Guide book for new learners (Operations)

GENERAL INSTRUCTIONS FOR AREA OPERATOR

10.

1. Take charge from relieving shift and to read log book/ log sheets.
2. Fill check list and take status of maintenance jobs in area.
3. Monitor process variables. Inform shift Engineers/ Boardman whenever any
abnormality observed and take corrective actions as per Work instructions in
consultation with the shift Incharge / Boardman.
4. Log data in the log sheets as per procedure.
5. Take samples at specified time.
6. Coordinate with Maintenance crew as per instructions of Shift Engineers.
7. Carry out any additional job assigned from time to time by the Shift Incharge.
8. Write shift report on log book and handover charge to next shift.
9. Maintain housekeeping of the operating area.
Prepare and handover maintenance jobs as per instructions.
11. Carryout safe startup and shutdowns.
12. Carryout all the routine audits during shifts.
13. Control plants parameters during emergencies as per standard operating work
instructions.
14. Actively participate in the safety and emergency handling discussions and share
the knowledge with juniors.
15. Give suggestions to improve the plant performance.

GENERAL INSTRUCTIONS FOR BOARDMAN

Guide book for new learners (Operations)

Take charge from relieving shift and to read log book/ log sheets.
Monitor operating parameters critically and control them within specified limits.
Report any abnormality to shift engineer and take corrective actions whenever
required and pass on instructions to Area Operators as per requirement.
Log data in the log sheets.
Coordinate with laboratory for recording the lab results and communicate any
abnormality to Shift engineers.
Coordinate with maintenance crew as per instructions of Shift Incharge.
Work on any additional assignments given by Shift Incharge.
Maintain housekeeping of control panel/ board.
Write shift report on log book and handover charge to next shift.
Fill the check list at start of shift and mention all the abnormalities for rectification.
Actively participate in the safety and emergency handling discussions and share
the knowledge with juniors.
Give suggestions to improve the plant performance.
To carryout safe shutdowns and startups.
To control different parameters during emergencies as per standard operating
work instructions.

Section#01
PUMPS

Guide book for new learners (Operations)

1. What is the purpose of pumps?
A machine used for the purpose of transferring quantities of fluids and or gases from
one place to another by adding energy in it.
2. What are the types of pumps?

3. What is a working principle of centrifugal pump?

In centrifugal pump, liquid enters at eye of the impeller. The speed of the rotating
impeller creates a centrifugal force that throws the liquid to the outer edge at a high
velocity and enters the volute which is an enlarged chamber where the velocity is
quickly reduced. This velocity reduction results in a pressure increase.
4. Start up of motor driven centrifugal pump
Pre-Checks:
Pump
Coupling is
OK.

Inlet/discharge
nozzles and Casing
bolts Tightened.

Pump motor ready

and supply turned

Turn shaft by hand, its

freely rotating (If
assessable)

Guide book for new learners (Operations)

Startup: Axillaries
Cooling water supply: Align cooling water to pump water jackets to cool the
lubricating oil, packing, pump casing and pedestals.
Glycol level: Ensure normal glycol level in bottles and its low level and high
pressure switches are in service. (Glycol used for ammonia pumps handling cold
ammonia).
Lubrication system: Make normal oil levels in bearing housing and oil cups. If
lubrication is forced then maintain oil console level, take console oil heating
system, cooling water exchangers and filters in service and start lubrication pump
and maintain normal lube oil pressure.
Seal flush water: Align Seal flush water to seals. (In some cases it is provided to
restrict pumping liquid into seals if pump is handling abrasive liquid).
Startup: Pump
Priming:
Open pump suction valve and close discharge valve.
Keep open recycle valve to maintain minimum flow.
Open pump casing vent until a steady stream of liquid comes out to ensure
complete removal of air or vapors from casing. Use close drain system if pump
handling toxic liquid.
Pump heating:
A pump that is to handle hot liquid should be warmed properly by circulating hot
liquid slowly.
Keep flowing liquid until pump casing temperature becomes equal to the
temperature of liquid to be pumped.
Starting:
Close pump casing vent and all drains and bleeders.
Start the pump and observe the discharge pressure it should rapidly increase
and then level off.
Slowly open discharge valve. And observe discharge pressure.
Note: If it drops to suction pressure, the pump has vapor locked. Shut it down.
5. What is vapor lock/cavitations and how to resolve it?
Cavitations and vapor lock occur when gas/vapors is present in the pump. A few gas
bubbles cause cavitations and more causes vapor lock. These problems can be
resolved during start up by:

Increasing the level of liquid in the vessel

Increasing suction pressure of pump
Decreasing liquid temperature
Sufficient cooling of pump casing if pump handling low temperature

Guide book for new learners (Operations)

Maintaining enough minimum flow while discharge valve is closed

Shifting load slowly on pump
Remove vapor from casing as mentioned above and restart pump again and
align with system if conditions are normal.
If pump handling volatile liquid and does not has minimum flow line then keep
opening casing vent valve until some flow starts through discharge valve.
Observe discharge pressure, sound, bearings temperatures, seal leaks and
vibrations are normal.
Keep running if all conditions are normal otherwise stop it and handover to
maintenance.

6. Start up of turbine driven centrifugal pump

Checks:
Pump
Coupling is
OK.

Inlet/discharge
nozzles and Casing
bolts Tightened.

Pump motor ready

and supply turned
Governor Knob at
Zero/minimum
Auxiliaries:
governor

Turn shaft by hand, its

freely rotating (If
assessable)

Turbine heating
complete, exhaust

Exhaust Safety
line PSV is in

Check list filled and

signed.

Startup: Axillaries
Cooling water supply: Align cooling water to pump water jackets to cool the
lubricating oil, packing, pump casing and pedestals.
Glycol level: Ensure normal glycol level in bottles and its low level and high
pressure switches are in service. (Glycol used for ammonia pumps handling cold
ammonia).
Lubrication system: Make normal oil levels in bearing housing and oil cups. If
lubrication is forced then maintain oil console level, take console oil heating
system, cooling water exchangers and filters in service and start lubrication pump
and maintain normal lube oil pressure.
Seal flush water: Align Seal flush water to seals. (In some cases it is provided to
restrict pumping liquid into seals if pump is handling abrasive liquid).
Pump startup:
Priming:
Open pump suction valve and close discharge valve.
Keep open recycle valve to maintain minimum flow.

Guide book for new learners (Operations)

Open pump casing vent until a steady stream of liquid comes out to ensure
complete removal of air or vapors from casing. Use close drain system if pump
handling toxic liquid.
Pump heating:
A pump that is to handle hot liquid should be warmed properly by circulating hot
liquid slowly.
Keep flowing liquid until pump casing temperature becomes equal to the
temperature of liquid to be pumped.
Close pump casing vent and all drains and bleeders.
Driver/Driven startup:
Slowly open steam inlet valve to put the turbine at slow roll and check shaft
movement.
Gradually open steam inlet valve up to 100% keep close eyes at pumps sound,
vibration and bearing temperatures.
Speed up turbine slowly from governor knob up to normal speed.
Observe the discharge pressure.
Slowly open discharge valve. And observe discharge pressure if it drops to
suction pressure, the pump has vapor locked. Shut it down.
7. CHANGE OVER OF CENTRIFUGAL PUMP

Checklist: Fill check list of standby pump and Put it on manual mode.
Startup: Start stand by pump as per start up procedure of centrifugal pump.
Inform Board man and make close contact during changeover.
Crack open discharge valve: Crack open discharge valve of newly started pump
to make some flow in discharge header. Confirm some increase in discharge
pressure. Confirm from Board-man also.
Closing of previous discharge valve: Keep closing slowly discharge valve of
already running pump till discharge pressure becomes at previous levels.
Parallel operation: Now operate both pumps discharge valves in parallel such
that first open discharge valve of newly started pump and let some little increase
in pressure then close discharge valve of already running pump to bring pressure
at previous level.
Conditions Checking: When load at both pump become equal, hold activity and
check operating condition of pump being taken in service thoroughly.
Note: load can be estimated by motor driven pump amps.
If all is OK. Precede activity up to full closing of discharge valve of pump being
stopped slowly.
Again check discharge pressure, sound, bearings temperatures, seal leaks and
vibrations of loaded pump.
Switch on manual and stop unloaded pump.
Open its discharge valve again and switch selector switch on auto as standby.

Guide book for new learners (Operations)

Select running pump also on remote.

8. Purpose of Ejectors and working principle:

An ejector is a device for removing air, gases or vapors from condensers and vacuum
equipment in industrial processes. It is a simplified type of vacuum pump which has no
moving parts.
Construction:
An ejector consists essentially of a steam nozzle that discharges a high velocity jet of
steam across a suction chamber and through a venture shaped combining tube. The air
or gases to be evacuated enter the ejector inlet entrained by the jet of steam and
discharges into the combining tube which by its construction produces a lower pressure
at the ejector inlet.

9. Taking vacuum condenser ejectors in service

Ensure Turbine lubrication system having been taken in service as per procedure
and lube oil pressure is normal.

Take cooling water in service of main condenser, gland ejector condenser, ejector
condensers as per procedures.

Align gland ejector and ejectors condenser shell side draining systems to main
condenser

Drain condensate from motive steam lines of ejectors and complete heating up to
main isolating valves.
Take all ejectors in service as per below sequence.
Open hogging ejector motive steam valve.
Open hogging ejector vapor side valve and let vacuum be pulled up to (0.5kg/cm2g).

Guide book for new learners (Operations)

Open second stage, secondary, ejector motive steam valve and maintain normal
steam pressure.
Open second stage, secondary, ejector vapor side valve.
Open first stage, primary, ejector motive steam valve and maintain normal steam
pressure.
Open first stage, primary, ejector vapor side valve.
Let vacuum be pulled up to normal operating limits (-0.98kg/cm 2g).
10. Putting vacuum condenser ejectors out of service
To put ejectors system out of service, follow sequence as bellow;

Isolate, first stage, primary, ejector motive steam valve.

Isolate, second stage, secondary, ejector motive steam valve.
Isolate hogging ejector motive steam valve.
Isolate ejector condenser drain system.
Isolate cooling system of ejector condenser.
Ejectors

Condens

11. Taking vacuum system of condensing turbine into service

Lubrication system: Ensure Turbine lubrication system having been taken in

service as per procedure and lube oil pressure is normal.
Cooling water: Take cooling water in service of main condenser, gland ejector
condenser, ejector condensers as per procedures.
Ejectors: Align gland ejector and ejectors condenser shell side draining systems
to main condenser.
Instrumentation: Take all level switches, level glasses, pressure gauges and
transmitters in service properly
Barring: Ensure barring is running normal prior to open sealing steam to turbine
seals to prevent shaft bow.

Guide book for new learners (Operations)

NOTE: (If barring is not working automatically it can be done manually, as large
turbines have arrangements to do it manually).
Drain condensate and heat gland ejector steam line up to isolating valve. Open
gland ejector motive steam valve. Open vapor side valves if provided.
Note: (Some turbine has gland ejectors and some have sealing steam vents).
Sealing steam: Open sealing steam to turbine seals and ensure pressure is
normal.
Drains: Ensure closing of following drains.
All drains at up stream of extraction steam hydraulic operated NRV if turbine has
extraction stream.
All drains downstream of induction hydraulic operated valve if turbine has
induction stream.
All drain valve of level switches and level glasses of condenser.
Any drain and bleeder at condensate pumps suction.
Any drain and bleeder at condensate pumps discharge which are not running.
Any drains and bleeder located at main condenser shell side.
Make level in condenser with DMW or with turbine condensate from any other
system and verify level switches settings and functions.
Start one condensate pump as per procedure and maintain over flow in hydraulic
PSV, s of condenser.
Take vacuum ejectors and hogging ejector in service as per procedure to pull
vacuum up to normal range (-0.98kg/cm 2g).
When primary & secondary ejectors become normal, put hogging ejector out of
service as;
First close vapor side valve.
Close motive steam valve.
If vacuum start coming down after shut down hogging ejector, find any air ingress
in the system.
If air leaks are not detectable and vacuum has come down, hogging ejector can
be left in service till leakage identification.
12. Changeover of PD Pumps

Open suction valve of standby pump

Check PSV, PIS and other instrument are service
Open recycle valve of pump for priming
Open discharge valve fully
Fill check list
Now start it on minimum load (low stroke)
Close recycle valve
Now reduce stroke of already running pump and increase stroke of newly running
pump.

Guide book for new learners (Operations)

When it take maximum load stop already running pump.
Check its pressure, flow, level temp. Noise for some time.
13. PD pump driver by turbine
Pre-check:
All maintenance jobs completed, blinds removed and PTW close
Check oil level in oil cups up to 60%
Check cooling water to bearing jacket is in service
Steam is available
Suction, discharge & recycle v/v are closed
Governor Knob is on minimum position
Governor oil level is normal up to 70%
Start up:
Fill the startup checklist.
Open suction, discharge & recycle valve of the pump.
Start heating of the turbine by opening steam exhaust v/v 2turn and drain.
Also open steam inlet line drain to remove the condensate from the line.
Slowly open steam exhaust v/v to full open position.
When heating of the turbine is completed and dry steam is coming then latches
the turbine.
Open steam inlet line v/v slowly and start the turbine on slow roll.
Slowly open steam inlet v/v to full open position to increase RPM, by governor
knob.
When turbine is running normal at rated RPM.
Close recycle v/v slowly to increase the discharge pressure of the pump.
Check any abnormality, vibration and inform to S/E if found.
14. PD pump driven by Motor
Pre-checks
All maintenance jobs completed, blinds removed and all PTW closed.
Check oil level in oil cups up to 60%.
Check and ensure that motor is rack in.
Pump suction, discharge and recycle v/v are closed.
Start up:
Fill the startup checklist.
Open suction, discharge and recycle v/v of the pump.
Put the PM on auto in case if start from CCR, also remove push button.
Start the PM by Boardman and check any abnormality.
Close the recycle v/v of the pump to increase the discharge pressure by
communicate with B.M.
Check any abnormality if found inform to S/E

Guide book for new learners (Operations)

Section II
Heat Exchangers
15. What are Heat Exchangers?
Heat exchanger is used to conserve heat and save fuel, or to supply heat
required by process.
The simplest heat exchanger is a Kitchen pan used to boil water. Heat is
transferred from the heating element on the stove to the water in the pan. An ice
tray in a refrigerator is another simple heat exchanger.
A heat exchanger is any piece of equipment in which heat is transferred from a
warm material to a cool material through a wall that separates the two materials.
16. Types of Heat Exchanger
Heat exchangers are of different types that are used for different duties but shell
& type is most commonly used is Shell & tube heat exchanger.
Other types are:
1. Shell and tube heat exchanger
2. Plate and frame heat exchanger
3. Double pipe heat exchangers
17. Procedure to take heat Exchanger in Service
All mechanical jobs completed
All pressure test should be OK
All work permits resign and returned
Before adding a liquid/ gas hydro carbon purge exchanger with steam or nitrogen
All drain valves should be closed
First introduce cooling fluid by crack open inlet valve
Open vent valve and completely purge any air in exchanger
Open inlet/ outlet valve
Then introduce hot fluid slowly by opening inlet valve
Prime by opening vent valve
Slowly pressurize by closing vent valve
Open inlet and outlet valve
18. Shell and tube Exchanger in Service
Ensure all maintenance jobs completed
and all PTW closed
Ensure cooling water is available
Close all drains by exchanger
Take cooling water of the exchanger in
service

Guide book for new learners (Operations)

Open bleeder of related side in which cooling water is given

Open cooling water supply v/v slowly and bleed air from the exchanger
When air remove and water come from bleeder then open CWR v/v to full open
position
Full open CWS v/v and close the bleeder.
Now pressurize the process side of the exchanger by bypass v/v if available.
Open bleeder of process side and remove air.
Slowly open inlet v/v of process.
When air remove then slowly open outlet v/v to full open position and close
bleeder.
Full open outlet v/v of process side.
Also open drain of low pressure side to check leakage.

19. Key steps of Deaerator

1. Level make up in Deaerator.
2. Drain water and again make-up (cleaning purpose).
3. Open steam in accumulator (V-1503) for heating of DMW.
4. Remove isolation and steam line in Deaerator. (for Deaeration Purpose)
5. Maintain level up to 60-70%.
6. Prepare BFW pump for start up.
7. Start one pump at close circulation.
8. Start dozing pumps at minimum stroke length. (Phosphate, hydrazine,
Ammonical Water).
9. Sent check samples to check normal conditions of BFW.
10. When conditions are ok, line up BFW to steam drum.
20. Stroke checking of Control Valve
Isolate control v/v from u/s and d/s side.
Close drain.
Inform Boardman.
Ensure instrument connection done.
Instrument air is available.
Open instrument air supply v/v.
Inform Boardman and open control v/v to check stroke of the control v/v as per
B.M instruction.
Ensure control v/v full open or full close position from CCR and field.
21. Control valve on Hand Jack
Open equalizing v/v properly.
Cut the instrument air supply from header.
Slightly engage the hand wheel pin by pulling the pin & inserting into slot.
Operate the hand wheel.

Guide book for new learners (Operations)

NOTE:
If equalizing v/v is not opened then there is a chance of damaging of actuator
internal seal.
If instrument air not close and v/v is being operated from CCR then there is a
chance of breakage of feedback linkage & seal.
22. Release Hand jack of Control valve
1. Close equalizing v/v.
2. Turn on instrument air from supply header.
3. Match the travel of v/v from DCS.
4. Release the hand wheel on neutral.
5. Now disengage the hand wheel by pulling back the pin.
NOTE: If equalizing v/v not closes properly then there is a error in operation of v/v.
23. Furnace (Ammonia) major parts and general operation step
PARTS:
i. Cell A/B
ii. Radiation section
iii. Arch section
iv. Convection section
v. Exhaust section
vi. Burners(160)
vii. Tubes (260)
viii.
ID fans(2)
General Operation steps:
Preparing for Operation
1. All jobs completed & box up of Furnace man way done.
Draft:
2. Starts FD fan and maintain draft in Furnace by opening PV-10
Fuel header:
3. Purge fuel header with N2 and pressurized the fuel header.
Coils protection:
4. Make level in D- 103 and starts one pump and circulate water from E-110.
5. Open N2 in gas circuit for purging purpose also carry heat after firing
Furnace.
6. Starts firing ignition some burner maintain heating rate 50 C/hr.
7. Increase firing rate when temperature arch section 350-400 C open steam in
system , before that stop N2 flow, after opening steam, open all reactor drain
and removed condensate.
8. When temperature 650-680 C in hot collector open gas in process system,
before doing that close all drain. And vent at desired vent located at process
system.

Guide book for new learners (Operations)

9. When hot collector temperate 700 C then introduced air in secondary
reformer increasing with temperature increase flow rate in E-110.
24. Liquid sample for lab
First depressurized circuit may be something remains in system.
After depressurized system closed all I/Vs.
Firstly open CWS I/V to sample cooler, and see water is coming from sample
cooler CWS drain.
Now crack I/V of other media that is important for sample required.
Open required liquid I/V 3turn for sample.
Now open sample collector I/V and purge for 5-10 minutes, and now check
temperature of sample liquid beat for taking sample, take sample, closed sample
liquid I/V after that close CWS I/V and depressurized the system.
25. Best way of
communication

radio

communication,

Shift

handover

and

writing

Radio communication:
Communication is best tool for efficient and safe operation.
To supervise an activity,
Communicate with speed that can be understandable to concern.

Press the button

First call the concerned person with designation and name e.g. shift Engr Mr
A call back. To call not the part of operation team, Maintance supervisor
Shakoor call back

On its call back, speaks your full message loud. During communication, keep
the button in pressed form. Otherwise communication disconnects.

After completing your message, leave the button and wait for reply.

Message must be clear, to the point and specific.

Shift handover
You cannot leave the area unless next take the charge.
Explain all the details of jobs throughout the day that how much done, left and whats
further status by relevant department, any special activity with further steps if any, any
routine job done or not/status like sample, running centrifuges.

Guide book for new learners (Operations)

Log book writing
Its an official document what serves for record purpose so its statement is considered
most accurate and all in all. Hence:
1. Mention all the jobs happened during shift with time, findings and conclusions.
Next steps in case if job left.
2. Safety issues faced each day.
3. SCDs and LTDs status.
4. Special results if any like TMTs each night shift.
5. No stories, job specific and explaining 5Ws. (what, why, how, when, who) and
findings.
26. Basic control loop /sensing element communication with DCS
Control system is technique because of which plant parameters/operation is controlled
remotely.
It has following 5 basic elements:

Sensor (sensing from process e.g. thermocouple)

Transmitter (transfer signal to comparator)

Comparator (compared the process value/variable with set value(target value)

and generates error)

Controller (send command to valve to operate to minimize error to achieve target

value).

Final control element (open/close to achieve the target value)

Sensing element communication with DCS

Sensor sense from process and convert into transmittable signals i.e. current which
went to transmitted that terminates in Junction box in field. From JB it enters in rack
room where it distributes to allocate points main is to controller. Set point is given by
BM which is compared with field value. Which send to field.

Guide book for new learners (Operations)

27. Refrigeration Cycle and operational steps of refrigeration unit

Refrigeration cycle consists of following unit:
1. Evaporator
2. Compressor
3. Condenser
4. Let down

Operational
refrigeration

Purge the refrigeration loop

with N2

Fill the accumulator with N2

and make the pressure
around 6-7kg.

steps

of

Guide book for new learners (Operations)

Fill it from storage.

Make the workable level in all evaporators through D-118 and start circulation.

Run the refrigeration compressor on minimum governor(1000rpms).

Turn on cooling water to condensers

Allow the gas to pass the evaporators

As gas starts to pass, evaporation occurs and increases machine rpm to

control pressure and sucks more vapors compress, condense then send to
accumulator.

28. Packed column / differentiate b/w absorber and stripper

Packed column:
It is continuous contact equipment used for mass transfer. It consists of cylindrical
shell filled with suitable packing material to provide a large interfacial area of contact
between phases.
The liquid flows down through the packing remains in contact at every point of the
packed section.
Absorber
A packed tower where one or more specie
is removed from gaseous stream by
dissolution in liquid. The gas which is not
absorbed is called carrier gas.
29.

Stripper
The reverse is called desorption/stripping.
To recover the absorbed gas from the
solution to regenerate it.

Differentiate
between
Pilot
operated PSV and spring loaded
PSV

Spring

Loaded Relief Valves

a.
valves.
These
pressure
pressure.
for TRVs.

Conventional spring loaded relief

shall be installed where backdoes not exceed 10% of the set
These are the recommended type

Guide book for new learners (Operations)

b. Balanced pressure relief valves
These are suitable for back-pressures ranging from 10% to 50% of the set pressure.
They can be of two main types : balanced piston and balanced bellows. Balanced
bellows shall be given preference
where the fluid is corrosive or fouling.
Pilot-Operated Relief Valves
Pilot-Operated valves are recommended for applications where the
back-pressure on the valves are very high (typically 50% or higher).
The other criteria for selecting pilot-operated valves are as follows:
a. Low accumulation rates are required.
b. The set pressure is required to be close to the operating
pressure.
c. Calibration is required without removing the valve.
d. Handling of large relief flows are required.
e. The service is non-fouling.

30. Difference b/w PSV and PRV

PRV

PSV

Pressure Relief Valve - is the term used to Pressure Safety Valve - is the term used to
describe relief device on a liquid filled describe relief device on a compressible
vessel. For such a valve the opening is fluid or gas filled vessel. For such a valve
proportional to increase in the vessel the opening is sudden. When the set
pressure. Hence the opening of valve is pressure of the valve is reached, the valve
not sudden, but gradual if the pressure is opens almost fully.
increased gradually.

Guide book for new learners (Operations)

31. Differentiate of Knockout drums/surge drums/Reflux drums and Reactors
A vaporliquid separator may also be referred to as a Knock-out drum, Knock-out
pot, Compressor suction drum or Compressor Inlet Drum. When used to remove
suspended water droplets from streams.
Surge drum
A surge tank (or surge drum) is a standpipe or storage reservoir at the
downstream end of a closed feeder pipe to absorb sudden rises of pressure, as well
as to quickly provide extra fluid during a brief drop in pressure.
Reflux drum
Reflux is that portion of a tower's condensed overhead liquid product that is cycled
back to the top of the tower where it flows downward to provide cooling and
condensation of the up flowing vapors. Challenge: The reflux drum serves as a
distribution point for reflux and distillate.
Reactors
Chemical reactors are vessels designed to contain chemical reactions. It consist of
different parts to provide sufficient energy/mixing or aiding components (Catalyst) to
get the maximum yield from the chemical reactants to get high yield.

32. Differentiate between Tank and vessel

Pressure vessel is maintained at a pressure above atmospheric, while in a storage
tank pressure is atmospheric. Thus mechanical maintenance is a bit hazardous in a
pressure vessel as the chances of explosion is higher.
33. CSTR and PFR
In a CSTR, one or more fluid reagents are introduced into a tank reactor (typically)
equipped with an impeller while the reactor effluent is removed. The impeller stirs
the reagents to ensure proper mixing.
In a PFR, one or more fluid reagents are pumped through a pipe or tube. The
chemical reaction proceeds as the reagents travel through the PFR. In this type of
reactor, the changing reaction rate creates a gradient with respect to distance

Guide book for new learners (Operations)

traversed; at the inlet to the PFR the rate is very high, but as the concentrations of
the reagents decrease and the concentration of the product(s) increases the reaction
rate slows.
34. Starting Centrifuge
Checks

The motor of centrifuge must be racked in.

Water sealing has been placed

O/L valve is full open

I/L is almost 2 turns open.

Startup:

Turn on the button.

Wait for 5 to 7 minutes when water moves out continuously

If not, then turn it off immediately and report to CCR shift Engr.

35. Centrifugal compressor into operation

Oil Circulation

Supply cooling water to tube oil coolers with discharge valve parlty closed

Make the sump filled with oil.

Align the whole circuit i.e. filters/exchangers.

Turn on pump and make circulation.

Check from the lube oil return

Startup
Remove water from casing drains, inlet and outlet line
Make the driver in ready state.
Pressurize the casing by opening I/L valve and o/L closed.
Turn on driver and slowly increase RPM

Guide book for new learners (Operations)

When pressure become higher that O/L line pressure, slowly open discharge valve and
set the operating rpms.
(For more detail, consult API)
36. Difference b/w DM and BFW
DM is water which have no hardness causing components i.e. free from Mg&Ca
chlorides /sulphates/phosphates/carbonates but contains Oxygen and CO2 in dissolved
form.
To remove these gases from it by deaeration, this water will be said as BFW.
37. GLG in Service:

First check physical condition of GLG, it should be mechanically OK.

Open drain valve of GLG.
Now open upper side isolation valve and crack open service valve of GLG to
heat up.
After some time when heating completed, open down side or lower side isolation
valve and crack open service valve.
When both legs of GLG temp. equal to service temperature reached.
Now close drain valve slowly.
Heating and pressurization should be done as per standard procedure.
When GLG is in complete service. If hot tightening is required ask mechanical
person to do it.
After hot tightening close observe GLG.

38. Taking transmitter in service:

Inform Boardman before taking in service.
Ensure transmitter service valves are closed and its bypass open.
Open isolation valves of tapping (one by one).
Open LP and HP tapping inlet valves of transmitter.
After opening of LP and HP valves close bypass valve slowly.
Check any leakages if so rectify it.
Compare transmitter reading with LG.
39. To check passing of PSVs
Check U/S and D/S flanges/ line temperature.
D/S flange / line should be colder than U/S flange /line.

Guide book for new learners (Operations)

If PSV is on steam circuit, check for any condensate. Passing through drain hole
available at PSVs D/S piping.
PSV on steam, check its exhaust vent, if PSV is passing, clear steam foraging
can be seen.

40. BACK FLUSHING/DRAINING OF COOLING WATER EXCHANGERS

BACK FLUSHING
Inform CCR for exchanger back flushing.
Back flushing one exchanger at a time.
Open 100% cooling water return valve of exchanger.
Slowly close the cooling water inlet valve & open back flushing valve in parallel.
Full close cooling water inlet valve and full open the back flushing valve.
During back flushing, critically monitor the process side temperature & pressures.
When clean water observe, close the back flushing drain valve and open cooling
water supply in parallel.
Adjust the cooling water valve as per process requirement.
During the back flushing, change in temperature should be made slowly in order
to avoid thermal stresses of the shell and tube bundle.
Clean the area with utility water.
DRAINING
Inform CCR about respective exchanger draining.
Ensure that second side of exchanger is depressurized and purged with Nitrogen
(especially NH3 coolers, condensers).
Open bleed valve to displace CW with air along with drain valve opening.
Clean the area with utility water.
41. To take lube oil cooler in Service
Priming cooling water side:
Open CWR line bleeder valve and crack open CWS valve.
When air is completely removed and CW over flows through bleeder close
bleeder valve.
Open CWS valve 10% and keep fully closed CWR valve.
Priming oil side:
Start filling of standby lube oil cooler through 3/4 filling line.
Open over flow line isolating valve.
When flow is visible through over flow glass, check cooler for any leakage
through flanges, gaskets etc.
After filling circulate oil through over flow line about 20-30 min.
Check lubes oil cooler body temperature with hand.

Guide book for new learners (Operations)

Open three way valves slowly and pass flow through, three-way valve and watch
on D/S header temperature / pressure and filter P.
When three way valves is 50%open, side by side crack open CWR valve one/
two turns as per requirement to control outlet lube oil temperature.
Open three ways valve to full open adjust cooling water return valve according to
control lube oil temperature.
After this monitor temperature about 10 minutes. When lube oil temperature and
pressure is normal close overflow and 3/4" filling line valves.

42. Changeover procedure of Lube/control oil filters

Start filling of standby filter via 3/4" filling line.
Open over flow line isolating valve.
When flow is visible through flow glass on overflow line that means filling is
completed.
Check any leakage in the system.
After filling circulate oil via over flow line about 10-15 minutes to maintain oil
temperature.
Check filters body temperature by hand.
Inform CCR B.E. Boardman.
Start opening of three way valve very slowly and keep close watch on filter P &
D/S header pressure.
When three way valves is 50-60% open, wait & check the position of standby
filter, P & header pressure.
If P of filter comes down slowly full open three way valve.
Check for P lube oil pressure and any leakage through flange.
If all is OK close 3/4" filling line.
Prepare checked/ exhausted filter to handover to maintenance.
Close inlet/ outlet valves of exhausted filter.
Open filter purge valve.
Open drain valve of exhausted filter to drain out.
Check & confirm that isolating valves are not passing
43. TO EXTINGUISHER FIRE
1. If there is a fire in any area.
2. Then check following:
i. Intensity of fire
ii. Types of fire
iii. Isolation is possible or not
iv. Wind direction
3. If fire is small, extinguish it with proper extinguisher.
4. If isolation is possible then isolate it.
5. If fire is heavy. Then first break safety glass then inform CCR with full information.

Guide book for new learners (Operations)

6. Meanwhile try to avoid its expansion and cool surroundings by sparging fire
water as per instruction of CCR.
7. Guide fire squad to reach in fire location.
8. Help them up to possible limit.
9. If all above is not possible then planned shutdown to safe other section of the
plant.
44. Reboiler in Service
45. How to take chiller in service
46. Changeover vaccume condensate pump
47. Taking seal oil traps in service
48. Backpressure turbine in service
49. Warm up of steam turbine
50. Start of reciprocating compressor
51. Steam boiler major parts and its operation
52. Valve operation clockwise & anti clockwise and no. of turns
53. Taking reciprocating compressor into operation
54. Taking desuperheater into operation

Guide book for new learners (Operations)