Mega – Cokers Commissioning Experience

Mega – CokersCommissioning Experience

01-Oct-13 1Raj Sharma

October 2013New Delhi, India

Raj SharmaCoker Consultant

Safety First Awareness – key for successful startups


Emerging Cokers due to heavier Crude Blends- Old Cokers at Digboi, Gauhati, Bongaigaon and

Barauni- New Cokers at Jamnagar (Reliance), Essar Oil,

IOC-Panipat, Vadodara, Bina and Bhatinda.- Proposed /Under construction Cokers at IOC-

Paradeep, MRPL-Mangalore, Cochin and Chennai.- 2 Cokers at Reliance Jamnagar are having 8 coke

drums each with capacity of 162000 and 175000 BPD.


Mega cokers in India are 9MMTPA + capacity 8 Coke drums with single fractionator Commissioning was done phase wise based on

construction progress. This earned extra revenue due to early startup of 4 drums.

Part commissioning was a safety challenge as many common lines like CBD/pump drains/OWS/Fire water /DCS/Alarm system/Gas detector system/Utilities were common


Steps at early stage to achieve stage wise start up if required. Mega cokers have lot of flexibility

4 drums clubbed with independent Blow down system. So plant is 4+4 drums operability.

Next each pair of coke drums with heater made an independent block. So total 4 blocks

Gas plant was common with suitable turn down capability. All trays were designed for this load.


Exhaustive positive isolation (Blind list) with proper Tags and administrative control.

Additional isolation valves were provided to achieve positive isolation. Also these isolation valves at construction interphase were chain locked additionally and position logged every shift.

All utilities were also provided with additional isolation valves with blinds including Flare header.


01-Oct-13 7

1. Whole area was hard-barricaded2. Security person manned the gates with cards 3. Block 1 Area declared safety permit area4. Construction area (block 4)was barricaded by

GI sheet /Fire blankets up to coke drum platforms

5. Live lines in non operating area were painted red & tagged. Valves were positive blinded and chain locked

6. Visible lights provided blockwise at each deck

Early Startup/seggregation

Raj Sharma

Escape routes

Existing escape routes reviewed in the new barricaded scenario and new escape route marked wherever applicable considering wind directions

Minimum two gates considered for entry / exit

Additional wind socks will be provided in prominent locations for easy identification of wind directions

Assembly points

Additional assembly points provided at suitable locations for both construction and operation personnel

Mock drills will be conducted to ensure rapid & orderly evacuation of people , in case of emergency

Escape route /Assembly points


01-Oct-13 9

UNDER GROUND SYSTEM

Raj Sharma

76

46

45

44

43

17

42

41

79 42

47

50

53

56

59

6261

58

55

52

49

48

51

4140 43

77 15 14

78

13

63

60

57

54

82

78

75

44

7475733

72

71

80 81

838485

89

76

77

70

21

3

4

5

6

12

117

9 29

21

2030 31

23

32

25

2434 35 36

26 27 38

64

372726

36

35

34

222120

33

2523

19

3231302928

17

68

88

37

39494847

65 66

67 40

16

18

38

3979

86

46

28

R01 R02 R03 R04 R05 R06R07 R08

C01FRACT

F 03F 02F 01

F 04

OSBL

OSBL

OSBL

01-Oct-13 10

Storm Water System

Raj Sharma

R01 R02 R03 R04 R05 R06R07 R08

C01FRACT

C03

C02/03

MC-372-C01COMP.

371-V11372-V20

C02

372C04

372-S06B

372-S06A

C15

V16

V10

372-S14

372-S12

372-S08

V07

372-S07

V14

V30V33

371-01

371-05

V06

S07C05371-V23

371-S08

C22

V31

CO-6

MH-3

MH-4

CO-5

CO-6

MH-6

MH-5

CO-8MH-7

HV-107

H631 H591 H632H592

MH-8MH-50MH-51MH-52MH-53MH-54

CO-33

CO-03

MH-56

MH-01

MH-60

CO-01CO-12

MH-02

MH-62MH-61

MH-63

MH-64

MH-65

MH-66

MH-67

MH-68

MH-69 CO-107

CO-104

MH-72

MH-71

CO-11

MH-85MH-84MH-83

MH-82

MH-81

MH-55

CO-10

FO1 FO2 FO3FO4

H621

H619H618H616

H615HV101H609 H607

H610H608H606H611

H612H613H614

H617H620

H676

H593 H594H595

H582

H583

HV104

H562H561

H560H563H566

H672H671H670

H570 H569H587

CO-7

HV108HV105

HV106

HV150HV151

HV152

H573

HV153

ME-

371-

S01A

-JH155

H154

H153

H156

H37

H152

H158 H157H151

H38

H100

H99

H84

H11

H75 HV-63

HV-69

H74

HV-64H12H13H14

H32

H15

H31H16

H17

H58H57H160

H18H23H21

H169

HV-65

H22

H30

HV-66

H26

H56

HV-67H165

H164

HV-68

H19

H49

H59

H60H61H62

H8H72

H71

H70H48H69

H35

H36H33

H65H66H67H68

H16

H34

H80

H73

H84

H85

H83

H159H82

H81

H76

H77

H78 H79

H39

H03

H93 H10

H91

H89

H95H94H07H02

H92H90

HV62H98

HV61

HV02

HV60

V12

C06

V11

S06

S10

S05

COKE PIT

H96 H 01 H5

HV56

HV85H826

HV84HV83

H800

H813

H822H814

H811

H825H824H808H823

H809 H810

H820

H815 H816

H817 H818

H819

HV54

H572

H574H576

H575

H577

H53 H28

H29 H51

H52

H802

H807

H804

H821

H801

H803

HV-82

HV-81

H805H806

H812

H601

H597 H602

H603H598

H604H599

H605H600

H678

H677H590

H581

H630

H586

H588H633

H589H673

H567

H564

H565

H622H623H624H625

H674

H675

H24 H64

H47

HV153

OSBL

OSBL

H27H46

H25

H41

H44

H42H43

H44

HV-72

HV-71

H40

H50

H55

H54

H154

H88

H04H628H627H626

H02

H584

371-A06

HV55

H585H580

H578

H579

FO5

01-Oct-13 11

Underground isolation: OWS

Raj Sharma

R01 R02 R03 R04 R05 R06R07 R08

C01FRACT

C03

C02/03

MC-372-C01COMP.

371-V11372-V20

C02

372C04

372-S06B

372-S06A

C15

V16

V10

372-S14

372-S12

372-S08

V07

372-S07

V14

V30V33

371-01

371-05

V06

S07C05

371-V23

371-S08

C22

V31

FO1 FO2 FO3FO4

ME-37

1-S01

A-J

V12

C06

V11

S06

S10

S05

COKE PIT

CO-116 CO-106

CO-120

CO-122

CO-111 CO-108

CO-103

CO-105

CO-102

CO-20 CO-21

CO-25

CO-22

CO-18

CO-140

CO-141

CO-143

CO-142

CO-144

CO-17

CO-15

CO-16

H644

H645

H636

H635

H634

H637

H641

H640 H639

H654

H653

H652

H642H643

H636

H655H659

H127H128

H137

H125H123

H130

H440

H138

H136

H124

H120

H134

H132H131

H135H135

H752

H756H754

H757

H753 H755

H129H126

H658

H121

H122H647

H641

H650

H651

H646

H649

H760

H758 H750 H751

CO-125

FO5

01-Oct-13 12

Underground CBD isoleted

Raj Sharma

01-Oct-13 13

ABOVE GROUND SYSTEM

Raj Sharma

R01 R02 R03 R04 R05 R06R07 R08

C01FRACTIONATOR

C02/03

372-C01

HP FLARE KO DRUM

C02

COKE CUTTING WATER TANK

SLUDGE TANK

HEATER FO3

FRES

H FE

ED

HEAT

ER

COKE PIT MT-371-02

Blowdown Tower

U/G SLO

P TANKB.D.HEATER

B.D. SETTLING

DRUM

STRIPPER

COMPRESSOR

STRIPPER REBOILER

ABSORBER/STRIPPER

SP. ABSORBER

LEAN/RICH SP OIL H E

DEBUT REBOILER

DEBUT REBOILER

DEBUTANISER

LLP FLARE KO DRUM

AMINE SUMP TANK

UNSAT FG KO DRUM

AMINE ABSORBER

AMINE KO DRUM

FG KO DRUM

SLOP OIL HEATER

HCN COOLER

LCN COOLER

N/S O/H RECEIVER

NAPHTHA SPLITTER N.S. REBOILER

WASH WATER DRUM

AMMONIUM POLY S DRUM

V30V33

U/G SLOP TANKS

MP STEAM GEN.

LP STEAM GEN.

LP STEAM GEN.

Blowdown Tower

B.D. HEATER

B.D SETTLING DRUM

B.D CIR. OIL

COO

LER

372-P16 A/B

372-P05 A/B

372-P06 A/B

372-P04 A/B

372-P02 A/B/C

372-P03 A/B

372-P01A/B

371-P10A/B

371-P16A/B

371-P09A/B

371-P18 A/B

HCN PUMP

371-P13A-D

371-

P15A

/B/C 371-P11 A/B

371-P12 A/B

371-P14 A/B

CHAR

GE

PUM

P

371-P17A/B

APHAPHAPHAPH

COKE CUTTING PUMP

371-P03A/B/C

371-

P04A

/B

371-

P05A

/B

P22

A/B/

C

P24

A/B

P23

A/B

COKE PIT MT-371-01

MP-371-P08 A/B/E MP-371-P08 C/D

372-A01

372-A03

371-A04

371-A03

371-A05 371-A02371-A01

LLP

FLAR

E CO

OLE

RHP

FLA

RE

COO

LER

SPONGE COOLER

LEAN

OIL

CO

OLE

RNA

PH

O/H

CO

ND.

LCG

O P

/A

COO

LER

LCG

O

COO

LER

HCG

O

COO

LER

B/D CONDENSER B.D CONDENSERB/D CIR.

OIL COOLER

STRUCTURE-B

COMP SUC. K.O DRUM

STRIPPER REBOILER

ABSORBER INTER COOLER

372-P18 A/B

372-A05

371-A08

371-A07

LEAN AMINE COOLER

372-P11 A/B/C

MP STEAM GEN.

LP STEAM GEN.

LP STEAM B/D DRUM MP STEAM B/D DRUM

KERO DRUM

FLARE SYS. SEAL POT

ANTIFOAM PACK DE-EMUL.

PACK

FD FAN

ID FAN

FD FAN

ID FAN

FD FAN

ID FAN

FD FAN

ID FAN

HEATER FO2

HEATER FO1

HEATER FO4

371-

P55A

/B

371-

P54A

/B

371-

P53A

/B

Z371-P21A/B

P36 A/B/C

371-P02 A/B/C

CRUSHER-I CRUSHER-II

PG KOD

UTILITY BOOSTER PUMP

DELTA VALVE WS PUMP

372-A02

FRESH FEED HEATER

SITE OFFICE

WORK SHOP

CONTRACTOR OFFICE

DINI

NG

HALL

FOUR DRUM START UP

UNSAT FG AA FEED COOLER

QUENCH WATER PUMP

STRUCTURE-A

371-A06

N.S. REBOILER

SUBSTATION

Z300 - 30

PIB - 57

371-V17 A/B/C

Z371-V28

CT - 03

Fresh feed Heater

Z371 F 05

MAPS PACKAGE POLY FLOW PACKAGE

V24 A/B/C

Z371-F07

FLUSHING OIL TANK

NEUTRALIZING AMINE PACKAGE

FILMING AMINE PACKAGE

CCD ICCD II

LEGEND

NORTH

EWSOUTH

E-14S 06A

E-17S 05A

E-16S 06

E-15S 05

E-18S 10

OPERATIONAL AREA

HOT WORK PERMIT AREACONSTRUCTION AREA

Above Ground System


R01 R02 R03 R04 R05 R06R07 R08

C01FRACTIONATOR

C02/03

372-C01

HP FLARE KO DRUM

C02


SLUDGE TANK

HEATER FO3

FRES

H FE

ED

HEAT

ER

COKE PIT MT-371-02

Blowdown Tower

U/G SLO

P TANKB.D.HEATER

B.D. SETTLING

DRUM

STRIPPER

COMPRESSOR

STRIPPER REBOILER

ABSORBER/STRIPPER

SP. ABSORBER


DEBUT REBOILER

DEBUT REBOILER

DEBUTANISER

LLP FLARE KO DRUM

AMINE SUMP TANK

UNSAT FG KO DRUM

AMINE ABSORBER

AMINE KO DRUM

FG KO DRUM

SLOP OIL HEATER

HCN COOLER

LCN COOLER

N/S O/H RECEIVER


WASH WATER DRUM


V30V33

U/G SLOP TANKS

MP STEAM GEN.

LP STEAM GEN.

LP STEAM GEN.

Blowdown Tower

B.D. HEATER

B.D SETTLING DRUM

B.D CIR. OIL

COO

LER

372-P16 A/B

372-P05 A/B

372-P06 A/B

372-P04 A/B

372-P02 A/B/C

372-P03 A/B

372-P01A/B

371-P10A/B

371-P16A/B

371-P09A/B

371-P18 A/B

HCN PUMP

371-P13A-D

371-

P15A

/B/C 371-P11 A/B

371-P12 A/B

371-P14 A/B

CHAR

GE

PUM

P

371-P17A/B

APHAPHAPHAPH

COKE CUTTING PUMP

371-P03A/B/C

371-

P04A

/B

371-

P05A

/B

P22

A/B/

C

P24

A/B

P23

A/B

COKE PIT MT-371-01

MP-371-P08 A/B/E MP-371-P08 C/D

372-A01

372-A03

371-A04

371-A03

371-A05 371-A02371-A01

LLP

FLAR

E CO

OLE

RHP

FLA

RE

COO

LER

SPONGE COOLER

LEAN

OIL

CO

OLE

RNA

PH

O/H

CO

ND.

LCG

O P

/A

COO

LER

LCG

O

COO

LER

HCG

O

COO

LER


OIL COOLER

STRUCTURE-B

COMP SUC. K.O DRUM

STRIPPER REBOILER


372-P18 A/B

372-A05

371-A08

371-A07

LEAN AMINE COOLER

372-P11 A/B/C

MP STEAM GEN.

LP STEAM GEN.


KERO DRUM

FLARE SYS. SEAL POT


PACK

FD FAN

ID FAN

FD FAN

ID FAN

FD FAN

ID FAN

FD FAN

ID FAN

HEATER FO2

HEATER FO1

HEATER FO4

371-

P55A

/B

371-

P54A

/B

371-

P53A

/B

Z371-P21A/B

P36 A/B/C

371-P02 A/B/C


PG KOD


DELTA VALVE WS PUMP

372-A02

FRESH FEED HEATER

SITE OFFICE

WORK SHOP

CONTRACTOR OFFICE

DINI

NG

HALL

FOUR DRUM START UP


QUENCH WATER PUMP

STRUCTURE-A

371-A06

N.S. REBOILER

SUBSTATION

Z300 - 30

PIB - 57

371-V17 A/B/C

Z371-V28

CT - 03

Fresh feed Heater

Z371 F 05


V24 A/B/C

Z371-F07

FLUSHING OIL TANK



CCD ICCD II

LEGEND

NORTH

EWSOUTH

E-14S 06A

E-17S 05A

E-16S 06

E-15S 05

E-18S 10

OPERATIONAL AREA

HOT WORK PERMIT AREACONSTRUCTION AREA

Above Ground System


R07 R08

B.D. HEATER

B.D SETTLING DRUM

B.D CIR. OIL COOLER

APH

P22 A

/B/C

P24 A

/B

P23 A

/B

371-A05

B/D CONDENSER

FD FAN

ID FAN

HEATER FO4

P36 A

/B/C

371-A06

Fresh feed Heater

Z371 F 05

V24 A/B/C

CCD II

C01FRACTIONATOR

FLARE SYS. SEAL POT

From V-06

HARD BARRICATED AREA

GATE WITH SECURITY GUARD

SP 3

Blowdown Tower

U/S of These valves will be

blinded & inspected in every shift


DCS graphics were also divided in Blockwise along with DS alarms grouping.

Since 4 drums startup was envisaged, underground piping was designed for such isolation facility.

Physical barricading was engineered between 4 live coke drums and rest, both at coke drum structure(at all levels) and at grade plot.


Safety interlocks were designed blockwise to avoid interference. Specific inputs from outside (load shedding)were identified.

Construction priority was given for systems in 4 drums, 2 drums and then last 2 drums

4 Drums started= 23rd January 2009 Next 2 drums started= 16th May 2009 Last 2 drums started = 23rd July 2009 Extra Revenue earned= millions of Dollars


Zero LTI- safety first during construction/Pre-comm/startup

Zero fire – Fire free startup Zero flaring during startup –save money Zero/Minimum Recycle –Maximize thruput Zero /Minimum slops(generation-Reprocess) Zero sludge –Reprocess all Zero steam leak- Steam traps/flanges tightness


Start up Outline

• Methodology & Sequence –Define ,Microplan

• Focus - Project basis, P&IDs, Hazops, Manpower (Team

coker),Training

• Expedite - Engineering

• Ensure -- Procurement in time

• Quality Assurance -Construction, Systemwise priority ,

Milestones, Critical Paths, ‘S’ Curve

• Essential- Proving – Precommissioning , RFSU

• Safety – PSSR, DCS, Startup

• Maximize –Revenue by operational excellence01-Oct-13z 20Raj Sharma

BuildingTeamCoker.Process/Operation/Maintenance. Organogram

EPCO Team concept. (Engg/Project/Construction/O&M. Focus on Safety/Quality/schedule/operability

Integration within and Other Refinery units/Upstream/downstream/Utilities Teams

Define clear responsibility to each team member. Set defined targets for everyone.


Select Process Licensor earlyAssist Project group Process Package/Layout/PFD/P&ID/Hazops

Assist Engineering group EPC/Engineering/Equipment Data sheet/PDS

Model/ISOs review /Spools/Fabrication

Assist procurement group Equipment PR/Procurement/Vendor packages


Assist Construction group

System-sub system- owners

Priority/Schedule/Equipment preservation, Erection/QA, QC Alignment/Hydrotest loops/PMI

Mechanical completion/Check Lists/Internals/Gaskets/Flushing/Cleaning/

Steam blow/RFC


Operation preparedness.Operating-manuals/SOP,SMP/Training manual/Safety manualCommunication/safety permit/shift /Licensor/manpower /op-shelters

DCS-system Graphics, Alarm priority, Inter-connectivity

Operator Training/on site/Simulator/validation/learning from incidents

System proving including vendor packages and instrumentation, safety interlocks


PSSR-Include all systems like electrical sub station, PIB, safety systems like fire/gas detectors

Hydrocarbon-In/Refractory dryout/Circulation RFSU Commissioning/Feed Cut In/Product–out Stabilization/Test Run


Major startup Pitfalls PMI – misses Heater coke up,Heater tube failure/BMS

failures/Burner extinguish Coke drum foam over- Level problems/Delays

in Cycle, Fractionator upsets/level losses/Feed failures


Identify right block- measures Flange leakages/opening-measures Wrong operation of coke drum-measures,

valves-interlock/Isolators Power failure-Tarry drum Utilities failure – Control fractionator temp Pump seal failures- seal selection, plan Pump failures due to strainer chock up-hot

circulation-more time Compressor failures


Expansion loops fouling with other piping-measures taken

Water hammers –steam headers Steam traps malfunctions-heater coke up Heater pass flow failures. Heater trips Coke drum cave in- shot coke problems Cutting tool jamming- experience manpower


Coke drum hot spot/Blow over Fire at Blow down tower/air coolers Fire–MOC-PMI misses Down stream units upsets- product storage-air

cooler sudden expansion Gas/H2S leakages Sampling errors Bad line breaks Coke drum cycle delays


Check valves in wrong direction Fire at coke drums- Safety valve blows Products going off specs. LPG, Naphtha Coke cutting Hose failures-Hose quality Instrument ferrules leakages- Hydrotest

problems HPV/LPD vibration cracks- gusset support-

engg standards


COKER COMPLEX

01-Oct-13 31

WE WILL MAKE IT HAPPEN …Raj Sharma

•Commissioned 5 Cokers in the world,Including IOCL, KNPC & Reliance Jamnagar.

•Enhanced capacity by 140% - 175000bpd • Reduced Coke drum cycle to 12 hrs

•Contact : [email protected]•Mobile: +91 8130577115•Landline : +91 124 2219558• 11,Birch Court, Nirvana Country, Gurgaon (122018)

01-Oct-13 Raj Sharma 33

INDIA - DELAYED COKERS AT GLANCE

Sl No DISCRIPTION LICENSOR LOCATION CAPACITY BPDYEAR OF START COKE DRUMS Unheading System Completion

(A) INDIAN COKERS

1 Reliance Industries Limited -- Coker 1 FWUSA Jamnagar Gujrat 161000 1999 8 DELTA 1999

2 Reliance Industries Limited -- Coker 2 FWUSA Jamnagar Gujrat 175000 2009 8 DELTA 2009

3 Essar Oil Limited ABB LUMMUS Jamnagar Gujrat 60000 6 DELTA 2010

4 IOC Baroda ABB LUMMUS Baroda Gujrat 71204 2010 4 ZIMMERMAN JENSON 2010

5 BPCL/Oman Petroleim-Joint venture ABB LUMMUS Bina M.P 60000 2010 4 ZIMMERMAN JENSON 2010

6 HPCL/Mittal ABB LUMMUS Bhatinda Punjab 60000 2012 4 ZIMMERMAN JENSON 2012

7 IOC Barauni - 2 Units EIL Baurani Bihar 30000 1984 2 MANUAL TROLLY 1985

8 IOC Bongaigaon EIL Bongaigaon Assam 30000 1981 2 MANUAL TROLLY 1980

9 IOC Bongaigaon EIL Bongaigaon Assam 30000 1990 2 MANUAL TROLLY 1990

10 IOC Assam EIL Assam 30000 1990 2 MANUAL TROLLY 1990

11 Oil India Limited OLD Assam Digboi 5000 1942 2 MANUAL TROLLY 1945

12 IOC Gauhati EIL Gahauti Assam 25000 1977 2 MANUAL TROLLY 1967

13 IOC Panipat ABB LUMMUS Panipat Haryana 60000 2005 4 HAAN & CLAY 2008

14 MRPL Manglore ABB LUMMUS Manglore Karnataka 60000 4 ZIMMERMAN JENSON 2014

15 BPCL Cochin ABB LUMMUS Cochin Kerala 60000 4 ZIMMERMAN JENSON 2015

16 IOC Paradeep Orissa FWUK Paradeep Orissa 74000 4 DELTA 2014

17 Chennai Petroleum ABB LUMMUS Chennai Tamilnadu 40000 2 2015

18 IOC Mathura Projected Uttar Pradesh

19 IOC- Haldia Projected Bengal

Blowdown 1

Blowdown 2


PRE-START-UP SAFETY REVIEW CHECKLIST

DATE Annexure1

PLANT

EQUIPMENT / SYSTEM

SR NO DESCRIPTION Supporting Documents STATUSYES/NO REMARKS

1.0 SAFETY AND HEALTH

1.1 “General” Safety

1.1.1 Has adequate and appropriate PPE (Personal Protective Equipment)been specified and provided in control room, field, SFE / FE porta cabin? PSCL

1.1.5 Are points of isolation clearly marked/labelled and readily accessible? PSCL

1.1.6 Have bump/trip hazards been identified and all sharp edges removed? PSCL

1.1.7 Has proper guarding, handrails/barriers, been provided to prevent falls? PSCL

1.1.8 Are Safety Showers and Eye Wash facilities provided, adequate & operational? PSCL

1.1.9 Has sufficient lighting been provided so that operation, servicing, maintenance and repair of the facility can be carried out safely? PSCL

1.1.10 Are display systems for providing operational instructions, safety warnings and emergency information provided and positioned so that they are clearly visible and easily read? PSCL



R01 R02 R03 R04 R05 R06R07 R08

C01FRACTIONATOR

C02/03

372-C01

HP FLARE KO DRUM

C02


SLUDGE TANK

HEATER FO3

FRES

H FE

ED

HEAT

ER

COKE PIT MT-371-02

Blowdown Tower

U/G SLO

P TANKB.D.HEATER

B.D. SETTLING

DRUM

STRIPPER

COMPRESSOR

STRIPPER REBOILER

ABSORBER/STRIPPER

SP. ABSORBER


DEBUT REBOILER

DEBUT REBOILER

DEBUTANISER

LLP FLARE KO DRUM

AMINE SUMP TANK

UNSAT FG KO DRUM

AMINE ABSORBER

AMINE KO DRUM

FG KO DRUM

SLOP OIL HEATER

HCN COOLER

LCN COOLER

N/S O/H RECEIVER


WASH WATER DRUM


V30V33

U/G SLOP TANKS

MP STEAM GEN.

LP STEAM GEN.

LP STEAM GEN.

Blowdown Tower

B.D. HEATER

B.D SETTLING DRUM

B.D CIR. OIL

COO

LER

372-P16 A/B

372-P05 A/B

372-P06 A/B

372-P04 A/B

372-P02 A/B/C

372-P03 A/B

372-P01A/B

371-P10A/B

371-P16A/B

371-P09A/B

371-P18 A/B

HCN PUMP

371-P13A-D

371-

P15A

/B/C 371-P11 A/B

371-P12 A/B

371-P14 A/B

CHAR

GE

PUM

P

371-P17A/B

APHAPHAPHAPH

COKE CUTTING PUMP

371-P03A/B/C

371-

P04A

/B

371-

P05A

/B

P22

A/B/

C

P24

A/B

P23

A/B

COKE PIT MT-371-01

MP-371-P08 A/B/E MP-371-P08 C/D

372-A01

372-A03

371-A04

371-A03

371-A05 371-A02371-A01

LLP

FLAR

E CO

OLE

RHP

FLA

RE

COO

LER

SPONGE COOLER

LEAN

OIL

CO

OLE

RNA

PH

O/H

CO

ND.

LCG

O P

/A

COO

LER

LCG

O

COO

LER

HCG

O

COO

LER


OIL COOLER

STRUCTURE-B

COMP SUC. K.O DRUM

STRIPPER REBOILER


372-P18 A/B

372-A05

371-A08

371-A07

LEAN AMINE COOLER

372-P11 A/B/C

MP STEAM GEN.

LP STEAM GEN.


KERO DRUM

FLARE SYS. SEAL POT


PACK

FD FAN

ID FAN

FD FAN

ID FAN

FD FAN

ID FAN

FD FAN

ID FAN

HEATER FO2

HEATER FO1

HEATER FO4

371-

P55A

/B

371-

P54A

/B

371-

P53A

/B

Z371-P21A/B

P36 A/B/C

371-P02 A/B/C


PG KOD


DELTA VALVE WS PUMP

372-A02

FRESH FEED HEATER

SITE OFFICE

WORK SHOP

CONTRACTOR OFFICE

DINI

NG

HALL

FOUR DRUM START UP


QUENCH WATER PUMP

STRUCTURE-A

371-A06

N.S. REBOILER

SUBSTATION

Z300 - 30

PIB - 57

371-V17 A/B/C

Z371-V28

CT - 03

Fresh feed Heater

Z371 F 05


V24 A/B/C

Z371-F07

FLUSHING OIL TANK



CCD ICCD II

LEGEND

NORTH

EWSOUTH

E-14S 06A

E-17S 05A

E-16S 06

E-15S 05

E-18S 10

Early startup –entry control

Z371 under Operation

Z371 under Construction

Z372 under Operation

01-Oct-13 38

PHASE 1 AREA

PHASE 2 AREA

ENTRY GATE

BARRICADING WITH TIN SHEETS

SECURITY

Raj Sharma

R01 R02 R03 R04 R05 R06R07 R08

C01FRACTIONATOR

C02/03

372-C01

HP FLARE KO DRUM

C02


SLUDGE TANK

HEATER FO3

FRES

H FE

ED

HEAT

ER

COKE PIT MT-371-02

Blowdown Tower

U/G SLO

P TANKB.D.HEATER

B.D. SETTLING

DRUM

STRIPPER

COMPRESSOR

STRIPPER REBOILER

ABSORBER/STRIPPER

SP. ABSORBER


DEBUT REBOILER

DEBUT REBOILER

DEBUTANISER

LLP FLARE KO DRUM

AMINE SUMP TANK

UNSAT FG KO DRUM

AMINE ABSORBER

AMINE KO DRUM

FG KO DRUM

SLOP OIL HEATER

HCN COOLER

LCN COOLER

N/S O/H RECEIVER


WASH WATER DRUM


V30V33

U/G SLOP TANKS

MP STEAM GEN.

LP STEAM GEN.

LP STEAM GEN.

Blowdown Tower

B.D. HEATER

B.D SETTLING DRUM

B.D CIR. OIL

COO

LER

372-P16 A/B

372-P05 A/B

372-P06 A/B

372-P04 A/B

372-P02 A/B/C

372-P03 A/B

372-P01A/B

371-P10A/B

371-P16A/B

371-P09A/B

371-P18 A/B

HCN PUMP

371-P13A-D

371-

P15A

/B/C 371-P11 A/B

371-P12 A/B

371-P14 A/B

CHAR

GE

PUM

P

371-P17A/B

APHAPHAPHAPH

COKE CUTTING PUMP

371-P03A/B/C

371-

P04A

/B

371-

P05A

/B

P22

A/B/

C

P24

A/B

P23

A/B

COKE PIT MT-371-01

MP-371-P08 A/B/E MP-371-P08 C/D

372-A01

372-A03

371-A04

371-A03

371-A05 371-A02371-A01

LLP

FLAR

E CO

OLE

RHP

FLA

RE

COO

LER

SPONGE COOLER

LEAN

OIL

CO

OLE

RNA

PH

O/H

CO

ND.

LCG

O P

/A

COO

LER

LCG

O

COO

LER

HCG

O

COO

LER


OIL COOLER

STRUCTURE-B

COMP SUC. K.O DRUM

STRIPPER REBOILER


372-P18 A/B

372-A05

371-A08

371-A07

LEAN AMINE COOLER

372-P11 A/B/C

MP STEAM GEN.

LP STEAM GEN.


KERO DRUM

FLARE SYS. SEAL POT


PACK

FD FAN

ID FAN

FD FAN

ID FAN

FD FAN

ID FAN

FD FAN

ID FAN

HEATER FO2

HEATER FO1

HEATER FO4

371-

P55A

/B

371-

P54A

/B

371-

P53A

/B

Z371-P21A/B

P36 A/B/C

371-P02 A/B/C


PG KOD


DELTA VALVE WS PUMP

372-A02

FRESH FEED HEATER

SITE OFFICE

WORK SHOP

CONTRACTOR OFFICE

DINI

NG

HALL

FOUR DRUM START UP


QUENCH WATER PUMP

STRUCTURE-A

371-A06

N.S. REBOILER

SUBSTATION

Z300 - 30

PIB - 57

371-V17 A/B/C

Z371-V28

CT - 03

Fresh feed Heater

Z371 F 05


V24 A/B/C

Z371-F07

FLUSHING OIL TANK



CCD ICCD II

LEGEND

NORTH

EWSOUTH

E-14S 06A

E-17S 05A

E-16S 06

E-15S 05

E-18S 10

Escape route & Assembly points (Contd)

Normal Wind direction – From West01-Oct-13 39

PHASE 1 AREA

PHASE 2 AREA

ESCAPE ROUTE

ASSEMBLY POINT

Raj Sharma

Sys System Description Oct'07No. PREREQUISITES 9 11 13 15 17 19 21 23 25 27 29 31

SYS REQD FROM CONST ON

RAW MATERIAL REDYNESS

FLUSHING BY

371-SO Office space 01.03.07 NA NA

371-SOA Porta cabin

371-SOB Site office space

371-SOC CCR ofice

371 C&T Communication & Transportation 01.03.07 NA NA

371 C&T-1 Telephone,Plant radio

371 C&T-2 PC network

371/372-ELE Electricity 15.10.07 NA NA

371/372-ELE-A Electric sub station charging SS charging

371/372-ELE-B Emergency power generator

371/372 LT Plant lighting system 15.10.07 NA NA Plant lighting charging

371-CS Storm water sewer(CS) 10.10.07 NA 2 Storm water sewer(CS)

371-OS Oily sewer(OS) 10.10.07 NA 3 Oily sewer(OS)

371-SH Closed drain(SH&SC) 10.10.07 NA 12 Closed drain(SH&SC)

371-CA Chemical drain 10.10.08 NA 2 Chem drain

371-CP Coke pit / maze 10.10.07 NA 2 Drain to maze

371-WF Fire water 10.10.07 NA 2 Fire water

371-WU Utility water 01.11.07 NA

371-WD Potable water/Drinking water 20.10.07 NA 2 Potable water

371-WC Cooling tower/ CT 3 10.12.07 NA

371-WP Process water 15.11.07 NA

371-BFW MP&LP BFW 20.01.08 NA

371-BFW HP BFW 20.02.08 NA



Overall Construction Progress - JERP COKER (Unit 371 / 372)

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

2007 2008

PlanFront AvlActualPlan 1



Flanges not aligned


Misaligned flanges will result in leakage


Low Point Drains Need Valves


Low Point Drains Need Valves


Small bore pipe needs bracing for strength


The Right Gasket can be identified by color coding


The Right Gasket Will Fit Properly in The Right Flange


Proper nuts and bolts can be verified with stamp


01-Oct-13 52

Coke drum vapor inlet nozzle

No provision for installation of Heat shield

Raj Sharma



01-Oct-13 55

POSITIVE MATERIAL IDENTIFICATION

Raj Sharma




Date post:	13-Apr-2022
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