SOP Hot Oil Heater [PDF]

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Alkhorayef Group Company, KSA Doc. Type



: Standard Operating Procedure (SOP)



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Facility Operating Procedures



1. HOT OIL SYSTEM LINE-UP  Ensure the fuel gas from fuel gas treatment section is available.  Confirm the unit control panel (UCP) is fully functional & rested.



2. Fuel gas initiating into the KO Drum. Equipment & Instrumentation line-up for Fuel gas KO drum (016-V-703) Tag Number



Tag Number



PIT-8661 PIT-8662 PDIT -8861 PI-8661



Isolation Valve Status Open Open Open Open



LT – 8661A LT – 8661 B LT – 8661C LT-8662



Isolation Valve Status Open Open Open Open



PI-8662 TI-8661



Open Open



LT-8663 LG- 8661



Open Open



   



3.



Ensure all Drain Valves from Level Transmitters & Gauges are in Closed Position. Ensure the Vent Valve & the Vent Blind on the Fuel Gas KOD are closed. Ensure the isolation valves upstream & downstream the PSV-8662 are Locked Open. Ensure the isolation valve downstream the PSV-8661 is Locked Open while Its Downstream Valve is Locked Close.  Ensure the 2” Isolation Valve on the Line from the Fuel Gas KOD to the HP Flare Header is closed.  Open the 4” isolation valve fuel gas inlet (upstream the ESDV-8661).  Open the ESDV-8661 from the DCS.  Open the Isolation Valve Upstream & Downstream the PV-8662.  Put PIC-8662 on Manual Mode & open gradually the PV-8662 to pressurize the fuel gas KOD with operating pressure of 4 barg, the Put back PIC-8662 to auto.  Open upstream/downstream isolation valves of PV-8662 and put it in auto and monitor the pressure.  Open Isolation Valves Upstream & Downstream the LV-8664 on the line to the Closed Drain System.  Put LIC-8662 to Auto & open the.  Open the ESDVHot oil drain tank (016-V-704)  Provide needed quantity of hot oil medium. (Total system volume 205 m3).



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 Make sure to take adequate safety precaution and the right PPE.  Ensure the drain tank 016-V-704 is ready to receive the hot oil clean and dry, lined up, all instrument calibrated and fully functional. Tag Number



Isolation Valve Status Open Open Open



LT -8632 LT -8634 LG -8633.



 Fill the hot oil from drums to the drain tank between normal and high level.(1000mm to



4.



1200mm)  Ensure the level transmitters functional. (LT-8634 & 8632.)  Ensure the hot oil drain pump 016-G-702 is ready for start. Lineup/open hot oil expansion Vessel instruments isolation valves. Tag Number PIT - 8631 PIT – 8632/8633 PI – 8631/8632 /8633



 



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Isolation Valve Status Open Open Open Open Open



Tag Number LIT -8633 LG -8631 LG -8632



Isolation Valve Status Open Open Open Open Open



TIT - 8631 TI 8631 LIT 8631 A/B/C TIT - 8632 (Note: During the initial filling of the tank and until the fuel gas supply is introduced (PV-8632), carefully monitor the levels in the vessel to ensure that the vessel does not overpressure or draw a vacuum) Ensure the hot oil expansion vessel is lined up  Lineup/open PSV-8321 Up & downstream Valve.  Ensure the blanketing fuel gas is available & flare system is fully functional.  Lineup/open PV-8632/8633 UP-Down Stream isolation Valve & open fuel gas tank isolation valve.  Start the drain pump (016-G-702) to fill the expansion vessel, the flow rate of this pump is 6 m3/h; this will give us around 6-7 hours to fill the expansion tank during that time check the pump performance.  Confirm the XV-8634 opens automatically when the pump operates.  Monitor the LOW LOW level trip logic that drains pump stops and XV-8634 closes.  Once low reached in the drain vessel, re-filled & start the drain pump until reached the level in expansion vessel. (HIGH HIGH LEVEL-2300 mm)  Set the fuel gas blanketing controller PIC-8632 to 0.5 bar (g  Cross check all the parameters in local and DCS. Rev. No: Approved



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5. Minimum flow Cold circulation of hot oil  Ensure the hot oil circulation pumps 016-G-701A/B/C are ready and lined up, a. Note: First cold oil circulation will be from the expansion vessel to heaters 



and back Line up/open all instrument isolation Valve in the hot oil circulations pump. Tag Number TIT-8641 PIT-8641 PI-8641/8642



PIT -8642



Isolation Valve Status Open Open Open Open



Tag Number PI-8643/8644 PIT -8643 PI-8645/8646 PIT -8644



Isolation Valve Status Open Open Open Open



Tag Number PIT-8645 PIT-8745 PI-8648 PI-8647 PDIT-8641



Isolation Valve Status Open Open Open Open Open



 Ensure the hot oil heater lines (04 passes) of both heaters 016-F-701A/B are ready to    



receive the fluid Ensure the side strainer 016-L-702 is ready and lined up/opened. Ensure minimum flow regulators and valves FIC 8621/FV8631, FIC8721/FV8731are calibrated and functional. Minimum flow: 280m3/hr, for heater A & B. Open outlet 16” Valve of expansion vessel to circulation pump Pull the plug and carefully open the vent valve to vent trapped gas/vapor then close and plug the vent valve when liquid appears.



6. Gravity Feed to fill the Piping.  Maintain the expansion tank level during filling operation



I.



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a. (Note: The level in the expansion vessel will drop down quickly as we fill the system.) b. (Note: Restarting the pump motor will require a time delay of 30 mints.)  Start filling the heaters and associated piping one by one by gravity filling. Pump A’  Line-up up the circulation pump A 016-G-701A to Heater 016-F-701A  Ensure basket strainers 01-L-701A/B/C are ready and lined up  Open FV-8631/8731 isolation valve & open by set of FIC-8621/8721  Reset the ESDV-8621 from the DCS to open it.  Open Suction / discharge isolation valve of pump A.  Open 12” inlet isolation valve of Hot oil heater (016-701A) to hot oil expansion vessel Rev. No: Approved



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 Vent the suction line and pump casing of pump A.



II.



7.



8.



Pump C’  Line-up up the circulation pump C (016-G-701C) to Heater 016-F-701B  Open Suction / discharge isolation valve of pump C  Reset the ESDV-8721 from the DCS to open it  Open heater 016-F-701B / 12” outlet isolation valve (Upstream of FIT-8721) to hot oil expansion vessel  Vent the suction line and pump casing of pump C.  Similarly, line up the inlet of pump B (016-G-701B), and vent suction line and casing. Ensure that the pump is ready for operation  Check DP from the difference between PI-8641/8645 and PT- 8642/8646 while operational and ensure it to be within safe limits.  Find a suitable filling point to fill the rest of the piping system including all the heat Exchangers above the expansion tank using an auxiliary pump. CRUDE HEATER TRAIN 1  Ensure all transmitter isolation valves are lined up in heater 016-F-701A.  Open hot oil heater A (016-F-701A) outlet isolation valve.  Open ESDV-1313 upstream isolation valve.  Open TV-1555 Up & downstream isolation valve  Open Inlet / Outlet isolation Valve of crude heater (016-E-102) train 1.  Reset the ESDV-1313 from the DCS to open it for initiate gravity flow in to Crude heater Train -1  Locate the high point vents / Pull the plug and carefully open the vent valve to vent trapped gas/vapor then close and plug the vent valve when liquid appears  Put the TIC-1555 in manual, and fully open TV-1555.  Check for any leakage of the hot oil in the crude side. CRUDE HEATER TRAIN 2  Ensure all transmitter isolation valves are lined up in heater 016-F-701B.  Open hot oil heater B (016-F-701B) outlet isolation (downstream of FIT-8721) Valve to Crude heater train-2  Open ESDV-2313 upstream isolation valve.  Open TV-2555 Up & downstream isolation valve.



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 Open Inlet / Outlet isolation Valve of crude heater (016-E-202) train 2.  Reset the ESDV-2313 from the DCS to open it for initiate gravity flow in to Crude   



9.



heater Train -2 Locate the high point vents / Pull the plug and carefully open the vent valve to vent trapped gas/vapor then close and plug the vent valve when liquid appears Put the TIC-2555 in manual, and fully open TV-2555. Check for any leakage of the hot oil in the crude side.



LP test heater (016-E-001)



   



Open 8” &10” isolation valves from Heater (016-701A) outline to LP test heater. Open TV-0180 Up & downstream Isolation Valve. Open heater (016-E-001) Up & downstream isolation valve. Reset the ESDV-0183 from the DCS to open it for initiate gravity flow in to LP Test Heater.  Pull the plug and carefully open the vent valve to vent trapped gas/vapour then Close and plug the vent valve when liquid appears  Locate the high point vents / Pull the plug and carefully open the vent valve to vent trapped gas/vapor then close and plug the vent valve when liquid appears  Put the TIC0180 in manual, and fully open TV0180.  Check for any leakage of the hot oil in the crude side. 10. Isolate again the three heaters from the hot oil loop, to start the refractory dry Out procedure



 NOTE: Make sure the both the fired heaters are filled either by gravity feed or by        Doc. No. Prepared by:



auxiliary pump and then vented Start the auxiliary pump to fill all the piping Close the outlet of the heaters to the heat exchangers trains 1,2 Put FIC-8631 in auto with set point of 280m3/hr.  (Note: Monitor expansion tank level and if the level rises above HIGH HIGH, put the valve in manual and close it.) Line-up the pump auxiliary systems (Lube oil, sealing systems etc.) Start Pump A for minimum flow circulation through Heater A. Monitor the suction strainers and the side stream filter differential pressure (PDIT- 8641) to detect any plugging. Monitor performance/condition of the pump for vibrations/sounds. Rev. No: Approved



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 Confirm that the system from the expansion vessel to heaters and back is filled and Ensure fluid comes out of ALL the high vent points.  Make up the expansion vessel through the transfer pump (016-G-702),if necessary and restart the recirculation pumps to continue filling the system 11. Start Circulation Pump A/B for Heater Train 1 & LP test Heater.  line up for Crude heater Train-1 and LP Test heater through Heater A (016-F701A)  Close the inlet valve of Crude Heater Train-2  Gradually open the outlet manual isolation valve outlet from the fired heater  Note: This is to allow for circulation by pump (016-G-701A) through heater (016-F-701A) and the crude heater train 1(016-E-102) and LP tester heater (016-E-001).



12. Start Circulation Pump B/C for Heater Train 2 & LP test Heater      



Start pumps C with opening isolation of side stream filter. line up for Crude heater Train-2 through Heater B (016-F-701B) Close the inlet isolation 12” & 8” valve of Crude Heater Train-1 Put FIC-8631 in auto with set point of 280m3/hr.



Gradually open the two outlet manual isolation valve from the fired heater. Note: This is to allow for circulation by pump (016-G-701C) through heater (016F-701B) and the crude heater train 2(016-E-202) and LP tester heater (016-E001). 13. Pump B as standby, with opening of 12” isolation valve can utilize for fired Heater 016-F-701A/B



14. Start the Fired heaters.  Ensure that all manholes,



peepholes & other openings on the fired heater are boxed up (tightly closed), Check that all nitrogen cylinders pressure Check the purge air fan status, and start it Check all ESD alarm are not acted condition.



   15.Burner light up using Burner Management System (BMS)



The requirements to be satisfied for the main interlock (016-XL-8805)



 Hot oil fluid Inlet valve ESDV-8621 open  Stack damper shall not be closed 016-ZSC-8601 Doc. No. Prepared by:



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ESD level 1&2 not active 016-UY-8651 Hot oil heater not tripped 016-UY-8652 Emergency stop is not operated 016-EMG-8800. Heater outlet temperature not very high (170ºC) 016-TAHH-8623. Furnace pressure not very high (10mmWC) 016-PAHH-8606. Knock out drum not very high (72%) LAHH-8661



16. Purge sequence The following steps are to be checked for successful start-up of the purging process  Main interlocks have been satisfied  There should be no flame in the furnace  Purge air fan running  Stack damper 100% open position  All fuel valves shall be closed and vent open 17. In the completion of the five above conditions, purge ready to start. Indication (016-XL-8802) appears in the HMI. 18. Start purging from HMI/LBP using (016-HS-901) 19. Purge running timer is 5 minute, after which “purge running” indication is put off & purge completed signal appears.  Note: Purge completed signal is available only for 10 minutes; if the burner is not started within this time then the heater has to be re-purged. 20. Stop the purge air fan after the completion of the purge.



 Note: “Purge completed” indication goes off when any of the burner is switched on 21.Pilot light up 22. Open the pilot gas MFT (master fuel trip) using (016-HSO-8802)  Note: This will open both pilot gas block valve (016-ESDV-8675 &77) and close the vent valve (016-ESDV-8676).







Any time the operator may stop pilot gas MFT using (016-HSC-8802) 23. The pilot gas interlocks to be satisfied before startup are:



   



Pilot gas pressure LOW LOW (0.4 bar(g), 016-PALL-8676 Main interlock OK Pilot gas valve close failure



Pilot gas MFT open 24. Once the above conditions satisfied, firing may start. Doc. No. Prepared by:



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Pilot Burner #A/B/C/D, use respectively the (016-HSO-8804A/B/C/D) to light up one by one the burner pilots, This will open 016-XV-8685/86/87/88 & activate the igniter (016-IGN868/82/83/84) for 3 sec,











There after the pilot flame will be monitored (016-IR-8681/82/83/84), if flame is present then the valves are kept open, otherwise they will close. Note: Pilot firing could be stopped using (016-HSC-8804 A/B/C/D) respectively.







25.Main burner light up 26. Start one burner at time, The second burner to be started should be diagonally Opposite to the running one The main gas interlocks to be satisfied for start-up are:



      



Fuel gas pressure LOW LOW (0.02 bar(g)) 016-PALL-8675 Fuel gas pressure HIGH HIGH (2 bar(g)) : 016-PAHH-8674 Pilot gas valve close failure. Main interlock OK One of the RC pump running : 016-M-8641/42 Heater outlet flow not LOW LOW (200 m3/h): 016-FALL-8622 Fuel gas MTF open.



27. Once the above conditions satisfied, firing may start 



Use burner #A/B/C/D respectively (016-HSO-8803 A/B/C/D) to light up the burners one by one, this will open 016-XV-8681/82/83/84, thereafter the burner flame will be monitored (016-BE-8681/82/83/84), if present then the valves are kept open, otherwise they will close.  Note: Burner firing could be stopped using (016-HSC-8803 A/B/C/D) respectively this will close the corresponding valve XV- 8681/82/83/84. 28. Check the burner flame patterns adjust if necessary, so that there isn’t flame Impingement on the radiation tubes. 29. Heater should be operated at excess air percentage level (3%), adjust the Burner air registers and keeps adequate draft typically (draft at the burners 9.5 mmH2O, at the arch 2.54mm H2O) 30. Put the FV-8771 in manual to control the temperature increase. 31. Refractory dry out (RDO)



 The refractory should be dried slowly to permit accumulated water vapor to escape slowly Doc. No. Prepared by:



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from the refractory lining.



 The entire refractory dry out procedure will generally take 3-4 days.  The RDO temperatures are meant as flue gas temperatures at radiation arch.  The number of burners to use will be accordingly to the temperature, the maximum fuel gas pressure in the each burner is 1 kg/cm 2.



 The hot fluid will be used during this operation to cool the coil tubes, circulating from the expansion tank through the recirculating pump to furnace and back to the expansion tank, the heaters section are excluded at this stage.



 The RDO follows the initial lighting up of burners and comprises an initial rise of furnace temperature at 20ºC/h to 110ºC .



 Hold this furnace temperature for 24 hours, provide sufficient ventilation by opening the air registers of the burners not in operation. The stack damper should be fully open.



 Increase the furnace temperature to 200ºC at the rate of 20ºC/h, and hold for 18 hours@200ºC.



 Check the coil outlet temperature of the process fluid; this should never exceed 175200ºC.



 Check skin temperature of radiation coil, this should never exceed the design TMT 300ºC.  Increase the flue gas temperature to 450ºC at the rate of 25ºC/h, and hold for 12 hours repeat checks as above.



 Increase the radiation arch temperature to 540ºC at the rate of 25ºC/h, and hold for 18 hours.



 Check for hot spots or localized overheating on the radiation shell, convection casing, chimney & stack shell



 During the RDO all instruments, , annunciator, analyzers may be checked, fine tune (automatic) of the controllers may be done during the temperature hold period. Instrument setting (appendix A)



 Check frequently that tubes do not glow red during the RDO.  When the drying has been completed, reduce firing so as to reduce the radiation arch temperature by 30 to 35ºC/h to 200ºC



 As the temperature reaches 200ºC the burners may be shut off and the flow through the coil stopped. Doc. No. Prepared by:



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 Opening of all burner air registers to achieve uniform cooling rate.  As the bridge wall temperature falls below 100ºC open the bottom manhole on the radiation floor plate for further cooling naturally.



 As the bridge wall temperature falls below 40C permission for man entry can be given for inspection of the refractory.



 If the heater must be shut down for a long period after the dry-out, all burner registers, peepholes and explosion door must be closed



 At this stage the hot oil system is ready.



32.Normal start up A. Walk down checks  Expansion vessel  Knock out drum  Heater B. Check the expansion vessel level ( operating level at xxx) C. Start the re-circulation pumps one for each fired heater. D. Burner light up E. See above from 9.4 to 9.4.8.7 F. The operating hot oil temperature at outlet header is 150ºC. G. Put TIC8622/8722 & FIC8671/8771 in auto when the operating temperature is reached. H. Each heater is designed to cool the flue gases leaving out the convection section 160ºC @ heater loads ranging between 50% & 100% thus resulting in a guaranteed fuel efficiency of 92% on fuel gas (LHV).



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