Reformer Start Up Requisites

DEPARTMENT: CODE:
PAGE 1 of 26
Operations WI.O.A2/A.11.302
TITLE: REV. NO: 0 ISSUE DATE:
Start-up for U-12 & U-13 ( REFORMER UNIT & CCR UNIT) March 21
REV. DATE:
SCOPE:
This work instruction covers the guidelines to in safely and properly Start up for U-12 & U-13
(REFORMER UNIT & CCR UNIT)
INTRODUCTION:
-The purpose of the Reformer unit (U-12) is to maximize the production of the valuable high octane
reformate stream and to ensure the production and consistent quality of hydrogen rich gas.
Byproduct LPG is to be sent to Deethanizer unit.
-The purpose of the CCR (Continuous Catalyst Regeneration) Unit (U-13) is to regenerate the
catalyst
continuously during the normal operation of the Reformer unit (U- 12) and so to maintain a steady
coke level in the reactors, and optimum operating conditions for the Reformer Unit.
These operating conditions are almost constant except for the catalyst end of life.
RESPONSIBLITIES:
This Work Instruction provides the guidelines for the Shift team leader, Control room operator and
Field Operator.
RELATED DOCUMENTS:
Override of Safety Devices
Health and Safety Rules – Refinery and Marine Terminal
Environmental Operating Criteria
Protective Clothing and Equipment
Law No. 4/1994 The Environmental Law and its Executive Regulation of Egypt
DISTRIBUTION:
All A2A Operation Team Work
ASSOCIATED DOCUMENTS:
NA
Contents
❖ Prerequisites prior unit start-up
❖ Unit status
❖ Unit start up
1. Preparation of chemical injection packages.
2. Preparation of steam generation section (D-1207).
3. Preparation of stabilizer section C-1201.
4. Pressurization of unit.
4.1. Nitrogen loop section pressurization.
4.2. Regeneration section pressurization.
4.3. Reaction section pressurization.
4.4. Reduction section pressurization.
5. Preparation of CCR washing Drum (D-1308).
6. Preparation of catalyst transfer.
7. Reformer Unit conditions before Oil in.
8. CCR conditions before Oil in.
9. Reformer unit & CCR unit is ready for Oil in.
10. Startup regeneration section.
SAFETY:
• Use caution when opening bleeders and vents.
• Use caution when energizing electrical circuits to any equipment.
• Use caution when opening valves on live utility systems.
•• Operators must use Personal Protective Equipment (PPE) during all operating activities.
❖ Prerequisites prior unit start-up

- Safety Valves (systems) shop certified and installed with seals, Lock open (LO) / Lock close
(LC) valves. Blinds and restrainers removed as per checklist.
- Safety valves for all equipment items shall have been de-isolated, and these actions recorded on
a checklist.
- Flare header is in service.
- All relief slops and drainage systems are ready for use.
- Restricted and flow Orifice (RO & FO) plates are installed at proper location with proper
direction.
- All control valves have correct flow orientations and have been stroke checked and left closed
on manual mode. The bypass is checked for no leakage and tight shut off whereas isolation
valves of control valve are in lined up condition.
- All instruments and analyzers have been calibrated and are ready for use.
- Strainers are installed and oriented correctly.
- Heat exchangers have been checked and are ready for operation.
- All check valves are in line with flow direction.
-All pumps and drives are aligned, lubricated, tested, checked for direction of rotation and all
guards are securely installed.
- All utility are available at the battery limit & remove blinds to open position at all battery limit
lines.
- Steam traps operation have been checked.
- Steam tracing & electrical tracing have been switched on and is working satisfactorily.
- Spectacle blinds inside the unit are at their normal operating position & as per process
requirement.
- Unit drains and vents not required purging have been ensured and capped / plugged or
blinded.
- All alarm circuits & ESD have been checked for its active and ready for use
- Emergency shut-off valves are tested twice.
- The unit has been ensured free of all debris, scaffolding, planking etc.
- Firefighting, safety equipment and gas emission detectors are checked for operability and
completeness.
- Radio and alternate communication are available.
- All concerned have been informed of the proposed time of start-up.
- Make a final check to remove out of use any isolating blinds at unit equipment or in less except
for any fuel gas blinds. Check “distance” spools are made up or disconnected as per checklist.
❖ Unit status
- The leak test has been successfully completed.
- The unit has been purged with nitrogen to be oxygen free, (less than 0.2% vol.) and is now
under a slight positive pressure.
-The reforming unit will be started when naphtha from NHT (U-11) is on specifications. The
specifications of the feed acceptable for the start-up are similar ASTM distillation than design
feed and impurities according the following:
Poisons Source
Poisons Max.level(wt) Source
Arsenic 5ppbmax CrackedNaphthas
Lead 5ppbmax Recycledslops
Copper <detectionlimit COIToSion
Mercurv 5ppbmax Naphtha-condensates
Iron <detectionlimit COITosion
Silicon <detectionlimit Additives(foaming)
Nickel <detectionlimit Corrosion
Chromium <detectionlimit CoIToSion
Organicnitrogen 0.5ppmmax
Totalsulfur 0.5ppmmax
Halogens 1ppmmax
Waterandoxygenated Lowerthan10ppm
products (startuponly)
❖ Unit start up
1. Preparation of chemical injection packages.
1- X-1202 ( Sulfiding agent injection package).

- Fill X-1202-DI with sulfiding agent (DMDS) diluted in 1% wt. in reformate.
- Fill injection line (1 ½"- P- 121902) till injection nozzle by start X-1202-P1 & open ¾" valve
before injection nozzle.( All safety precautions be respected)
- Line up nitrogen line (PCV-0001) to the drum & open the vent to the flare header.
2- X-1203 (Chloriding agent injection package).

- Fill X-1203-DI with chloriding agent (C2Cl4) diluted in 1% wt. in reformate.
before injection nozzle.( All safety precautions be respected).
3- X-1204 (Water injection package).

- Fill X-1204-DI with Demineralized water.
before injection nozzle.
4- X-1205 (Phosphate injection package).

- Fill X-1205-DI with NALCO-72215 or Equiv.
- Fill injection line (¾ "-ZC- 122901) till injection nozzle by start X-1205-P1 & open ¾" valve
before injection nozzle. (All safety precautions be respected).
5- X-1301 (Caustic injection package).

- Fill X-1301-DI with 15% caustic solution.
- Fill injection line (1 ½"- ZC- 132702) till injection nozzle by start X-1301-P1 & open ¾" valve
before injection nozzle.( All safety precautions be respected).
6- X-1302 (Chloriding agent injection package).

- Fill X-1302-DI with chloriding agent (C2Cl4).
- Fill injection line (1 ½"- ZC- 131001/02) till injection nozzle by start X-1302-P1 & open ¾"
valve before injection nozzle.( All safety precautions be respected).
7- X-1303 (Oxychlorination water injection package).

- Fill X-1303-DI with Demineralized water.
- Fill injection line (1 ½"- DW- 131003) till injection nozzle by start X-1204-P1 & open ¾" valve
before injection nozzle.
2. Preparation of steam generation section (D-1207).
1- Line up BFW to D-1207 (3"- BFH-122807), FV-0037 to be online (MANUAL mode).

2- D-1207 to be filled with BFW till 80% (LT-0030).
3- M-1201 to be online & stopper check valve to be closed.
4- Make sure 2 isolation valves on HSS production line (10"-HSS-122803, 04) are open & steam
trap online (SST-007).
5- P-1205A to be lined up, suction valve & discharge valve to be fully open.
6- FV-0036B Min flow valve to be on service (AUTO mode @ 100 M3/hr.)
7- Warming up ST-1205 exhaust line (8”-LSS-122801) by opening the steam trap by pass valve (
SST-801) till complete steam coming then put the steam trap online .
8- Warming up ST-1205 inlet line -MSS line (6"–MSS-122801) by put M-1203 on service.
9- When the MSS line Pressure PT-0152 reach to 10 bar & Temperature TT-0171 reach to 183.3
C (MIN), Close the M-1203 & the inlet MSS is ready to use.
10- Warming up ST-1205 casing by using LSS Line (ALL steam traps by pass valve on
casing are open).
11- ST-1205 Trip valve (UX-9500) will be open automatically when the D-1207 level (LT-
0037A/B/C) not low.
12- SOS (HS-0035RBY) to be ON if required. ((FALL-0035)).
13- Start up ST-1205 by push (HS-0027LO ) from the field which open UV-0027 then
continue opening slowly main MSS line gate valve& close MSS warming up bypass valve ¾" .
- To open UV-0027, D-1207 level not low (LT-00037) & not close signal from trip valve (UX-
9500).
14- Adjust ST-1205 speed to 1480 RPM & adjust P-1205A flow rate (FIC036B) to 214
M3/hr.
15- Increase the pressure of D-1207 to 10 bar (PT-0149) by using MSS start up line (6"– MSS-
122701) & put PV-0150 online.
16- Keep PV-0150 in MANUAL mode and continuous venting steam to M-1201 for warming D-
1207 (TT-0170 around 200 C).
17- TIC -0164 to be online & 30% opening (Manual mode).
18- Line up continuous & intermittent blowdown drums (D-1208 & D-1209) as follow:-
- Line up E-1212.
- Fill D-1209 with treated water by using (2"- WT-122703) till water come from overflow line
to OS (to make water seal).
- Line up D-1208 inlet line (1 ½"- BD-122703).
- Line up FV-0033 to D-1209 with put LIC-0033 AUTO mode @40%.
- Line up D-1208 out let line (2"- LS-122702) to LSS header.
- Adjust FI-0034 @0.86 M3/hr. by adjust continuous blowdown valve (SPV-002).
- Intermittent blowdown valve (SPV-001) in close position & can be use when required.
19- Start phosphate injection to D-1207 & adjust the dosing rate of X-1205-P1A/B which achieve
the phosphate = 15 ppm @ 12-SC-014
20- P-1205B to be standby with Auto mode.
- Suction &discharge valve fully open.
- Warming up bypass valve ¾” on discharge check valve is open.
Note:-
After the H-1201-02-03-04 Start & the steam become generated with increasing the pressure of
D-1207, when the pressure become near to MSS pressure:
- Close the MSS start up line.
- Maintain the level of D-1207 (LIC -0030) at 50% by put LIC-0030 AUTO mode cascaded with
FIC-0037.
- TIC -0164 to be online & AUTO mode @110 C
- Put PV-0150 AUTO mode @42 bar.
- When TT-0163 located after PV-0150 become 380 C, Slightly open stopper check valve and
slightly close to M-1201 step by step till complete change over.
- Put DS-0001 online with TIC-0165 AUTO mode @ 380 C.
3. Preparation of stabilizer section C-1201
1- NHT unit ON-SPEC treated heavy naphtha from C-1102.
2- UV-0001 to be closed.
3- UV-0002 to be closed. ( D-1201)
4- Open startup bypass line (6"- P-121902) to suction P-1201A/B.
5- P-1201 suction and discharge valves to be fully open.
6- Line up (4"-P-121006) & (4" -P- 121301) to D-1205 (two isolation valve on P-1202 discharge to
closed).
7- E-1208A/B, E-1211& E-1209 to be lined up .

8- Adjust the C-1201 pressure (PI -0089) at 6-7 bar by using N2 or H2 located on D-1206.
9- Put PIC-0083 AUTO mode0 @ 7 bar & PIC-0069 AUTO mode @ 7.5 bar.
10- Increase the level D-1205 (LIC-0015) to 50%
11- To reset UV-0011
- EHS-0011LC to be released
- push HS-0011R from DCS to open UV-0011
12- P-1202 suction valve to be fully open & discharge valve to be cracked open.
13- P-1202 min flow FIC-103 to be online and 50% open (MAUNAL).
14- R-1206A/B to be on service. (Follow the filling procedure)
15- FV-0019 to be online and in close position.
16- Start P-1202 to R-1206A/B to C-1201 by opening discharge valve full open and adjust FIC-0103
AUTO mode @ 34.1 NM3/hr.
-To start P-1202A/B, UV-0011 to be open & LT-00014 (D-1205) not low
17- Open FV-0019 in manual mode and adjust the flow to C-1201
18- Follow the level of C-1201 (LIC-0017) till reach 90%.
19- Close FV-0019 (Manual Zero)
20- Stop P-1202 and close Isolation valves of startup Bypass line.
21- Open UV-0013 by push HS-0013R from DCS.
-To open UV-0013, C-1201 level not low (LT-0018) & EHS-0013LC to be released.
22- P-1204A suction valve to be fully open & Discharge valve cracked open.
23- Open FV-0022 A/B 30% then start P-1204A circulation on H-1205.
-To start P-1204A/B, UV-0013 to be open & C-1201 level not low (LT-0018).
- Suction &discharge valve fully open.
- Warming up bypass valve ¾” on discharge check valve is open.
25- Adjust the flow of FIC-0022 to be 177.4 M3/hr. AUTO mode cascaded with FIC-0022A/B.
26- To start H-1205
- Heater box pressure not high (PT-0147 less than 3mmH2O)
- Damper feedback ZI-0002 to be full open
- EHS-1205AL to be released.
- EHS-1205AR to be released. (Auxiliary console)
- EHS-1205F to be released. (Local panel)
- C-1201 top pressure not high. (PT-0086)
- UV-0013 to be opened. (C-1201 bottom)
- C-1201 level not low. (LT-0018)
- EHS-1205BL to be released.
- EHS-1205BR to be released. (Auxiliary console)
- EHS-1205C to be released. (Local panel)
- H-1205, flow in passes not low (FT-0022)
- SOS (HS-0022RBY)( FALL-0022)to be ON (if required) till flow stabilized, never start H-1205
without flow in heater passes.
- D-1109 level not high (LT-0044)
27- Start H-1205 (Follow fired heater start up procedure).

28- Increase H-1205 out let temp. (TIC-0085) by rate 20c/hr. till 180 C
29- If level appear in D-1206 (LT-0022) , Put C-1201 total reflux by start P-1203 & open FV-0020.
-To start P-1203A/B, UV-0014 to be open & D-1206 level not low (LT-0022).
-To open UV-0014, EHS-0014LC to be release then push HS-0014R.
4. Pressurization of unit
4.1. Nitrogen loop section.
4.2. Regeneration section.

4.3. Reaction section.
4.4. Reduction section.
4.1. Nitrogen loop section pressurization

1- Line up Nitrogen loop as follow:-
-UV-0007, UV-0009 & UV-0011 to be closed
- E-1303 to be online
- PDV-0107A/B to be online and in close position.
- D-1306 to be in service.
- K-1301A/B suction & discharge valves to be fully open
- Spill back PV-0100 to be online & in close position
- E-1304 to be online
- D-1307 to be on service
- D-1307 outlet lines to be isolated.
- Nitrogen line to 1st & 5TH lift pots to be closed.
- Startup nitrogen line (3"- N-132318) to E-1301 to be isolated.
2- Start nitrogen loop pressurizing to 3.5 bar by using:-
- Startup line (3"-P-120701) which injected to E-1303 inlet line.
- PDV-0107A which injected to D-1306 inlet line.
- Nitrogen line (2"- N-132322) injected on suction &discharge lines of K-1301A/B.
3- To start K-1301:-
A- HS-0065R to be normal from DCS.
B- EHSK-5013A/B to be released from local panel.
C- EHS-0065L to be released from filed.
D- All K-1301 permissive to be cleared:-
- Compressor to be 0% load.
- Lube oil pressure to be not low PT-5015 (1.5 bar).
- Ready to start from DCS.
- Process start permissive from DCS.
- D-1306 level not high (LT-0026).
- K-1301 discharge temperature not high.
E- Acknowledge & reset to be push from local panel.
4- Put PV-0100 AUTO mode @ 8.2 bar.
5- Start up K-1301A/B (Follow compressor Start up procedure) @ 100 % capacity.
6- Select HS-0107 to start up mode & put PIC-0108 AUTO mode @ 2.2 bar.
st
7- Line up nitrogen to 1 lift pot and put FV-0017 online and in close position.
st
8- Line up CTP (3"-CA-131202) to 1 upper hopper (D-1310).
9- Line up D-1310 out let line (6"-N-131303) to E-1309 then to F-1302.
10- F-1302 to be online.
11- Put PDV-0058 online.
th
12- Line up nitrogen to 5 lift pot and put FV-0027 online and in close position.
13- Line up CTP (3"-CA-132002) to upper serge drum (D-1301).
14- Line up D-1301 out let line (6"-N-131104) to F-1301.
15- F-1301 to be online.
16- Put PDV-0082 online.
17- Put FIC-0017 AUTO mode @ 302.5 NM3/hr.
18- Put FIC- 0027 AUTO mode @ 240.5 NM3/hr.
19- Put PDIC-0058 AUTO mode @ 0.15bar.
20- Put PDIC-0082AUTO mode@ 0.15bar.
21- Service nitrogen sealing as follow:-
A- To reset UV-0008, UV-0010 & UV-0012:-
- HS-0103 to be NORMAL.
- PT-0103(D-1307) not low.
- Note: HS-0102RBY it is not required to use because the pressure (PT-0103) is achieved.
B- Put PDV-0052 online with AUTO mode @ 0.05 bar. (D-1303)
C- Put FIC-0019 online with AUTO mode @ 10.4 NM3/hr. (D-1310)
D- Put FIC-0028 online with AUTO mode @ 61.6 NM3/hr. (D-1324)
22- To start BL-1301:-
- Suction & discharge valve to be opened.
- Line up seal gas system with FI-1301F @0.22 NM3/hr. &adjust PCV-1301F1 @ 6.4 bar
- Put FIC -0036 AUTO mode @ 1455 NM3/hr. (The flow to be adjusted according to fines
sample)
23- Start BL-1301 & put it in remote mode with cold mode by adjusting the speed to 1980 PRM
via HIC-1301.
Note:-
In normal operation the temperature will be increase to 150 C, so the BL-1301 will be change to
hot mode by adjusting the speed to 2250 PRM via HIC-1301.
4.2. Regeneration section pressurization

1- Line up regeneration loop as follow:-
- PDV-0038A/B to be online and in close position.
- Open bypass line of DR-1301.
- F-1303A to be online & F-1303B to be stand by.
- Open K-1302A/B suction & discharge valves.
- FV-0007 to be online and in close position.
- TV-0022 to be online and in close position.
- FV-0009 & FV-0010 to be online and in close position.
- PDV-0026 A/B to be online and in close position.
- KV-0001, KV-0002, KV-0003 & KV-0004 to be closed.
2- Start regeneration loop pressurizing to 4.5 bar by using:-
- Startup line (2"- N-130903) which injected to OXYCHLORINATION ZONE.
- Nitrogen line (2"-N-130301) which injected to suction & discharge line of K-1302A/B
- PDV-0038B
3- To start up K-1302A/B.
A- HS-0053R to be normal.
B- EHSK-5113A/B to be released.
C- EHS-0053L to be released.
D- 1308 inlet temperature (TT-0001) not high.
E- All K-1302 permissive to be cleared:-
- Process start permissive from DCS.
- D-1308 level (IS-01) not activated (LAHH-0004).
F- Acknowledge & reset to be push from local panel.
4- Put FIC-0007 Auto mode @ 3285 NM3/hr. & PIC -0013 AUTO mode @ 6.5 bar.
5- Put FIC-0009 AUTO mode @ 154NM3/hr. & FIC-0010 AUTO mode @ 159 NM3/hr.
6- Select HS-0012 to start up mode & put PIC-0038 AUTO mode @ 4.5 bar.
7- Put PDIC-0026 AUTO mode @ 0.1 bar.
8- Put PDIC-0019 AUTO mode @ 0.03 bar.
9- Start up K-1302A/B (Follow compressor Start up procedure) @ 100 % capacity.
10- Line up DR -1301 by opening the inlet valve & keep the bypass valve open.
11- Start UP DR-1301 (Follow DR-1301 start up procedure) then slowly close the bypass valve.
12- To switch on EH-1302:-
- EHS-1302L to be released.
- TT-0011 to be not high.

- LT-0004 not high.
- Note: HS-0018RBY it is not required to use because the flow (FT-0008) is achieved.
13- Switch on EH-1302 (from field & select RUN from DCS) to 300 C (TIC -1302) at the rate of 40
C/ hr.
- LT-0004 not high.
C/ hr.
- LT-0004 not high.
C/ hr.
4.3. Reaction section pressurization
The resulting nitrogen in these sections is about 25 vol. % which is favorable for a steadier
catalyst circulation. It will also be helpful for the oil-in. Indeed molecular weight of recycle gas
has an impact on the lifting of liquid in the Packinox exchanger. If pure H2 is used, the lifting
will be more difficult. N2 will increase Molecular weight and consequently ease start-up
operation. However, N2 content is the recycle gas must never exceed 30vol%.
1- Before reaction pressurization makes sure the follow:-
- Inlet H.N feed UV-0001 to be closed & isolate upstream UV-0001 isolation valves.
- UV-0002 to be closed. (D-1201)
- UV-0003, UV-0004, UV-0006, UV-0008 & UV-0010 are in close position. (need to be reset)
- R-1205A/B to be by passed.
- Hydrogen rich gas to CCR (3"- P-121212) to be isolated.
- Hydrogen rich gas to PAS (PV-0101) to be isolated.
- Hydrogen Rich gas to F.G header (PV-0062) to be isolated.
- Hydrogen rich gas to TGTU (2"- P-121215) to be isolated.
- Hydrogen rich gas to DHT (6"- P-121205) to be isolated.
- X-1201 inlet & out let process lines to be isolated & by pass line to be opened.
- Discharge P-1201 FV-0010 to be isolated.
- P-1201 min flow FV-0102 to be isolated.
2- Line up Reaction section as follow:-
- E-1201 to be online.
- H-1201.02,03,04 to be online.
- R-1201,02,03,04 to be online.
- EA-1201 to be online.
- E-1202 to be online.
- D-1201, D1202 & D-1203 to be online.
- E-1203, E- 1204, E-1205 & (E-1206(shell side)) to be online.
3- To reset K-1201 suction & Discharge valve (UV-0003 &UV-0004):-
- EHS-0003LC to be released.
- EHS-0003RC to be released.
- Reset UV-0003 by push RHS-0003R on DCS
- Reset UV-0004 by push RHS-0004R on DCS
4- To pressurizing K-1202 section (UV-0006, UV-0008& UV-0010) to be reset as follow:-
A- UV-0010 to be reset as follow:-
- LT-0011 to be not high. (D-1204)
- EHS-0054R to be released. (Auxiliary console)
- EHS-0010RC to be released. (Auxiliary console)
- Reset UV-0010 by push RHS-0010R on DCS.
B- UV-0006 & UV-0008 to be reset as follow:-
- UV-0010 to be opened.
- ESH-0052R to be released. (Auxiliary console)
- Reset UV-0006 & UV-0008 by push RHS-0052R on Auxiliary console.
5- Start Reaction section pressurizing to 3 bar on K-1201 discharge line by using start up
hydrogen line from PSA (2"-P-132203).
6- Put PIC-0026B AUTO mode @ 3 bar & PIC-0026A & PIC-0036 AUTO mode @ 3.5 bar
7- Put PIC-0044 MANUAL mode @ 50% (PV-0040 & PV-0041 in close position).
8- To start up K-1201:-
A-All K-1201 permissive to be cleared:
- Comp. running status (not running).
- Comp. trip (not trip).
- Primary seal gas supply diff pressure (not low)….. PDAL-9004 (more than 0.5 bar)
- Primary seal gas supply diff pressure (not low)….. PDAL-9013 (more than 0.5 bar)
- Lube oil rundown tank level (not low)….. LAL-9001 (more than 57%)
- T&T valve (fully close).
- Control oil supply header pressure (not low)..... PAL-9005 (more than 4.6 bar)
- Lube oil header pressure (not low)….. PAL-9002 (more than 0.9 bar)
- Lube oil supply header temperature (not low)….. TAL-9039 (more than 21 C)
- ASV manual not close.
- Fully open on K-1201 discharge valve (UV-0003).
- Fully open on K-1201 suction valve (UV-0004).
- Not high level in reformer separator (D-1201)
B- SOS (HS-0061RBY) to be ON (FALL-0002).
C- EHS-0051L to be released.
D- EHS-0051R to be released. (Auxiliary console)
E- EHSK-9008B on local panel to be released.
F- Reset K-1201 by push RHS-0051R on Auxiliary console.
G- Acknowledge & reset to be push from local panel.
(Reset can be done from DCS by RHSK- 9002R)
9- Preparation & start up k-1201 (follow start up K-1201 procedure).
- ASC to be AUTO mode
- Push compressor start (12-HSK-9004ST) from local panel (UV-0005, governor valve will open
&ASV FX-0025 will be energized).
- Adjust the K-1201 discharge flow (FT-0003) by adjusting ST-1201 speed (12-HIC-9001).
10- To start H-1201, 02, 03,04 :-
- Heater box pressure not high (PT-0136 less than 3mmH2O).
- Damper feedback ZI-0001 to be full open.
- Put SOS on reformer unit feed (HS-0006RBY) ((FALL-0006))
- All reactors inlet temperature to be not high (TT-0179, TT-0101,TT-0105& TT-0106).
- D-1109 level not high. (LT-0044)
- EHS-1201F to be released. (Local panel)
- LT-0037 to be not low. (D-1207)
- FT-00035 to be not low.
- EHS-1201C to be released (Local panel)
- K-1201 to be running.
- Push reaction section reset (RHS-0050R) on auxiliary console.
11- Start H-1201,02,03,04 (Follow fired heater start up procedure).
12-Increase R-1201,02,03,04 inlet temperature ( TIC-0021, TIC-0027, TIC-0033 & TIC-0039) by

rate 40C/hr. till 400 C.
4.4. Reduction section pressurization
1- Before reduction chamber pressurization makes sure the follow:-
- UV-0009 between D-1310 & D-1311 to be closed.
- Line up hydrogen gas line from HPU (2"-P-132201)

- FV-0033 to be online and in close position.
- E-1301, E-1302 & EH-1301 to be in service.
- Line up D-1311 out let line (4"- P-131302).
- PDV-0057, HV-0001& PV-0091 to be online & in close position.
2- Put PIC-0057 in AUTO mode @ 0.1 bar.
3-To reset PV-0091:-
- PT-0099 of hydrogen inlet from HPU to be not low or push SOS ( HS-0099RBY) to be ON.
4- Reset PV-0091 by push (RHS-0091R) on DCS & put PIC-0091 in AUTO mode @ 3.8 bar.
5- Put FV-0033 AUTO mode @ 2241NM3/hr.
- TT-0046A to be not high.
- PT-0099 of hydrogen inlet from HPU to be not low or push SOS (HS-0099RBY) to be ON.
C/hr.
nd rd th
8- Line up 2 , 3 & 4 lifting lines as follow:-
- Line up hydrogen from PSA (2"- P-132108).
Note:-
After reformer produce hydrogen and the unit become stabilize, Line up hydrogen lifting line
from reformer (3”-P-121212) instead of PSA line (2”-P-132108)
- Line up PV-0090 & put PIC-0090 AUTO mode @7.2 bar.
nd
- Line up 2 lift line & put FIC-0021 AUTO mode @ 586.1NM3/hr.
- Line up CTP to D-1312 & Put D-1342 online.

rd
- Line up 3 lift line & put FIC-0023 AUTO mode @ 557.4 NM3/hr.

th
- Line up 4 lift line & put FIC-0025 AUTO mode @ 527.8 NM3/hr.
5. Preparation of CCR washing Drum (D-1308)
1- Line up DW line to P-1302 (2"-DW-130201).
2- E-1307 to be online.
3- P-1302 suction valve to be full open & discharge valve to be cracked open.
4- P-1302 Min flow line RO-0138 to online.
5- Open FV-0001 OP=30%
6- HS-0051 to be normal.
7- Fill the water section of D-1308 by Start P-1302 and follow LT-0001 till the level 40% then close
FIC -0001.
- To start P-1302, D-1308 level not high (LT-0004) & HS-0051 to be normal.
8- Fill the Caustic section of D-1308 by line up (1 ½" – DW-130205) with full open the valves
& P-1301 suction valve to be close, till the level 50% then adjust the FT-0003 at normal flow =
0.174 M3/hr.
9- SOS (HS-0006RBY) to be ON. ((PT-0006))
10- Reset UV-0092 by push (HS-0092R) from DCS.
11- To reset UV-0092
- D-1208 level not low (LT-0003).
- SOS (HS-0006RBY) to be ON.
- HS-00050 to be normal.
12- Put FIC-0001 AUTO MODE at 4.75M3/hr.
13- Put LIC-0001 & LIC-0002 AUTO mode.
14- P-1301 suction valve to be full open & discharge valve to be cracked open.
15- P-1301 Min flow line RO-0137 to online.
16- Start P-1301A & open discharge valve then put FIC-0002 AUTO mode @ 3.1M3/ hr.
- To start P-1301,( HS-0050 to be normal, D-1308 level not low(LT-0003) & SOS (HS-0006RBY)
to be ON).
6. Preparation of catalyst transfer
1- To reset UV-0007:-
- HS-0006 to be Normal.
- PDT-0054 not low.
- PDT-0060 not low.
- FT-0020 not to be low (SOS HS-0020RBY to be use if required).
- LT-0004 not high.
- AT-0008 not high.
- PDT-0085 not low.
- AT-0008 not to be high.

st
4-To reset PDV-0053 (1 lifting):-
- R-1301 (LT-0007) not low.
- D-1310 (LT-0015) not high.

- UV-0007 to be full open.
- HS-0067(IS-15) to be normal (catalyst circulation stop).
- PDT-0054 not low.
- Regeneration shutdown to be cleared (IS-07) as follow:-
* TT-0017 not low (EH-1302 out let).
st
* TT-0016 not high (1 burning outlet).
nd
* TT-0023 not high (2 burning outlet).
* PT-0124 not low (K-1303 discharge) ((SOS (HS-0124RBY) is required)).
* HS-0055 to be normal.
* EH-1302 to be running.
* K-1302 to be running.
- Reset PDV-0053 by push RHS-0053R on DCS.

nd
5- To reset PDV-0061 (2 lifting):-
- Regeneration shutdown to be cleared (IS-07) (cleared before).
- EH-1301 to be running.
- D-1310 (LT-0017) not low.
- D-1311(LT-0016) not low.
- UV-0009 to be full opened.
- PDT-0060 not low.
- FT-0020 not to be low (SOS (HS-0020RBY) to be use if required).
- LT-0004 not high.
- AT-0008 not high.
- PT-0099 not low (SOS (HS-0099RBY) to be use if required).

rd
- HS-0067(IS-15) to be normal ((catalyst circulation stop)
- D-1312 (LT-0019) not low.

th
- D-1313 (LT-0021) not low.
- Reset PDV-0074 by push RHS-0074R

th
8-To reset PDV-0083 ( 5 lifting):-
- Regeneration shutdown to be cleared (IS-07)(cleared before).
- D-1314 (LT-0023) not low.
- D-1301 (LT-0014) not high.
- UV-0011 to be full open.
- PDT-0085 not low.
- AT-0008 not to be high.
9- Adjust the levels in upper hoppers to be 40%-50% (LT-0018, LT-0020, LT-0022 & LT-0024)
by using (PDV-0053, PDV-0061, PDV-0067, PDV-0074 & PDV-0083) manually then to be in
close position.
10- During adjusting the levels in upper hoppers LT -0008(R-1301) need to be loaded, so we have
to operate lock hopper sequence manually as follow:-
- Make level in D-1302 by equalizing the pressure between D-1301& D-1302 Push UV-0004
BYPASS & open UV-0004.
- Push KV-0003 BYPASS & open KV-0003.
- Catalyst will be loaded to D-1302, then close KV-0004, after 10 Sec close KV-0003.
- Close UV-0004.
- Pressurize D-1302 to be near to the R-1301 pressure by Push UV-0006 BYPASS & open
UV-0006 then close it.
- Make level in R-1301 by equalizing the pressure between R-1301& D-1302 Push UV-0003
BYPASS & open UV-0003.
- Catalyst will be unloaded to R-1301 , then close KV-0002 , after 10 Sec close KV-0001
- Close UV-0003.
11- Lock hopper adjustment to be ready for sequence:-
A- KV-0001, 02, 03, 04 to be in AUTO mode.
B- UV-0003, 04, 05,06 to be in AUTO mode.
C- Lock hopper (PT-0050) should be higher than Upper surge drum (PT -0051).
D- If PT-0050 is not higher than PT-0051.(PT-0050< PT-0051- 0.15 bar), lock hopper can not be
ready to start sequence, so PT- 0050 will be adjusted as follow;-
- Push UV-0006 BYPASS & open UV-0006 to increase PT-00050 above PT-0051 then close it.
- Change UV-0006 to AUTO mode.
E- Now lock hopper sequence is ready.
7. Reformer Unit conditions before Oil in
1- C-1201 is under total reflux.
2- R-1201,02,03 &04 inlet temperatures (TIC-0021, TIC-0027, TIC-0033 & TIC-0039) are 440 C
( for fresh catalyst , RITs are 400C)
3- H-1201,02,03,04 fuel gas controllers are in manual mode (PIC-0121, PIC-0124, PIC-0127
& PIC-0130)
4- K-1202 is standby & ready for start as follow:-
A- All K-1202 permissive to be cleared:-
- Turning device disengaged on local panel and DCS.
- Main motor purge complete.
- UV-0006, UV-0008 & UV-0010 to be full open. (Cleared before)
- LT-0008 (D-1203) not high.
- LT0005 (D-1202) not high.
- Discharge temperature not high
B - EHS-0053L to be released.
C - EHS-0053R to be released (Auxiliary console).
D - EHS-1202AL/BL to be released.
E - EHS-1202AR/BR to be released (Auxiliary console).
F - EHSK-5003A/B to be released (local panel).
G- Reset K-1202 A/B RHS-0053R (Auxiliary console).
H- Acknowledge & reset to be push from local panel.
6- Line up H.N feed as follow:-
- UV-0001 to be opened by reaction section reset on Auxiliary console ( RHS-0050R).
Note:- to reset reaction section (IS-01 & IS-02 )to be cleared ( it cleared before H-1201.02.03.04
started).
- FV-0001 to be online & in close position.
- F-1201A/B to be online.
- P-1201 A/B are stopped & UV-0002 (D-1201) is closed.
- P-1202 A/B are stopped.
- Start up by pass line to be close (4"-P-121006).
- UV-0042 is close & UV-0043 is opened.
- FV-0012 to be closed (D-1204).
- E-1207 is bypassed.
- R-1205 are A/B are by passed
- EA-1203 is online.
- E-1210 is online.
- FV-0017 is isolated & off spec reformate line to be open (6"-P-121413).
7- Reset UV-0012 by push RHS-0012R.
- To reset UV-0012, C-1201 level not low (LT-0018).
8. CCR conditions before Oil in

1- Washing drum (D-1308) under water circulation.
2-K-1301 is running.
3- Catalyst circulation is stopped.
4- Select HS-0107 to be in normal mode & put PDIC-0107 AUTO mode @ 1.3 bar.
5- Select HS-0012 to be in normal mode & put PDIC-0039 AUTO mode @ 0.67 bar.
6- Reduction chamber ( D-1311) inlet temperatureTIC-1301 increase to 480 C.
7- Regeneration gas loop is standby as follow:-
- First burning in let temperature TIC-1302 increase to 450 C.
- Second burning in let temperature TIC-0022 AUTO mode @ 450 C.
- Oxychlorination inlet temperature TIC-1303 increase to 510C.
- Calcination inlet temperature TIC-1304 increase to 520 C.
8- Preparation Air loop as follow:-
- Line up Instrument air line to DR-1302.
- DR-1302 to be on service (follow start up D-1302 procedure).
- Line up D-1305.
- K-1303 A/B suction & discharge valves to be fully open.
- Put PIC-0127 AUTO mode @ 8.2 bar.
- FV-0011 & FV-0004 to be isolated.
- UV-0001 is open & UV-0002 is closed.
9- To start K-1303:-
A - HS-0072R to be Normal.
B - EHS -0072L to be released.
C- EHSK-5189A/B to be released.
D- All K-1303 permissive to be cleared:-
- LT-0030 not high (D-1305).
E - UV-0014 to be open (HS-0070 to be normal & IS-07 to be cleared) then reset RHS-0014R.
F- Reset to be push from local panel.
10- Start K-1303 & the capacity to be 50%.
11- Catalyst levels for all upper hoppers are steady @ 40%-50%.
12- CCR unit now ready to run as BLACK BURN MODE.
-Black mode (HS-0056) (IS-08) in Active mode.
9. Reformer unit & CCR unit is ready for Oil in as follow:-
1- Introduce feed to reaction section with 60% capacity (56 M3/hr.)((@RITs = 440 C))
via FV-0001 @ 5-10 min.
Note:- After feed introduced→

- Start Chloriding agent injection to the feed & adjust the dosing rate of X-1203-P1A/B which
achieve the chloride = 25 ppm @ 12-SC-002 .
- Start Sulfiding agent injection to the feed & adjust the dosing rate of X-1202-P1A/B which
achieve the sulfur = 0.2 - 0.3 ppm @ 12-SC-002.
- Monitor the H2S @ hydrogen recycle gas (12-SC-003) to be 3 ppm during startup.
- Monitor the HCL @ hydrogen recycle gas (12-SC-003) to be 5 ppm during startup.
2- Adjust & maintain reactor inlet temperatures@400 C-480 C Via ( PIC-0121,0124,0127&0130)
3- Monitor carefully D-1201 level (LIC-0002) & when level not low, open UV-0002
To open UV-0002
- Push HS-0002R to open UV-0002 from DCS.
4- Start P-1201A/B & Put FIC-0102 AUTO mode @ 38 M3/hr.
- To start P-1201A/B, UV-0002 to be open & D-1201 level not low.(LT-0001).
5- Put LIC-0002 AUTO mode cascaded with FIC-0010.
6- Monitor carefully D-1201 pressure PIC-0026.
7- D-1205 level increase (LT-0014) till 50%, Open UV-0011 (opened before).
8- Start P-1202A/B & Put FIC -0103 AUTO mode @ 34.1 M3/hr.
9- Put LIC-0015 AUTO mode cascaded with FIC-0019 & put PIC-0079 AUTO mode @15.5bar.
10- C-1201 level will increase (LIC-0017) till 70%.
Note:- To reset recontacting section

- Increase D-1205 level (LT-0015) to 80% to avoid any disturbance C-1201 level during
switching.
- FV-0012 to be online & in close position. (Never open FV-0012 before D-1204 pressure
become near to normal)
- When K-1202 start & before increase the load to 25%, Push RHS-0042R from DCS, so
UV-0042 will open & UV-0043 will close.(IS-05(overfilling) is cleared before).
- D-1204 level (LT-0012) will increase till become not low, open UV-0009 by push RHS-
0009R from DCS.
- Open FV-0012 manually to adjust D-1205 level, and then put it in cascade mode with
LIC-0012
- Monitor carefully D-1204, D-1205 & C-1201 levels during switching, to avoid any levels
disturbance.
11- Put LIC-0017AUTO mode cascaded with FIC-0017 to off spec line.
12-((Don’t forget: Monitor carefully D-1201 pressure PIC-0026B to flare))
13- Increase TIC -0085 slowly till 251 C.
14- C-1201 pressure will increase; change PIC-0083 set point @11.5 bar & PIC-0069 set point
@12bar.
15- D-1206 level (LT-0022) will increase & when level become not low, open UV-0014
To open UV-0014
- Push HS-0014R to open UV-0014 from DCS
16- Start P-1203 if it stopped.
17-Adjust C-1201 top temperature Ti-0077 around 64 C & TI-0075(tray 9) around (77 Cto90 C)
by adjusting reflux flow rate FIC-0020.
18- Put LIC-0022 AUTO mode cascaded with FIC-0021 to LPG off spec line (2"-P-121719).
19- Monitor carefully D-1201 pressure PIC-0026B to flare, If PV-0026A/B wide open. Ready to
start K-1202 as follow:-
- Hydrogen rich gas to PAS (PV-0101) to be online. (Auto & in close position)
- Hydrogen Rich gas to F.G header (PV-0062) to be online. (Auto & in close position)
- Put PIC-0044 AUTO mode @ 7.5 bar.
- Put PIC-0057A AUTO mode @ 22 bar.
- Put PIC-0057B AUTO mode @ 21.4 bar.
- Put PIC-0059 AUTO mode @ 21.4.
- Put PIC-0062 AUTO mode @ 20.5.
- Start K-1202 (follow startup K-1202 procedure )& keep the capacity 50% (Monitor carefully D-
1201 pressure PIC-0026B)
- increase K-1202 capacity according to PIC-0026A/B opening , if PV-0026A/B is still open proceed
K-1202 loading , But if PV-0026A/B close , keep the K-1202 capacity as it is.
- Adjust PIC -0026A/B set point @ 2.3 bar & PIC-0036 set point @ 2.2bar
20- Monitor H2/H.C ratio which will be high than normal value 1.5 (feed at 60% & recycle gas at
full capacity).
21- Stabilize RITs @480 C & capacity 60% & keep this temperature as long as the moisture
content in hydrogen recycle gas ( 12-SC-003) is high than 200ppm vol.
22- When moisture content in hydrogen recycle gas (12-SC-003) is falls under 200 ppm vol. & H2S
below 3 ppm vol. , increase RITs temperature till 495 C by 2 C/hr.
23- When moisture content in hydrogen recycle gas (12-SC-003) is falls under 30 ppm vol. & H2S
is normal 1 ppm vol. , increase RITs temperature up to the required value to obtain the desired
RON 2 C/hr.
24- Adjust chloride injection rate during startup the unit according to moisture content in
hydrogen recycle gas (12-SC-003) as follow:-
Recycle gas moistureChloride addition rate in feed
Over 200ppm 25ppm
200-100ppm 10ppm
30-100ppm 5ppm
If Less than 30ppm adjust injection to keep HCL in Recycle gas (1-3ppm)
Note:-
• During normal operation there is no need for chloride injection into the feed.
- Chloride injection into the feed may be required if water upset in the feed (upset of NHT or
water contamination in the storage should be correct) or stop chloride injection in CCR. (Max
allowance water in the feed is 4 ppm).
- If the Recycle gas moisture above 100 ppm, lower RITs to 460 C with decreasing the unit
severity & inject chloride 5ppm related to the feed.
- If the Recycle gas moisture 50-100ppm , lower RITs to 480 C with decreasing the unit severity
& inject chloride 2ppm related to the feed.
- If the Recycle gas moisture 35-50 ppm, inject chloride 2ppm related to the feed.
- If Less than 30ppm adjust injection to keep HCL in Recycle gas (1-3ppm).
• During normal operation sulfur content in the feed is lower than 0.5 ppm which
corresponds to H2S lower than 1 ppm in recycle gas which corresponds to 5 ppm in C-1201 off
gas.
- when the H2S level reaches to 5 ppm in recycle gas , RITs must be lowered to 480 C & the
reformer feed must be reduced to maintain RON
- The high severity operating conditions can be only resumed when the H2S content in recycle
gas is lower than 1ppm .
25- Check & adjust C-1201 condition as follow:-
26- Sample to be taken form C-1201 bottom product (12-SC-007) & when the sample result is
on spec as following, Route reformate to on spec line (6"- P-121407).
27- If RON is not achieved, increase RITs by 1 C to 3 C & other sample to be taken .
28- Sample to be taken form C-1201 top product (12-SC-011) when the sample result is on spec as
following, Route LPG to U-23.
29- If LPG spec not achieved, adjust C-1201 condition (Reflux ratio) &other sample to be taken.
30- When moisture content in hydrogen recycle gas sample (12-SC-003) become below 30 ppm,
Refrigeration package (X-1201) is ready to start.
31- Start X-1201 (follow startup procedure).
- Master reset from DCS (RHS-9316R) to be push.
- Check Chiller(E-1207), inlet & outlet valves of tube side in close position & bypass valves are
fully open.( before start Refrigeration package, open bypass valve(1") of inlet isolation valves
tube side(E-1207) for pressurizing, after that open outlet isolation valves full open, then open
inlet valves full open& slowly close by pass valve till suction pressure of compressor more than
suction pressure set point, start Refrigeration package , with increasing suction pressure more
than set point , increase compressor capacity load.
32- R-1205A/B to be online (follow startup procedure).
33- Line up Hydrogen product lines as required & as unit status.
- Hydrogen rich gas to CCR (3"- P-121212) to be online.
- Hydrogen rich gas to TGTU (2"- P-121215) to be online.
- Hydrogen rich gas to DHT (6"- P-121205) to be online.
34- Increase the feed by 4.5 M3/hr. with rise RITs at the rate of 1 C-2 C /hr. in order to maintain
the reformate RON.(( A flow increase must be always be achieved prior to temperature increase ))
35- During startup & after unit stabilized, monitor the following:-
-Reactors ∆T ((TDI-0006, TDI-0022, TDI-0028, TDI-0034 & TDI-0007))
-Reactors ∆P ((PDI-0014, PDI-0017, PDI-0020 & PDI-0023))
-Packinox ∆P ((PDI-0001 & PDI-0003))
Note:-
Now the reformer unit produce on spec reformate & the unit capacity is 56 M3/hr. with required
RITs.
-It is preferred to increase unit capacity to normal (93.3 M3/hr.) after CCR unit run as white
burn mode to maintain unit performance.
10. Start up regeneration section
10.1. Spent sample (AP.7 -006) to be taken from D-1302

If the coke% more than 3% , so regeneration can start but if the Coke% less than
3%, so start catalyst circulation without burning till Coke % become more than 3%.
1- To start catalyst circulation without burning make sure the following :-
- HS-00067(IS-15) to be normal.
- Regeneration shutdown (IS-07) to be cleared. (Cleared before)
- Lock hopper sequence is ready. (Adjusted before)
- Upper hoppers levels to be adjusted. (Adjusted before)
- Secondary lifting valves (PDVs) to be reset. (Reset before)
- Push reset for lock hopper sequence from DCS.
- Start lock hopper sequence by push load from DCS.
2- Start catalyst circulation as follow:
- Put PDIC-0053 Auto mode @0.1- 0.3 bar
- Put PDIC-0061AUTO mode cascaded with LIC-0018
- All upper hoppers levels to be steady @ 40 %
3- Spent sample (AP.7 -006) to be taken from D-1302 & check Coke%
- When coke % become 3% , stop catalyst circulation by closing PDVs
4- Now regeneration can start.
10.2. Start burning without catalyst circulation as follow:-
1- Before burning start, caustic injection to be start & keep total salt content (expressed in
H
total sodium) not excessed 3% (13-SC-002) &P (AT-0001) to be 7.5 and less than 8.5 .
To start caustic injection pump
- P-1301 is running. ( HS-0050 to be normal, D-1308 level not low(LT-0003) & SOS (HS-
0006RBY) to be ON).
2- Make sure HS-0056 is activate (black burn mode).
3- UV-0002 is close & UV-0001 is open
4- FV-0011 & FV-0004 to be online & in close position
5- All oxygen analyzer to be online ( AT-0002 , AT-0003, AT-0004, AT-0005, AT-0006 & AT-
0007).
st
6- Increase 1 burning inlet temperature to 480 C by TIC-1302.
nd
7- Put TIC-0022 AUTO mode @ 480 C to adjust 2 burning inlet temperature.
st
8- Open slowly FV-0011 (MANUAL mode) & monitor carefully 1 burning zone bed
nd
Temperature (TI-0019A-I) & 2 burning zone bed Temperature (TI-0025A-I).
9- Increase oxygen content carefully (AT-0003) to avoid any rapid increase in bed
temperatures.
10-When bed temperatures become stable & start decreasing , we observe increasing in
st nd
oxygen content in 1 & 2 out let burning zones (AT -0004. AT-0005& AT-0006), this
indicates there is no coke in the burning zone.
11- Start catalyst circulation with black burn mode as follow:-
- Select HS-0008 black burn mode then put it in AUTO mode (AT-0003 AUTO mode
cascaded with FIC-00011)
- Put AT-0003 set point 0.4%- 0.8% according to burning bed temperatures & inlet - out
let ∆T not exceed 40 C
- After adjust regenerator conditions, start catalyst circulation as before.
- Catalyst circulation to be 50% by adjust master controller PDIC-0053 set point .

st nd
- Monitor carefully ∆T for 1 & 2 burning zone
- Monitor carefully AT-0004, AT -0005 & AT-0006

nd
- If AT-0005 & AT-0006 (out let 2 burning zone) begin reduced less than 0.2%, start put
AIC-0002 AUTO mode with set point which adjust the out let oxygen content more than
0.25%.
- CCR unit is running as black burn mode.
- Regen. Catalyst sample (AP.7-0007) from D-1310 to be taken after 8-10hr & according to
catalyst circulation rate (100% rate = 7 hr.).
- If coke % is lower than 0.2%, CCR is ready to run as white burn mode. If not, continue
run as black burn till the sample become below 0.2%.
12- To switch to white burn, check the following:-
- AT-0005 to be not low
- PDT-00031 to be not low
- In let oxychlorination zone (TT-0040A-C) & outlet oxychlorination zone(TT-0041A-F) to

be not high.
13- Just HS-00056 become normal, HS-0008 will change automatically to white mode ( AIC-
0003 AUTO mode cascaded with AIC-0007 cascaded with FIC-0011)
14- Reset UV-0002 & keep UV-0001 open till:-
- AT-0007 become increase
- AT-0003 become increase
*This meaning the oxygen content becomes increase in the system
15- Close UV-0001

16- To start oxychlorination water pump & chloriding agent pump:-
- IS-07, IS -08 & IS-12(EH-1303) to be clear. (Cleared before)
- HS-0064 to be normal. (chloriding pump X-1302-P1A/B)
- HS-0065 to be normal. (water pump X-1303-P1A/B)
- Line up nitrogen line to MX-1302 & adjust FI-0014.
17- Start water & chloride injection to oxychlorination zone& adjust the dosing rate of X-
1302-P1A/B & X-1303-P1A/B which achieve the chloride = 1% - 1.1% @ AP.7-0007
18- Stop chloride injection pump X-1203-P1A/B in reformer feed after 8-10 hr. from
switching to white burn.
Note:-
During CCR unit normal operation, monitor carefully the following:-
➢ Adjust TIC-1302 between 470 C-480 C

➢

➢

➢

➢
st
➢ 1 burning zone outlet temperature between 535 C-545 C
➢
nd
➢2
➢ burning zone outlet temperature between 500 C-510 C
st nd
➢ 1 burning, 2
➢ burning & specially oxychlorination bed temperatures to be not high.
st
➢ Oxygen content at 1 burning zone inlet: 0.5% to 0.8%
➢
nd
➢ Oxygen content at 2 burning zone outlet: 0.2% to 0.3%
➢ Oxygen content at calcination zone inlet: 8% to 12 %
➢ Monitor Regenerator ∆Ps which can indicate screen plugging or flow distribution
➢
problems in the generator which may affect catalyst regeneration.
- Burning beds (PDI-0020, PDI-0028 & PDI-0027)
- Oxychlorination & calcination bed (PDI -0043)
➢ Washing drum (D-1308) inlet temperature (TT-0001) to be not high.

➢
➢ Monitor ∆P sealing to be not low.

➢
➢ Washing drum level LT-0001 to be not high

➢
➢ Upper hoppers levels to be stable & no fluctuation.

➢
➢ Lock hopper sequence to be normal.

➢
Prepared/Updated by: Approved by: Authorised by:

Area supervisor Department Manager Refinery Manager
Date: Date: Date:
Note: This printed copy is for information only. Consult Company server for valid updated copy.

Reformer Start Up Requisites

Uploaded by

Copyright:

Available Formats

Reformer Start Up Requisites

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Reformer Start Up Requisites

Uploaded by

Copyright:

Available Formats

DEPARTMENT: CODE:

❖ Prerequisites prior unit start-up

1- X-1202 ( Sulfiding agent injection package).

2- X-1203 (Chloriding agent injection package).

3- X-1204 (Water injection package).

4- X-1205 (Phosphate injection package).

5- X-1301 (Caustic injection package).

6- X-1302 (Chloriding agent injection package).

7- X-1303 (Oxychlorination water injection package).

2. Preparation of steam generation section (D-1207).

1- Line up BFW to D-1207 (3"- BFH-122807), FV-0037 to be online (MANUAL mode).

3. Preparation of stabilizer section C-1201

1- NHT unit ON-SPEC treated heavy naphtha from C-1102.

3- UV-0002 to be closed. ( D-1201)

4- Open startup bypass line (6"- P-121902) to suction P-1201A/B.

5- P-1201 suction and discharge valves to be fully open.

7- E-1208A/B, E-1211& E-1209 to be lined up .

10- Increase the level D-1205 (LIC-0015) to 50%

11- To reset UV-0011

- push HS-0011R from DCS to open UV-0011

14- R-1206A/B to be on service. (Follow the filling procedure)

15- FV-0019 to be online and in close position.

18- Follow the level of C-1201 (LIC-0017) till reach 90%.

19- Close FV-0019 (Manual Zero)

21- Open UV-0013 by push HS-0013R from DCS.

24- P-1204B to be standby with Auto mode.

- Suction &discharge valve fully open.

- Warming up bypass valve ¾” on discharge check valve is open.

26- To start H-1205

- Heater box pressure not high (PT-0147 less than 3mmH2O)

- Damper feedback ZI-0002 to be full open

- EHS-1205AR to be released. (Auxiliary console)

- EHS-1205F to be released. (Local panel)

- C-1201 top pressure not high. (PT-0086)

- UV-0013 to be opened. (C-1201 bottom)

- C-1201 level not low. (LT-0018)

- EHS-1205BR to be released. (Auxiliary console)

- EHS-1205C to be released. (Local panel)

- H-1205, flow in passes not low (FT-0022)

- D-1109 level not high (LT-0044)

27- Start H-1205 (Follow fired heater start up procedure).

-To open UV-0014, EHS-0014LC to be release then push HS-0014R.

4.1. Nitrogen loop section.

4.2. Regeneration section.

4.1. Nitrogen loop section pressurization

-UV-0007, UV-0009 & UV-0011 to be closed

- PDV-0107A/B to be online and in close position.

- K-1301A/B suction & discharge valves to be fully open

- Spill back PV-0100 to be online & in close position

- D-1307 outlet lines to be isolated.

- Nitrogen line to 1st & 5TH lift pots to be closed.

- Startup nitrogen line (3"- N-132318) to E-1301 to be isolated.

2- Start nitrogen loop pressurizing to 3.5 bar by using:-

- Startup line (3"-P-120701) which injected to E-1303 inlet line.

- PDV-0107A which injected to D-1306 inlet line.

- Nitrogen line (2"- N-132322) injected on suction &discharge lines of K-1301A/B.

A- HS-0065R to be normal from DCS.

B- EHSK-5013A/B to be released from local panel.

C- EHS-0065L to be released from filed.