripper Feed Exchangers(EA-33306 A / B / C) tube side---
 Diesel Product Air Cooler (EC-33304)---
 Diesel Product Trim Cooler (EA-33314 A / B)---
 Back to Feed Surge Drum (FA-33302) through Feed Filter (FD-33301).
The start-up circulation flow rate is fixed at 60% design throughput.
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5.2. Procedure for Establishing Vessel Levels
Note: This procedure assumes that the Amine Treatment System is ready for
receiving Stripper (DA-33302) off gases.
Establish level in Feed Surge Drum (FA-33302)

 Feed surge drum level control valve (LV-333001 A / B) on the line from cold
feed from storage should be closed. Downstream isolation valve of the feeds
should be opened. Suction line isolation valve to the feed pumps (GA-33301 A
/ B) should be opened. One of the discharge line valves of the selected feed
pump should be opened, the other one is kept closed.
 Ensure that the upstream and downstream block valves of feed surge drum
pressure control valves (PV-333020 A / B) are open. Switch control to
automatic (DCS) and adjust set point to control at normal operating value
(2.5Kg/cm2).
 The Feed Surge Drum (FA-33302) is now operating under fuel gas pressure /
vent to flare on set point of pressure controller PIC333020.
 Switch control of feed surge drum liquid feed valve (LV-333001 A) to manual
and open approximately 5%.
 Line up start-up gas oil feed (cold feed from storage) to Feed Surge Drum
through feed Pre-Filters (FD33302), Feed Coalescer (FA33301) and Feed
Filters (FD33301).
 Allow the feed system to fill slowly with start-up gas oil - avoid hydraulic
shocks since the system is not hydraulically loaded at this point in time.
 Allow the level in the Feed Surge Drum to increase up to approximately
50%.Put the feed surge drum level controller (LIC-333006) on auto.
 Line up one of the Feed Pumps (GA-33301 A / B) and start on mini flow
operation. Adjust the minimum discharge flow controller (FIC-33310 for GA-
33301 A and FIC-333090 for GA-33301B) to 331 m3/hr as per pump
manufacturer’s specification, pump discharge spill-back is to the feed surge
drum (FA-33302). Failure to achieve recommended minimum flow rate will
result in a pump trip on FSLL-333012.
 Check the level in LG333007 of water in the feed surge drum boot and drain
to the oily water drain when necessary. During all the operation of the unit,
the level of water in the feed surge drum boot will have to be checked
carefully.
 Now, Feed Surge Drum is filled with start-up gasoil and Feed Pump (GA-
33301 A /B) is running.
Establish level in Stripper

 Line up the start-up line from the discharge of the Feed Pumps (GA-
33301A/B) to the inlet of the stripper (DA-33302).
 The level / flow control valve (FV-333045) of the stripper (DA-33302) should
be closed in manual control mode.
 Make sure the Stripper Ovhd Gas Line is open towards the LP amine absorber
section.
 Slowly crack open the discharge line valve of Feed Pumps and simultaneously
slowly open start-up line FIC-333011 valve (DCS) in order to establish a
start-up gas oil flow from the feed surge drum to the stripper.
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 As levels begin to fall in feed surge drum, bring in additional start-up gasoil
inventory to the system.
 Build-up Stripper Bottom Level steadily to approximately 60% of level
indicator range. Cross-check the LIC-333044 indication in the DCS with the
LG-333046 indication in the field. When a level of 60% is achieved, close the
start-up line FIC-333011 valve.
 Do not loose stripper pressure. If pressure bleed-off is too rapid and stripper
pressure falls below about 5 kg/cm² g, restore the pressure via nitrogen
pressurization line.
 Open the level / flow control valve (FV-333045) at the bottom of the stripper
(DA-33302) to fill the line towards the splitter (DA-33303).
Establish level in Splitter (DA-33303)

 The level / flow control valve (FV-333071) for the splitter should be closed
in manual control mode. Ensure the isolation valve (UV-333026) at the
bottom of the splitter is closed via local hand switch (HS-333078).
 By using the stripper level / flow controller (LIC-333044 / FIC-333045) in
manual control mode, open the control valve (FV-333045) steadily in order to
establish a start-up gasoil flow from the stripper (DA-33302) to the splitter
(DA-33303).
 As levels begin to fall in feed surge drum (FA-33302) and stripper bottom
bring in additional start-up gasoil inventory to the system to keep levels in
drums and columns.
 Build-up splitter bottom level steadily to approximately 60% of level indicator
range.
Vessels levels established

Stop all pumps. Close all vessel level control valves in manual control mode, and
close all downstream isolation valves. Allow the system to “settle” for approximately
2 hours, then drain free water from low points and proceed to next step.
5.3. Dewatering pump-out to slop (off spec)

The feed section and stripper /splitter sections vessels now contain start-up gas oil
at more or less normal vessel levels. Since the initial inventory of start-up gas oil
will be rapidly contaminated with water and dirt /scale, it is advisable to dump the
initial contaminated inventory to slops (off spec), for subsequent settling, water
draw-off and recovery.
 Contaminated start-up gas oil is routed to slop.
 This is a significant point in the overall start-up at which to ascertain

the correct functioning of the various vessel level control loops, and to
carry out rectification works if problems are encountered.
The next step is to line-up the system in order to bring in fresh start-up gas oil feed
and to pump-out the contaminated gas oil to slop.
 Open the block valve in the off-spec product to slops line.
 Switch control of feed surge drum level controller (LIC-333006) to automatic.
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 Adjust the level / flow controller (LIC-333044 / FIC-333045) set point in the
stripper (DA-33302) to approximately 60% and start one of the feed pumps as
detailed earlier.
 Open the start-up gasoil flow control valve (FV-333011) to approximately
10% via the flow controller (FIC-333011).
 As the level increases in the stripper (DA-33302), open the downstream
block valve of the level /flow control valve (FV-333045) in the stripper to the
splitter feed line. When the stripper level reaches the set point of the level
indicator/controller the level control valve will open, routing start-up gasoil to
the splitter.
 As the level increases in the splitter (DA-33303), open the downstream block
valve of the splitter level control valve (FV-333071) and the isolation valve
(UV-333026) located at the splitter bottom. When the splitter level reaches
the set point of the level indicator / controller the level control valve will
open, routing start-up gasoil to the slops (off spec) through diesel product
pumps.
 Flow to slops will be set by the feed pumps rate from feed surge drum.
 The different circulations are stopped from time to time until no more water is
found at all low points.
 Continue to sample the start-up gasoil to slops at regular intervals. When the
oil appears to be cleared, compare the aspect of the initial sample to the
latest one. If quality appears satisfactory (when the gasoil is no longer cloudy)
continue to the next step.
5.4 Closed Loop Circulation

This circulation will be maintained until the feed, stripper and splitter sections are
completely dry, when the reaction section oil-in point is considered to have been
reached. At this chronological point in the start-up proceedings, the reactor heater
(BA-33301) and splitter reboiler (BA-33302) will still require refractory dry-out.
Note: During start-up gas oil circulation, rust and scale and other debris will collect
in the pump strainers. Clean the strainers when necessary and keep the circulation
going as long as the strainers need to be cleaned.
To commence circulation, proceed as follows:
 Close the block isolation valves and blind on the gasoil to slops line and
simultaneously open the closed isolation valves in the start-up line to feed
surge drum.
 Monitor the levels in the feed surge drum and stripper to see that they cope
with the change back to closed loop circulation.
 Maintain start-up line flow at 60% of design throughput.
 Remove water if any. This is mandatory to avoid blowing out the column
trays, while heating up the loop. When circulation is well established, and if no
significant problems arise, such as a pump suction strainer blocking,
instrumentation anomalies and so on, heat can be added to the stripper
section. Proceed as follows:
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 Select the Splitter Reboiler Pumps (GA-33309 A / B) and start in the

prescribed manner.
 Establish a flow through the Splitter Reboiler (BA-33302) and set-up the
heater pass balance control system.
 Light-up the Splitter Reboiler (BA-33302). Carry out dry-out procedure if
required
 Do not increase the heater coil outlet temperature too rapidly. Aim to increase
the inventory temperature in the Splitter very slowly so that trapped water, or
water that is emulsified in the start-up gasoil, has time to change state (water
to steam) in as controlled manner as possible. It is recommended to hold the
heater coil outlet temperature at 150°C for some time.
 As the splitter bottoms temperature begins to increase, water vapour will rise
up through the column and will eventually condense in the Splitter Ovhd Air
Condenser (EC-33303). The OVHD air condenser, which is an air fin cooler,
need not to have its fan motor started yet. Condensed water will build-up in
the water draw-off boot of the Splitter Reflux Drum (FA-33311), and is
removed to the Sour Water Stripper (SWS) unit or drain (since no H 2S is yet
present).
 Commission stripper overhead condenser loop by introducing start up naphtha
from H2 feed tanks.
 When all dissolved water is removed, increase splitter reboiler outlet
temperature without exceeding the column OVHD design temperature.
 Check the level in the splitter reflux drum, if it increases and reaches about
50%, commission one reflux pump (GA-33306 A /B).
6. Catalyst Treatment
6.1 Hydrogen Circulation
The reaction section is under H2 atmosphere used for the leak test. Re-start the
recycle gas compressor in closed loop through the reaction section (following
circuit):
Schematic for the following shall be prepared
 Recycle Gas Compressor (GB-33301)---

 First Reactor Feed / Effluent Exchangers (EA-33301 A / B / C), shell side---
 Second Reactor Feed / Effluent Exchangers (EA-33302 A / B), shell side)---
 Reactor Heater (BA-33301)
 HDS reactor (DC-33301)---
 Second Reactor Feed / Effluent Exchangers (EA-33302 A / B), tube side---
 Reactor Effluent / Stripper Feed Exchanger (EA-33303), tube side---
 First Reactor Feed / Effluent Exchangers (EA-33301 A / B / C), tube side—
 Reactor Effluent Air Cooler (EC-33301)---
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 HP Separator (FA-33304)---
 HP Amine Absorber KOD (FA-33305)---
 HP Amine Absorber Is Bypassed---
 Recycle Gas Compressor KOD (FA-33306) ---
 Recycle gas compressor (GB-33301).
The unit conditions at this point are as follows:
 Reaction section is under H2 recycle gas at maximum flow rate.

 Reaction section pressure and reactor temperatures: the suitable initial
conditions are as follows:
 Reactor catalyst temperatures shall be 80°C minimum over the whole beds
and 150°C maximum.
 The reaction section pressure shall be the normal operating pressure
(73.2ksc).
 Make up H2 is available.
 HP Amine Absorber (DA-33301) is bypassed and not in service (no amine
circulation) during sulphiding but ready to start just after feed injection.
 HP purge gas valves (PV-333109 A/B) are closed: throughout the sulphiding
operation, this valve will be closed to minimize H 2S losses and pressure will
be controlled by the H2 make-up valve (Valve no.). The purge may be opened
only if the H2 purity of the recycle gas falls below 50%.
 High pressure wash water is shut down. It is recommended to test the Wash
Water Pumps (GA-33302 A/B) and establish interface level in the HP
Separator before sulphiding.
12
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 Quench valves (FV-333024 and FV-333025) are fully operational. It is

recommended to keep the quench valves at least crack open during the
sulphiding to avoid excessive thermal stress on the check valves and possibly
on the quench valves themselves.
 Stripper is in service, preheated and pressurized at normal operating
pressure.
 DMDS injection facilities at feed pump suction are ready to be operated.
6.2 Pre-Wetting
 The reaction section is under hydrogen pressure (normal operating figure
minus 10%ie,65.9ksc) with the reactor bed temperatures at 150°C, and with
no more free water found at the HP separator, FA-33304 (one will check that
this pressure is in accordance with reactor P /T Chart).
 Slowly introduce the start-up gas oil into the reactor by opening the isolation
valve (UV-333003) and de-isolating the double block valves upstream
/downstream of the feed flow control valve (FV-333009), and commencing
flow via FIC-333009 in manual control from the DCS. The flow will be
steadily increased (normally) to 60% unit design throughput. Whilst the start-
up gas oil flows from storage to the Stripper (DA-33302) is reduced to 40%.
Note: Gas oil contact with catalyst under hydrogen atmosphere gives a small but
noticeable increase of temperature in the reactor (depending on the recycle flow
rate, the delta “T” may be around 20°C).
 When the start-up gas oil is introduced into the reaction section the
operating level in the Feed Surge Drum (FA-33302) should be
maintained by allowing new start-up gas oil to the unit. Due to the
lowering of gas oil flow rate going directly to the stripping section,
take care that the liquid level in the stripper is not lost.
 Start-up gas oil will eventually appear in the Cold MP Separator (FA-
33309). Open the Cold MP Separator liquid level isolation valve, when
the level in the separator is high enough to permit this action. Set LIC-
333023 to manual control mode and ensure zero % output (level control
valve fully closed). Open the upstream and downstream isolation valves
of the control valve (LV-333023).
 When the gas oil level in the cold MP Separator (FA-33309) HC side reaches
approximately 60%, match the set point of its LIC-333024 to this value and
switch the loop to automatic control mode. Gas oil will now be routed to the
Stripper and then the Splitter (DA-33303). But the Power Recovery Turbine
will be under Bypass at this point.
 Note that, as soon as liquid is shown in Cold MP Separator the once-through
circulation must be established to remove any fine particles of catalyst which
are carried over with the gas oil. Send gas oil to slops.
 Raise the feed flow rate to the reaction section up to 100% design throughput
and isolate the start up line from feed surge drum to the stripper (FV - 11).
 After 4 hours, take a sample of gas oil and make a visual check. If gas oil is
clear, open the recirculation line 8”P-3330230 via FV-333072 back to FSD
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and isolate the slop connection, otherwise continue the once through
circulation until gas oil becomes clear.
 As soon as flows and levels are stabilized in the reaction section, raise the
pressure to the normal operating figure, keeping reactor beds at 150°C.
 Once recirculation is established, reduce if possible the recycle gas flow
down to 50% of the nominal flow. The purpose of this step is to ensure that
the whole catalytic beds and the pores of the catalyst have been in contact
with hydrocarbons prior to the sulphiding. This catalyst wetting has a
beneficial impact on the sulphiding achievement on the catalyst activity and on
the reactor hydrodynamics.
 Maintain these operating conditions for 4 hours.
 If catalyst activation cannot be performed after this step, temperature is kept
at 150°C and unit will be put in stand-by. Otherwise, temperature will
increase to 170°C.
6.3 Catalyst Sulphiding Procedure
 Refer chapter-10 "Catalyst specifications and special procedures" and

also attachment-23 for schematic representation.
 Then follow the procedure of first feed-in after catalyst pre-sulphiding.
7. Fresh Feed-in
7.1 Switch to Normal Feedstock (at a throughput of 100% design capacity)
Note: Target temperatures given in this procedure are only a guide as actual desired
target temperatures will depend on the composition of the feed.
The operating conditions are:
 Hydro Treating Reactor (DC-33301), inlet temperature (SOR inlet

temperature, 308°C).
 HP Separator (FA-33304) temperature: 50°C
 Recycle Gas rate at design figure (10.336tph).
 Sulphiding agent injection to have between 0.5 and 1% vol. H 2S concentration
in the recycle gas.
 Water wash flow at design flow rate (23.125tph).
 Start-up gas oil circulation: 100% design throughput as during the sulphiding /
activation step.
 The normal feedstock analysis is available and in accordance with the design
specifications.
 Feed Filter (FD-33301) is in service.
 Stripper (DA-33302) is in operation.
 Splitter (DA-33303) is in operation.
 Splitter (DA-33303) is in total reflux.
 Amine circulation is on in the LP amine absorber (DA-33305).
 Amine circulation needs to be started to HP Amine Absorber (DA-33301).
 Corrosion inhibitor injection is in operation.
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 Note: The LP amine absorber (DA-33305) should be started as soon as the

stripper (DA-33302) is in service and the reaction section needs to be
purged. Make sure the H2S content in the LP amine absorber OVHD is low
enough to route this stream to the fuel gas network or to Recovery PSA.
1st Step - Amine Circulation in HP Amine Absorber
 Check the level of amine and pressure in the lean amine surge drum (FA-
33314). Start one of the Amine HP Pumps (GA-33303 A / B, if not already
started).
 Start lean amine flow to the HP Amine Absorber (DA-33301) in the normal
fashion. Set the flow controller (FIC-333080) at mid scale (50%) and verify its
operation.
 Verify that the HP Amine Absorber has a good working level and unblock the
level control valve, and verify that the level control is operating correctly and
that rich amine is being transferred from the HP to the LP amine absorber
(DA-33305) and then returned to the ARU.
2nd Step
Switching to normal feedstock requires that a number of tasks be carried out

in order to reconfigure the gas oil flows from the start-up scenario to the
normal feedstock "feed-In" scenario. These changes are as follows.
 Introduce wash water at design flow rate.

 Make sure that all chemicals are in service at design conditions.
 Open isolation block valves on the hydro treated diesel line to storage.
 Set all controllers in auto mode (especially reactor inlet temperature), as soon
as possible.
 Start anti-fouling injection and check corrosion inhibitor injection is
commissioned.
 Normal feed is introduced into the feed surge drum at 25% of the circulating
gasoil flow rate (by step of 5% every 30 minutes) whilst the re-circulating
gas oil flow to the Feed Surge Drum is decreased down to 75%. Feed to the
Reactor is kept constant at an overall total of 60% of design flow - as
required by the procedure.
 As the amount of gas oil being allowed to recirculate to the feed surge drum
has been reduced by 25%, the total system inventory will begin to increase
once the extra feed passes through the reaction section and into the
stripper/splitter sections. When the level starts to rise in the Splitter, excess
gas oil is sent to storage in the normal level control scenario.
 Reactor inlet temperatures are increased at 5°C/hr to obtain 300 °C at the
outlet of each bed in order to obtain an initial measure of conversion, and to
properly commission the Stripper.
 When reactor feed is stabilized, check the H 2S content in the recycle gas and
reduce sulphiding agent injection to obtain approximately 0.5% to 1 % vol.
H2S.
 With the amine section in full operation, increase the amine flow rate to each
amine absorber to the design rate. This flow rate will probably be higher than
16
necessary but will somewhat offset the lower tray efficiencies expected when
absorber hydrocarbon feed rates are below design.
 The recommended sampling and analytical testing schedule should begin
immediately to determine if further plant adjustments are required.
3rd Step
 Progressively increase stepwise (5% per hour) fresh feed flow rate to 50% of
the design gas oil flow rate, decrease the recirculating gas oil to the feed
surge drum to 50%.
 Next, progressively raise the reactor inlet temperature so that an outlet
temperature of 300°C is achieved (5°C per hour). Check H 2S in the recycle
gas and reduce sulphiding agent injection (stop it if necessary).
 At this time the Stripper and the Splitter should be brought up to conditions
as near to normal as possible. Excess stripped gas oil is sent to storage (then
will initially be turned out to slops (off-spec.), until design quality product is
achieved).
4th Step
 Repeat this procedure by increasing the fresh feed up to 75% of design feed
rate, decreasing re-circulating gas oil flow to 25% of design feed rate. Adjust
the reactor temperatures and the different parameters in the same way as
previously, this time aiming for a reactor outlet temperature of 320°C.
5th Step
 At this point, increase the fresh feed to 100% and block in the recirculation
flow to the feed surge drum, and adjust the reactor temperatures to get the
required specification in the hydro treated products.
Note:
 This step-by-step fresh feed-in procedure allows a progressive plant
start-up without any shocks to the equipment, such as Feed Pump
Exchangers, Reactor, Stripper and Splitter.
 Do not forget to check all hot equipments for proper unrestricted
thermal expansion.
 Feed filter backwash frequency is to be closely monitored when raising
the fresh feed throughput.
 To ensure a minimum duty for the heater during transient phase, the
feed bottom exchangers of the reaction section can be by-passed.
 Hot bolting of the Reactor and heat exchangers is to be carried out as
a normal practice.
7.2 Increase Throughput to Design
 Adjust quench flow rate to obtain the reactor temperatures needed for
achieving the desired product specification.
17
 After the unit operation has been stabilized for a few hours (unit running at
60% fresh feed), increase feed flow up to 100% design capacity, in increments
of 5%.
Temperatures Adjustment Guidelines:
When it is necessary to change feed rate, feed type, hydrogen make-up quality or
anything, which will affect operating temperatures, anticipate the change by
adjusting reactor temperatures as follows:
 If it is expected that a more severe operation will be required as the result of

a change, then make the change first before increasing the temperature.
 If it is expected that a less severe operation will be required as the result of a
change, then the reactor temperature should be decreased first before the
change is made.
 During transient operation, it is always safest to be slightly under converting.
 Before making a change in operation, make sure the reactor temperatures are
increasing or decreasing as the case required. The high alarms are set at
5°C above the bed outlet temperature.
 Make changes in small adjustments, not more than 1°C every 2 hours.
Frequent small changes are preferable to few large adjustments.
 Under normal steady operation, keep the bed outlet temperatures equal by
adjusting the inlet of each bed.
 When plant will be stabilized start the power recovery turbine as per
manufacturer instructions.
7.3 Stripper
Note: The following operations on the stripper are normally carried out during
the sulphiding procedure when sufficient heat is available for the first time to
operate this item correctly.
 The operations are written here as a reminder and can also be found in
the sulphiding procedure in the chapter-10 “Catalyst specification and
special procedures”.
 The stripper bottom level control (LIC-333044 / FIC-333045) is in automatic

mode.
 During the sulphiding of the catalyst a small amount of stripping steam will be
required to limit the H2S in the gas oil. Start the stripper OVHD air condenser
(EC-33302) when required.
 As feed is introduced to the reaction section and as reaction starts, the
stripping steam rate is increased. Water in the stripper reflux drum (FA-
33310) is recycled to the sour water stripper (SWS) unit.
 An H2S rich gas will also start flowing to the LP amine absorber.
 The stripping steam rate to the stripper (DA-33302) is adjusted at
design value to meet the Copper Corrosion spec. in the stripper bottoms
and to obtain the Design reflux rate.
18
 Corrosion inhibitor injection is adjusted at design flow rate.
7.4 Splitter
The splitter bottom level control (LIC-333052 / FIC-333071) is in auto mode. The
Splitter Reflux Pumps (GA-33306 A / B) shall be already in operation. The Splitter
Reboiler (BA-33302) outlet temperature is slowly adjusted to reach the products
specifications and to obtain the design reflux flow rate.
19

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Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.

DHDT Unit – Phase-3 - Operating Manual F ……….

1. Status of the unit

As the hydro treating process gives rise to a highly significant production of

1. Status of the unit

 As the reaction section produces a significant amount of hydrogen disulfide,

 1 Ensure that sulphiding injection line is in service and DMDS is available to

3. Chronology of Start-Up Operations

Start-Up Schedule - TASKS

 Pressurize the Stripper And Splitter, LP absorber to operating pressure

 Start-up of the Amine Section (except the HP Absorber – establish

4.1. Amine Inventorying

4.2. Amine Circulation

 Circulation of amine to and from the HP amine absorber (DA-33301)

5. Closed loop Short Oil Circulation

5.1. Schematic for the Start-up Oil Loop

 Start-up gas oil circulation is represented in the following schematic:

 Start-up gas oil from storage –

 Second Splitter Feed / Bottom Exchangers (EA-33308) tube side—

The start-up circulation flow rate is fixed at 60% design throughput.

5.2. Procedure for Establishing Vessel Levels

Establish level in Feed Surge Drum (FA-33302)

Establish level in Stripper

Establish level in Splitter (DA-33303)

Vessels levels established

5.3. Dewatering pump-out to slop (off spec)

 This is a significant point in the overall start-up at which to ascertain

5.4 Closed Loop Circulation

To commence circulation, proceed as follows:

 Select the Splitter Reboiler Pumps (GA-33309 A / B) and start in the

 Recycle Gas Compressor (GB-33301)---

The unit conditions at this point are as follows:

 Reaction section is under H2 recycle gas at maximum flow rate.

 Quench valves (FV-333024 and FV-333025) are fully operational. It is

6.3 Catalyst Sulphiding Procedure

 Refer chapter-10 "Catalyst specifications and special procedures" and

The operating conditions are:

 Hydro Treating Reactor (DC-33301), inlet temperature (SOR inlet

 Note: The LP amine absorber (DA-33305) should be started as soon as the

1st Step - Amine Circulation in HP Amine Absorber

Switching to normal feedstock requires that a number of tasks be carried out

 Introduce wash water at design flow rate.

7.2 Increase Throughput to Design

Temperatures Adjustment Guidelines:

 If it is expected that a more severe operation will be required as the result of

 The stripper bottom level control (LIC-333044 / FIC-333045) is in automatic

 Corrosion inhibitor injection is adjusted at design flow rate.

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