Com .& Start-Up Strategy 120926
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Transcript of Com .& Start-Up Strategy 120926
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TABLE OF CONTENTS
1
1. Objective
2. Scope of Work
3. Process Configuration
4. Priming Fluids5. Commissioning & Start-up Sequence
6. Schedule
7. Work Definitions & Flow
8. Organization & RR Involvement
9. Areas of Concern
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- Implementation of HSE Plan& Procedures
- Safety Audit- Pre-Startup Safety Review- Safety Training & Emergency Drill- TRA & Risk Assessment
- Qualified & ExperiencedCommissioning Work Force
- Develop Detailed Procedures- Implementation of Training- Faultless Execution ofPre-commissioning /Commissioning Activities
Safe Completion
Good Performance
- Well Planned Preparation- Implementation of CMS- Tight Control of Commissioning
& Start-up Activities/Schedule- Interface Management- Harmonized Communication& Coordination
Schedule On-Time
Safety
QualitySchedule
1. Objective
2
Turnover
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Construction
By UnitBy Subsystem
50 M
Punch A Clear
Commissioning
Start-up &Stabilization
Test Run
2. Scope of work
3
Pre-commissioning
35 M
By Unit /Discipline
48 M
By Subsystem/System
41 M 44 M
Punch B Clear Punch C Clear
Commercial
Production
Pre-Commissioning Team
Construction Team
Commissioning & Start-up Team
COMPANY Operation / Maintenance Team
CONTRACTORs Care, Custody & Control CONTRACTORs Care, Custody & ControlCOMPANYs Assistance
MC Certificate&
Ready ForCommissioning
CommercialProduction
Certificate &Ready For
Test Run Certificate
ProvisionalAcceptanceCertificate &Hand-Over
Nov.2012 May.2013 Aug.2013 Dec.2013 Feb.2014
CommissioningCompletion
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3.
Process Units - EPC #1
Unit No. Unit Name Capacity Licensor / (FEED)
1 1100 Crude Distillation 417.1 KBPSD (Bechtel)
2 1110 Sat. Gas Plant 142.4 KBPSD -
3 1120 Sat. LPG Treating 22.2 KBPSD UOP
4 1130 Sat. LPG Splitter 23.7 KBPSD (Bechtel)
5 1210 SR Heavy Naphtha Hydrotreating 68.9 KBPSD UOP
6 1300 H2 Manufacturing 151.2 kNm3/h Haldor Topsoe (SSW)
7 1400 Kerosene Hydrotreating 107.8 KBPSD UOP
8 1510 LGO Hydrotreating 74.8 KBPSD UOP
9 1520 HGO/LCO Mild Hydrocracking 57.4 KBSPD UOP
10 1530 MHC H2 Recovery 2 t/h (Bechtel)
11 1690 Benzene Reduction 26.9 KBPSD UOP
12 1700 Sour Water Stripping 120 m3/h (Bechtel)
13 1800 MDEA Regeneration 440 m3/h (Bechtel)
14 1810 DEA Regeneration TBA (Bechtel)
15 1900 SRU & TGTU 400 TPSD CB&I
16 1036 Spent Caustic - (Bechtel)
17 1045 Acid Gas Flare - -
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1100CDU
1110SGP
1120/1130LPG Treating
/ Splitter
1210H/N HDT
1400Kero HDT
1510LGOHDT
1520MHC
1300HMU
1690BRU
CrudeOil
AR
LCO/LLCO
Natural Gas
H2
SR Kero
SR LGO
SR HGO
LPG
HDT H/N, S
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1700Sour WaterStripping
Phenolic SW (RFCC)Non-Phenolic SW
(Process Units)
Brine (CDU)
1800MDEA
Regeneration
1810DEA
Regeneration
Rich MDEAUnit 1110/1520/1530
Rich DEAUnit 1600/1220
1900
SRU & TGTU
1045
Acid Gas Flare
Stripped Water to WWTUPhenolic Stripped Water to RFCC
Lean MDEAUnit 1110/1520
1530
Lean DEAUnit 1600/1220
Molten Sulfurto Granulation Plant
1036
Spent CausticTreatment
Acid
Gas
Acid
Gas
Spent CausticUnit 1120
Unit 1610/1620
Oxidized Causticto WWTU
3.
6
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7
UnitPriming
Fluid
Approx. Required Amount (BBls)Expected
DateRequired
Reasons forRequirementTotal EPC1
EPC 3Intercon.
Piping
EPC 4Intercon.
Piping/Tank
11001110
HeavyNaphtha
6,000 6,000 Same line with Unit 1210Heavy Naphtha feed line
26 Jun 2013 - Inventorying for facilitates of Initial S/U- Removing remaining water in LPG serviceline to avoid icing during Initial S/U.
1100LGO
- Flushing Oil26,600 26,600
Same line with Unit 1520LGO line
21 Jun 2013
- Allows flushing of System & checking outof Rotating Machinery.
- For cleaning of filters & strainers duringflushing rather than using Crude Oil.
1110
1120
1130
LPG 1,586 1,500 86 - 25 Jun 2013
- Allows earlier S/U of Unit 1110, 1120 &1130 before feed off-gas introduction fromUnit 1100
- Earlier introduction of main feedstock fromexisting Ruwais Refinery
1210HydrotreatedNaphtha orSR Naphtha
68,219 46,700 134Line: 925Tank: 20,465
15 Jul 2013- Allows the pre-sulfiding of catalystper Licensors requirement.
1400SR Kerosene
- S/U Oil100,400 79,600 327
Line: 308Tank: 20,165
04 Jul 2013- Allows the pre-sulfiding of catalystPer Licensors requirement.
1510LGO
- S/U Oil70,963 50,400 134
Line: 264Tank: 20,165
06 Jul 2013- Allows the pre-sulfiding of catalyst per
Licensors requirement.
1520LGO
- S/U Oil59,195 58,600 86 Line: 509 06 Jul 2013
- Allows the pre-sulfiding of catalyst perLicensors requirement.
- From Unit 1510 LGO Feed Tank
1900Granular
Sulfur6 tons 6 tons - - 12 Jul 2013
- Allows fill-in of Seal Leg & Sultrap to avoidtoxic H2S gas release from SulfurCondenser to Sulfur Degassing Pit
1300 Methanol 14 tons 14 tons - - 24 May 2013- Allows production of recycle H2 for InitialS/U before feed Natural Gas in.
- No need if H2 is available from OSBL
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8* Tank Volume is based on Min. Operating Volume
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UNITS / UTILITY SYSTEM REQUIRED FOR STARTUP BY OTHER EPCS
EPC #1 UNITS Start-up
EPC #2
EPC #3
EPC #4
UNIT 1300
UNIT 1100 UNIT 1110 UNIT 1120 UNIT 1130
UNIT 1530
UNIT 1690
UNIT 1400
UNIT 1045 UNIT 1900
UNIT 1510
UNIT 1520
UNIT 1036
UNIT 1210
UNIT 1800
UNIT 1810
UNIT 1700
UNIT 1600
Utilities Flare FG
CrudeStorageTanks
IntermediateProduct Tanks
Balance &Product Tanks
NG
High Level Unit Interface For Start-up
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ReformateTanks
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Overall
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Unit - Typical
7 Work Definitions & Flow
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7.Work Definitions & Flow
The System is defined as a major subdivision of an installation, being either
process or non-process, which performs a major operational function of theunit.
Each System is further broken down into a Sub-System, which performs agiven operational function, with no or little interference from other Sub-Systems for the Commissioning execution.
The most efficient way for achieving plant completion in a limited period oftime will be to carry out Pre-commissioning and Commissioning activities bySystems and/or Subsystems according to the predetermined MechanicalCompletion and Commissioning priorities.
The Pre-commissioning & Commissioning Schedules are prepared based on
Sub-Systems.
Each Sub-System will be tied to a database containing all elements of each
Sub-System for tracking & recording the status of Sub-System MechanicalCompletion and Commissioning.
System Approach
7 Work Definitions & Flow (continued )
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The System / Subsystem has been erected in accordance with approved drawings,
specifications and applicable codes.
Activities include non-operating checks, inspections, testing, adjusting andcold alignment, etc. of equipment, piping, instrumentation, electrical to bringthe System / Subsystem to MC and Ready for Commissioning.
- Piping Cleaning : Flushing / Air Blowing / Steam Blowing / Chemical Cleaning- Reinstatement & Box-up- Energize Electrical Network- Rotating direction, Driver Solo-run, Alignment- Instrument & Electrical System / Equipment SIT- Loop Test & Functional Checks- Operational Tightness Test- Purging & Inerting (O2 Free)
Punch List A Clear
Utilities in service
7.Work Definitions & Flow (continued..)
Mechanical Completion incorporating Pre-commissioning
7 Work Definitions & Flow (continued )
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Work Flow for Pre-Commissioning & Mechanical Completion
7.Work Definitions & Flow (continued..)
7 Work Definitions & Flow (continued )
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7.Work Definitions & Flow (continued..)
Work Volume _ No. of Components
16
7 Work Definitions & Flow (continued )
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All works, activities and tests associated with preparing the Plant for theintroduction of feedstock for the purpose of starting initial productionof the end products prior to commencement of Test Runs.
- Introduce Fuel Gas- Flares / Hydrocarbon Drains activation- Heater Firing & Drying out / Boil out- Catalyst Loading- Initial filling of Chemicals
- Operational Test
Priming Fluids Introduction
Pre-Sulfiding & Cold Circulation
Punch List B Clear
Company assist with experienced refinery plant operation supervisoryand shift operating personnel to supplement Contractor Commissioning Team.
7.Work Definitions & Flow (continued..)
Commissioning
7 Work Definitions & Flow (continued )
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Work Flow for Commissioning Completion
7.Work Definitions & Flow (continued..)
7. Work Definitions & Flow (continued..)
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Start-up & Commercial Production Operation
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Feedstock-in
Initial Start-up & Stabilization
The plant will achieve stable, safe, continuous operation
at no less than 80% of guaranteed capacity for a continuous period of 15 daysat guaranteed product quality conditions.
To demonstrate to Company that Units can be operated safely under alloperating conditions in accordance with Contract
- At Design Capacity for 72 hrs
- At Turndown Capacity for 72hrs
Performance Test Run
7.Work Definitions & Flow (continued..)
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Commissioning & Start-Up Organization Chart
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1) Early Involvement of Companys Personnel for Integrated One-Team
- Familiarization with Facilities
- Witness & Supervision- Training
2) Interface between with other Contractors
- On-Time Power Energizing & Introduction of Utilities
3) PSSR (Pre-Startup Safety Review)- Timing of Implementation
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