HP-49 Start up plan

Guidelines
When warming up the V-3/4 &V-18, line up feed gas and establish
3.5-5 knm3/h flow to flare from V-018. Keep V-49-003 inlet
temperature set at 385C.
When the H2S is <0.2 ppm and HCL/Chloride <0.1 ppm, start for
warm up LTSC & prepare and cut in feed to reformer catalyst
tubes
Note:
LTSC warm up can be done from other running HP unit V-018
outlet gas
When CO2 Absorber outlet gas result CO + CO2 content less than
1.3 % , start warming up methanator, flare the gas through PCV023B,

Precautions
While increasing Reformer / system temperature and pressure, to
check for any leak from all the system

Lab testing of additional samples.

When the V-003 & V-018 bed temperature reaches 360C & 310C
respectively, inform lab & collect sample from V-018 outlet for
H2S,TS,Cl2 and HCL.
After establishing Benfield circulation & introducing feed to
Absorber, send Lean & Rich Benfield sample for full analysis
After one hour of line up LTSC, send CO2 absorber outlet sample
to lab to check for CO and CO2,

Send H2 product sample to lab to check H2,CH4,and CO / CO2,if

result CO / CO2 is <20 ppm and H2 is >96%,route product H2 to
H2 header and line up recycle H2.
Check V-010 / 011 process condensate sample and route V-10 / 11
condensate to V013.

After CBD line replacement job is over, below start up

procedure to follow
1. Deblind the reformer heater as per master blind list
2. Keep steam drum vent/silencer vent open, line up BFW to
steam drum, fill the system and start circulation,
3. Light two end burners in each cell and rotate the burners for
two hours,
4. Line up PCV-017 and start warm up the steam through FCV022/023 u/s vents,
5. Increase reformer arch temperature to 275C, and the rate
of 28 C/hour,
6. When arch temperature is 275C,check FCV-022/023 u/s
vent steam, if steam is dry and introduce steam to reformer
cat. tubes,
7. Line up feed gas and establish 3.5 knm3/hr flow to flare from
V-018 outlet and start warm up the V-3/4A/B and V-18,
(temperature rise in V-003 bed is below 50C ),

8. When the V-003 bed temperature reaches 360C , inform lab

collect sample from V-018 outlet for H2S,TS,Cl2 and HCL.
When the H2S is <0.2 ppm and HCL/Chloride <0.1 ppm,
start for warm up LTSC ( or from other running HP unit V-018
outlet gas) as per LTSC warm up procedure. When the LTSC
bed temperature have reached 205C, stop warming up
LTSC, increase pressure to 15.0 kg/cm2 by V-018 outlet gas,
isolate inlet and outlet to flare. Now LTSC is ready receive
feed from HTSC,
9. Increase reformer arch/outlet temperature to 700C and the
rate of 28C/hour
10.
While increasing arch temperature, increase steam
flow, reformer back pressure and steam drum pressure as
per below table,

Arch
temperatur
e oC
275
300
350
400
500
600
700

Total steam
flow FIC-019
Tons/hr
20
20
20
20
28
36
38

Reformer
back pressure
kg/cm2
0
2
4
5
7
9
11

Steam generation
system pressure
kg/cm2
7
10
15
20
25
29
30

11.
Once all burners are inline, set the reformer heater
minimum firing at 0.058 kg/cm2 LP fuel gas pressure and car
seal the HCV-062/063,
12.
Start Benfield circulation by H2 pressure from other
running HP unit,

13.
Benfield system is ready to receive feed from HTSC and
start warming up of HTSC as per procedure,
14.
When the feed gas from V-018 outlet sample results:
H2S is <0.2 ppm and HCL/Chloride <0.1 ppm, prepare and
cut in feed to reformer catalyst tubes as per procedure,
15.
Increase feed gas to reformer to 1.2 tons/hr per each
cell (total 2.4 tons/hr) and maintain reformer back pressure
at 17.0 kg/cm2 ,
16.
Start venting u/s of CO2 Absorber and maintain
reformer back pressure and reboiler level,
17.
Pressurize the CO2 absorber and start venting u/s of
methanator through PCV-022 ( make sure V-007 inlet B/V,
XV-903 and its bypass B/V close),
18.

Line up LTSC and close LTSC bypass B/Vs,

19.
After ONE hour, send CO2 absorber outlet sample to lab
to check for CO and CO2,
20.
Increase feed gas to reformer to 2.3 tons/hr per each
cell (total 4.6 tons/hr),
21.
When CO2 Absorber outlet gas result CO + CO2 content
less than 1.3 % , start warming up methanator, flare the gas
through PCV-023B,
22.
Send H2 product sample to lab to check H2,CH4,and CO
/ CO2,if result CO / CO2 is <20 ppm and H2 is >96%,route
product H2 to H2 header and line up recycle H2.
23.
Check V-010 / 011 process condensate sample and
route V-10 / 11 condensate to V013.

24.

While increasing temperature and pressure, to check for any

leak from all the system.