Module 20 – Startup & Shutdown Procedures

Objective:
By the end of this module, a trainee will be able to:

1. Understand the conceptual steps involved in starting up and shutting down a petrochemical plant or process unit.

2. Identify operator responsibilities during startup and shutdown.

3. Recognize safety checks and precautions.

4. Understand common issues and basic troubleshooting during these operations.

5. Apply a systematic approach for smooth, safe, and efficient operation.

20.1 – Introduction to Startup & Shutdown

Definition:

• Startup = bringing a process or equipment from cold or idle state to normal operating conditions.

• Shutdown = taking a process or equipment from operating condition to a safe, idle or off state.

Importance:

• Startup and shutdown are critical periods; many incidents occur if steps are skipped or rushed.

• Ensures safety, equipment integrity, and product quality.

• Proper procedure prevents damage, leaks, and hazards.

Operator Role:

• Follow SOPs and checklists strictly.

• Monitor instrument readings, alarms, and equipment status.

• Communicate clearly with control room and maintenance.

Analogy:

• Startup = “warming up a car engine carefully before driving.”

• Shutdown = “cooling down and parking the car safely to prevent damage.”

20.2 – Conceptual Startup Steps

Step 1: Pre-Startup Checks

• Inspect equipment, valves, pumps, compressors, instruments, and utilities.

• Verify electrical, instrument, and utility readiness (steam, cooling water, air, nitrogen).

• Ensure safety interlocks, alarms, and emergency systems are functional.

Step 2: Initial Equipment Start

• Start pumps, fans, compressors as per sequence.

• Check flow, pressure, temperature, and vibration trends.

• Verify instruments are reading correctly.

Step 3: Process Startup

• Introduce feed to the unit gradually.

• Bring heating/cooling systems online.

• Monitor key variables (temperature, pressure, level, flow).

Step 4: Stabilization & Normal Operation

• Adjust setpoints for flow, pressure, temperature, and reflux (if applicable).

• Monitor product quality parameters.

• Record observations and trends in logbook.

Operator Tips:

• Follow the sequence exactly as per SOP.

• Never bypass safety interlocks.

• Communicate continuously with the control room.

20.3 – Conceptual Shutdown Steps

Step 1: Pre-Shutdown Preparation

• Notify control room and maintenance.

• Ensure product recovery or safe containment.

• Check utility availability for safe cooldown.

Step 2: Process Shutdown

• Gradually reduce feed rate and heat input.

• Allow process variables to reach safe levels.

• Monitor temperatures, pressures, and levels during cooldown.

Step 3: Equipment Shutdown

• Stop pumps, compressors, fans, and other rotating equipment sequentially.

• Drain or isolate liquids if required.

• Lockout/tagout for maintenance or safe idle.

Step 4: Post-Shutdown Checks

• Ensure all equipment is off, isolated, and safe.

• Check for leaks, abnormal temperature, or pressure.

• Record shutdown data and observations in logbook.

Operator Tips:

• Maintain sequence and communication to prevent hazards.

• Never rush; allow proper cooldown of sensitive equipment.

• Verify all interlocks and alarms remain functional.

20.4 – Operator Safety Considerations

• Always wear PPE.

• Verify emergency shutdown and interlock systems before starting or stopping equipment.

• Be aware of hot surfaces, high-pressure lines, and chemical hazards.

• Ensure safe handling of residual chemicals, steam, and compressed air.

• Communicate continuously with team members.

Analogy:

• Safety checks during startup/shutdown = “checking brakes, lights, and engine before driving a car in traffic.”

20.5 – Common Issues During Startup & Shutdown

• Startup

Feed pump not primed

Stop, check suction, follow SOP

• Startup

Pressure spike in column

Reduce feed, verify valves, monitor alarms

• Startup

High vibration on compressor

Stop, check alignment, report to maintenance

• Shutdown

Slow cooldown of exchanger

Verify cooling water flow, adjust heat input

• Shutdown

Product left in line

Drain safely, notify maintenance

• Both

Alarm floods

Acknowledge as per SOP, monitor priority alarms, notify control room

Operator Tips:

• Observe trends carefully; small deviations can escalate.

• Follow SOPs strictly; avoid improvisation.

• Document all anomalies for future reference.

Recommended Visuals:

• Example trend showing startup temperature rise

• Example trend showing shutdown cooldown

20.6 – Best Practices for Operators

1. Always review SOPs before starting work.

2. Maintain clear communication with control room, maintenance, and lab teams.

3. Use logbooks and digital monitoring to track variables.

4. Observe equipment during critical steps of startup/shutdown.

5. Participate in training drills and emergency simulations.

Analogy:

• Operator during startup/shutdown = “pilot during takeoff and landing: highest attention, follow sequence, monitor instruments.”

20.7 – Quiz / Knowledge Check

1. What is the purpose of pre-startup checks?

2. Why is sequence important during startup and shutdown?

3. Name three common issues during startup and operator actions.

4. What safety precautions must an operator observe?

5. Give an analogy for startup and shutdown operations.

6. What should an operator do if alarms flood during startup?

20.8 – Media Sites Integration

• Videos:

  • Step-by-step conceptual startup animation

  • Shutdown sequence demonstration

  • Operator monitoring during startup/shutdown

• Diagrams / Infographics:

  • Startup and shutdown flowcharts

  • Checklists for critical equipment

  • Alarm priority diagram

• PDF Downloads:

  • Startup checklist template

  • Shutdown checklist template

  • Operator observation log

• Interactive:

  • Embedded quizzes

  • Scenario exercises: detect abnormal trends during startup/shutdown and suggest operator action

20.9 – Summary & Key Takeaways

1. Startup and shutdown are critical operational phases; safety and sequence are paramount.

2. Operators follow SOPs, monitor instruments, and maintain communication.

3. Pre-startup/pre-shutdown checks prevent incidents.

4. Common issues include pressure spikes, pump/compressor problems, temperature deviations, and alarm floods.

5. Systematic, careful operation ensures safety, equipment integrity, and product quality.