PLANT OPERATING MANUALS (PROJECT STANDARDS AND …

1 KLM TechnologyGroupProject :1of19 Rev: 01 Feb2011 KLM Technology Group#03-12 Block Aronia,Jalan Sri Perkasa 2 Taman Tampoi Utama81200 Johor BahruMalaysiaPLANT OPERATING MANUALS (PROJECT STANDARDS AND SPECIFICATIONS)TABLE OF CONTENTSCOPE2 REFERENCES2 DEFINITIONS AND TERMINOLOGY2 SYMBOLS AND ABBREVIATIONS3 UNITS4 FORMAT4 General4 Covers and Size4 Titles4 Dividers5 BASIC CONSIDERATIONS IN PREPARING OPERATING MANUALS5 Non-licensed Processes5 Licensed Processes6 CONTENTS OF OPERATING MANUAL6 NOTEWORTHY POINTS7 General7 Chapter II (Design Basis)8 Chapter III (Process Description)10 Chapter IV ( OPERATING Variables and Controls)10 Chapter V (Auxiliary Systems)11 Chapter VI (Equipment Operation)11 Chapter VII (Instrumentation and Control)12 Chapters VIII-X (Start-Up and Shut-Down)12 Chapter XI (Emergency Shut-Down Procedure)12 Chapter XII (Miscellaneous Procedures)

2 13 Chapter XIII (Safety)13 Chapter XIV (Analytical Tests)13 Chapter XV (Catalysts, Chemicals, and Packings)14 Chapter XVI (Drawings)14 APPENDIX A15 APPENDIX B19 KLM TechnologyGroupProject Engineering StandardPLANT OPERATING MANUALS (PROJECT STANDARDS ANDSPECIFICATIONS)Page2of19 Rev: 01 Feb2011 SCOPEThis Project STANDARDS and Specifications covers the minimum requirements offormat, in preparing process and/or utility units OPERATING MANUALS , includingessentialinstructions and points of purpose of this Manual is to standardize the content and format of operatingmanuals which shall be prepared by the Contractor. Although OPERATING manualsdiffer to some extent from process to process, the basic philosophy and generalaspects shall conform to the concepts of this this Standard the following dated and undated STANDARDS /codes arereferred to.

3 These referenced documents shall, to the extent specified herein,form apart of this standard. For dated references, the edition cited applies. Theapplicability of changes in dated references that occur after the cited date shallbe mutually agreed upon by the Company and the Vendor. For undatedreferences, the latest edition of the referenced documents (including anysupplements and amendments) ( International Organization for Standardization)6708-1980 (E) "Pipe Component Definition of Nominal Size", 1st. Ed., 1980 DEFINITIONS AND TERMINOLOGYC ontractor-The persons, firm or company whose tender has been accepted bythe "Employer", and includes the Contractor s personnel representative,successors and permitted or Licensor-A company duly organized and existing under the lawsof the said company s country and as referred to in the preamble to the equipment, machinery and materials to be procured by the"Contractor" and/or company and the works and/or all activities to be performedand rendered by the "Contractor" in accordance with the terms and conditions ofthe contract or Units-One or all process.

4 Offsite and/or utility Units and facilities asapplicable to form a complete operable refinery/ and or TechnologyGroupProject Engineering StandardPLANT OPERATING MANUALS (PROJECT STANDARDS ANDSPECIFICATIONS)Page3of19 Rev: 01 Feb2011 SYMBOLSANDABBREVIATIONSSYMBOL/ABBREVIATI ONDESCRIPTIONAPIA merican Petroleum InstituteBFWB oiler Feed WaterBhPBreak horsepowerBkWBreak kilowattBPSDB arrel Per Stream Day (bbl/sd)CondCondensateDNDiameter Nominal, (mm)FBPF inal Boiling PointGNGeneralhhourHPHigh PressureIBPI nitial Boiling PointKgkilogramkJkilojoulekWkilowattLLiq uidLHVLow Heating ValueLLPLow Low PressureLPLow PressureMass (ppm)Mass parts per million, (mg/kg)MPMedium PressureMWMolecular mass (weight)NPSN ominalPipe Size, (inch)PFDP rocess Flow DiagramP & IDsPiping & Instrumentation DiagramsPONAP araffinic, Olefinic, Naphthenic, and AromaticRVPReid Vapor Pressuressecondsdstream daySp GrSpecific Gravity (Relative Mass Density)UOP KUniversalOil Products FactorVVaporVolVolumeWtWeight (mass)

5 KLM TechnologyGroupProject Engineering StandardPLANT OPERATING MANUALS (PROJECT STANDARDS ANDSPECIFICATIONS)Page4of19 Rev: 01 Feb2011 UNITSThis Standard is based on International System of Units (SI) except whereotherwise principle, a separate OPERATING manual shall be prepared for each processand/or utility unit. However, in the case of short volumes, OPERATING MANUALS fortwo or maximum three units can be integrated into one book upon approval of theCompany. The compiled OPERATING MANUALS should consist of related units,where and SizeThe format of OPERATING MANUALS shall essentially conform to the of covers:225 mm (Width) 300 mm (Length)-bound on 300 mm and type of bottom : Free thickness, up to 70 mm : Integral types with of front and bottom covers: Dark blue without of title on front and bottom covers: of title character: Helvetica of character: Leaf of papers shall be A4-size (210 mm 297 mm).

6 Manual shall be named as:" OPERATING Manual" titles on the front cover shall name and TechnologyGroupProject Engineering StandardPLANT OPERATING MANUALS (PROJECT STANDARDS ANDSPECIFICATIONS)Page5of19 Rev: of " OPERATING Manual". or unit or unit (s) name and , it shall be referred to the month and year of the titles on the bottom cover shall include all requirements as should be provided to separate each chapter with appropriatedesignations of the concerned CONSIDERATIONS IN PREPARING OPERATING MANUALSNon-licensed purpose of an OPERATING manual, is not only to help the operationengineers and staff at the customer side to operate the PLANT safely, but alsoto present all detailed procedures for the PLANT start-up and shut down in thevarious operation of MANUALS should contain all OPERATING procedures,guidance,hints, cautions andtrouble shooting guides necessary for PLANT safe andcorrect detailed operation procedures should also include the sequence ofvalve operation, time schedule.

7 Contractor should carefully study the past history of troublesexperienced and countermeasures, employed in similar processes andprovide the latest TechnologyGroupProject Engineering StandardPLANT OPERATING MANUALS (PROJECT STANDARDS ANDSPECIFICATIONS)Page6of19 Rev: levels of OPERATING variables (temperature, pressure, flow rate,fluid level in vessel, etc.) together with appropriate countermeasuresshould be listed inthe OPERATING manual as far as possible to avoid check of basic manual, should be checked carefully against basic design operation philosophy which was prepared at the early stages of thebasicdesign shall be necessary facilities, equipment, instruments and lines, etc., for eachoperation mode (namely start-up, normal shut down, emergency,regeneration, maintenance, etc.)

8 Must be taken into designer shall prepare an OPERATING manual for the Licensed Unit inaccordance with the conditions stipulated in this Standard for non-licensedUnits and based on the contents of OPERATING manual furnished by theLicensor. All modifications/changes resulted from the detailed engineeringactivities should be reflected in the final revision of the OPERATING making any unavoidable modifications/changes by the Contractor, it isnecessary to obtain the approval of the process OF OPERATING order to standardize the quality of the OPERATING manual, the chapterswhich shall be included in the OPERATING manual, are listed in of the items specified in AppendixAmay be modified and/or changeddepending upon the particular process and shall be approved by TechnologyGroupProject Engineering StandardPLANT OPERATING MANUALS (PROJECT STANDARDS ANDSPECIFICATIONS)Page7of19 Rev.

9 01 Feb2011 NOTEWORTHY , the necessary documents providing a guide to operation s instruction s Instruction MANUALS have priority over the OPERATING manualprepared by the Contractor in order to place the responsibility for maloperation on the following figures and tables to be inserted in the OPERATING manual for theoperator sconvenience and easy :i)Trip sequence (flow) )Simplified flow scheme of PLANT )Simplified flow scheme of catalyst reduction, activation, oxidation andregeneration (generally, for Licensed Units).iv)Simplified flow schemeof feed cut-in, shut-down and other )Furnace drying )Other charts as :i)Pressure relief valves load summary )Setting point list for instruments (especially alarm and trip elements).iii)Analytical )Utility summary )Heat and material balance )Major Equipment Specification TechnologyGroupProject Engineering StandardPLANT OPERATING MANUALS (PROJECT STANDARDS ANDSPECIFICATIONS)Page8of19 Rev: 01 Feb2011 Chapter II (Design Basis)* A, B, and source of feed and unit different OPERATING modes to characteristics of feed, products and by-products (if necessary) shallbe specified.

10 The typical feed and product charateristics for refinery arepresented in AppendixB.* For Chapter I "Introduction" see DUtility conditions shall cover OPERATING pressure and temperature as well asapplication of each type for all utilities concerned in the and Material Balance Tables including the following characteristics ofeach stream as marked on the relevant process flow diagram to becovered in this basis (datum level) for all fluids to be identified. Computerprogram used for preparation of Heat and Material Balance Tables shallalso be FUtility Summary Tables shall cover the following requirements (whereapplicable) as shown below typical tables:-Item BkW (BhP), power, , 1000 steam , pressure in, bar (ga).-MP steam , pressure in, bar (ga).-LP steam , pressure in, bar (ga).