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Refinery Start Up Sequence

This document outlines prerequisites and timelines for starting up various units at a refinery, including: 1) The AVU-IV unit is estimated to take 30 months for mechanical completion and various downstream and utility units need to be ready 4 months prior for interconnection. 2) The OHCU and FGTU units require 31 other units and utilities to be ready first, including the AVU-IV, and are estimated to take 5-7 years to build from start to finish for a greenfield site. 3) The PRU, LPG, and propylene units require 25 other units and utilities to be ready in advance, including the LTU-II and RFCCU,

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656 views5 pages

Refinery Start Up Sequence

This document outlines prerequisites and timelines for starting up various units at a refinery, including: 1) The AVU-IV unit is estimated to take 30 months for mechanical completion and various downstream and utility units need to be ready 4 months prior for interconnection. 2) The OHCU and FGTU units require 31 other units and utilities to be ready first, including the AVU-IV, and are estimated to take 5-7 years to build from start to finish for a greenfield site. 3) The PRU, LPG, and propylene units require 25 other units and utilities to be ready in advance, including the LTU-II and RFCCU,

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bikas_saha
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© © All Rights Reserved
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Refinery start up sequence

Has your refinery operation manuals to review?


How about records of your refinery startups?
And the technical documentation for consult about this issue.
You need specifically the operation manuals for each units and review and
studied it carefully.
You need a technical advisor for this job if your refinery has not experience in
complex refinery start ups. This is the cheapest solution. if you think about
HSE.

In my experience, it took 7 days to start CDU. First, cold circulation for 3~4


days ,then, hot circulation for 3~4 days ,then, load up slowly.
To live CCR and BTX , it took almost one month. When you heat up big
column, take care of thermal expansion.
Unfortunately, I don't have documents show detail.

A refinery consists of many other sub-units. Considering a optimum green refinery then
it may take Detailed Engineering = 24 months, Construction 24–36 months,
Commissioning = 6–8 months, Production in 24 + 36 + 8 = after 68 months. Considering
procurement to be in parallel to Engineering & Construction. (Procurement of material is
the biggest bottle neck which cannot be compressed & will depend from where it is
procured & what quality, being a variable did not add its duration).

It depends of course of size of the refinery. If we take average size (between 10-15
million ton of crude oil processing), it will take between 5-7 years to build greenfield
refinery.

Example: STAR refinery in process of building in Turkey is estimated to cost $5.5 bn with
10 million ton crude oil processing capacity. It was started in 2011 and expected to be
online at 2018.
Dear Uday san,

Please refer below prerequisite for AVU-IV,OHCU,ATU-II,PRU,LPG MOUNDED BULLETS & OFFSITES
UTILITIES for your information and further alignment of BR-09 integrated time line schedule.

AVU-IV: (EPCC-01A)

1) SWS-II (EPCC-03)
2) ARU-III (EPCC-03)
3) ARU-I (Existing) Alternate for ARU-III
4) RFCCU Revamp-LVGO,HVGO,VR,VS feed (EPCM-03)
5) Coker-B- VR FEED (EPCM-02)
6) ATU-II (EPCC-06)
7) DHDT-II(EPCC-05) AGO & Vac. Diesel feed
8) NHDT-II+ISOM-II (EPCC-04) Light Naphtha feed
9) LTU-I Tie ins with existing unit for treating AVU-IV LPG (EPCM-24)
10) BELCO- For spent caustic handling (EPCM-03)
11) Caustic Solution System (EPCC-07)- 45% Fresh Caustic supply
12) ETP (EPCC-15)- For spent caustic handling
13) ETP readiness for handling of Brine effluent from Desalter
14) OWS to ETP (EPCM-24)
15) CRWS to ETP to BTP Transfer facility (EPCM-11)(EPCM-24)
16) OFFSITE Tank farm (EPCC-11)-Crude Tanks, OHCU Feed tanks, SKO/PCK Tanks, SRN Tanks
17) Offsite Area Feed & Dispatch Pumps (EPCM-14)
18) ATF Tanks (EPCM-10)
19) Flushing Oil from Storage(EPCM-24)(EPCM-14)(EPCC-11)
20) Slop (EPCM-24)
21) FIRE WATER SYSTEM (EPCC-02)
22) FLARE (EPCC-09)- HC Flare & Acid Flare(EPCM-24)
23) Fuel Gas (EPCM-24)
24) Cooling Water- From PCT Cooling Tower (EPCC-10)
25) DM+CPU (EPCC-15)
26) BFW (EPCM-24)
27) Drinking water (EPCM-xx)
28) Power Import Facility
29) Instrument Air (IA) & Plant Air(PA) (EPCC-14)(EPCM-24)
30) Nitrogen (EPCM-24) & N2 plant on BOO basis
31) Service Water(EPCM-24)
32) HP,MP,LP Steam (EPCM-24)

OHCU+FGTU (ATU-II): (EPCC-06)


1) AVU-IV (EPCC-01A)
2) Coker-B- HCGO FEED (EPCM-02)
3) ARU-III- Lean & Rich Amine (EPCC-03)
4) HGU-III- Hydrogen (BOO BASIS)
5) RFCCU Revamp-UCO & Off spec Filter Backwash (EPCM-03)
6) ATU-II (EPCC-06)
7) RFCCU Existing Merichem & LTU-II (EPCC-07)for off spec LPG handling
8) Sour water to existing SWS
9) BELCO- For spent caustic handling (EPCM-03)
10) Caustic Solution System (EPCC-07)-45% Fresh Caustic supply
11) ETP (EPCC-15)- For spent caustic handling
12) OWS to ETP (EPCM-24)
13) CRWS to ETP to BTP Transfer facility (EPCM-11)(EPCM-24)
14) OFFSITE Tank farm (EPCC-11)-OHCU Feed tanks, SKO/PCK Tanks, SRN Tanks
15) Offsite Area Feed & Dispatch Pumps (EPCM-14)
16) ATF Tanks (EPCM-10)
17) Flushing Oil from Storage (EPCM-24)(EPCM-14)(EPCC-11)
18) Slop (EPCM-24)
19) FIRE WATER SYSTEM (EPCC-02)
20) FLARE (EPCC-09)- HC Flare & Acid Flare (EPCM-24)
21) Fuel Gas (EPCM-24)
22) Cooling Water- From PCT Cooling Tower (EPCC-10)(EPCM-24)
23) DM+CPU (EPCC-15)
24) BFW (EPCM-24)
25) Drinking water (EPCM-xx)
26) Power Import Facility
27) Instrument Air (IA) & Plant Air(PA) (EPCC-14),(EPCM-24)
28) Nitrogen (EPCM-24) & N2 plant on BOO basis
29) Service Water(EPCM-24)
30) HP,MP,LP Steam (EPCM-24)
31) LABORATORY (EPCM-xx)

PRU + LPG & PROPYLENE MOUNDED BULLETS (EPCC-07)

1) LTU-II (EPCC-07)
2) RFCCU Revamp-Treated LPG feed (EPCM-03)
3) PP Unit (EPCC-08)
4) Caustic Solution System (EPCC-07)-Caustic supply
5) ATU-II (EPCC-06)
6) BELCO- For spent caustic handling (EPCM-03)
7) Existing LPG Bottling Plant & TTL facility Tie ins and connecting pipelines (EPCM-24)
8) Caustic Solution System (EPCC-07)-45% Fresh Caustic supply
9) ETP (EPCC-15)- For spent caustic handling
10) OWS to ETP (EPCM-24)
11) CRWS to ETP to BTP Transfer facility (EPCM-11)(EPCM-24)
12) Offsite Area Off spec LPG Pump (EPCM-14)
13) FIRE WATER SYSTEM (EPCC-02)
14) FLARE (EPCC-09)- HC Flare (EPCM-24)
15) Fuel Gas (EPCM-24)
16) Cooling Water- From Propylene Cooling Tower (EPCC-10)(EPCM-24)
17) DM+CPU (EPCC-15)
18) BFW (EPCM-24)
19) Drinking water (EPCM-xx)
20) Power Import Facility
21) Instrument Air (IA) & Plant Air(PA) (EPCC-14),(EPCM-24)
22) Nitrogen (EPCM-24) & N2 plant on BOO basis
23) Service Water(EPCM-24)
24) HP,MP,LP Steam (EPCM-24)
25) LABORATORY (EPCM-xx)

OFFSITES & UTILITIES:

All Off-sites & Utilities including interconnection piping (EPCM-24) shall be made progressively ready
~4 months before mechanical completion of AVU-IV (MC-30 Months).

For AVU-IV Following utilities shall be ready as per LSTK Schedule,

1. Power Supply- June 2021


2. Service Water-June 2021
3. Fire Water- June 2021
4. Instrument Air & Plant Air – August 2021
5. Drinking Water- October 2021
6. DM Water- November 2021
7. HP,MP,LP Steam- December 2021
8. Cooling Water- December 2021
9. Nitrogen- January 2022
10. ETP Readiness- January 2022
11. Amine from ARU-III- February  2022
12. Caustic Solution System- February 2022
13. Flare System(HC & Acid Flare)- March 2022
14. Fuel Gas / Fuel Oil Supply - March 2022
15. Feed (Crude supply)- March 2022
16. AVU-IV Products to downstream units- March 2022

Also note that Interconnection Piping + Pipe rack (EPCM-24,25), Fire water system(EPCC-02), Flare
Package (EPCC-09) & DM+CPU (EPCC-15) plant are on critical path. Since execution of these systems
is linked to Refinery shut down & tight schedule.

AVU-IV Initial operation or 6 MMTPA case is no more applicable. Therefore it is considered that AVU-
IV shall be running to its design capacity of 9 MMTPA after commissioning.

Please update BR-09 integrated time line schedule based on above understanding.
For balance BR-09 units Muktesh san will issue details similarly with in today.

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